Pallet wrappers

About pallet wrappers

In the following sections, we address common questions about why a pallet wrapper is necessary, the price range for stretch wrap machines, how a pallet wrapper can improve productivity and speed up packing, and the main benefits of pallet wrapping equipment.

Pallet wrapper pricing

The price of a pallet wrapper depends on several factors, but you can typically achieve a return on investment within months, thanks to time savings and increased output. Prices for pallet wrappers range from around 1,300 EUR to 25,000 EUR, depending on the degree of automation. The cost varies according to whether the machine is fully automatic or semi-automatic. Another important consideration is whether the pallet wrapper features intelligent touch control, a human-machine interface, a comprehensive safety system, IoT module, and other advanced options.

How pallet wrappers work

Stretch wrapping starts with pallet loading

Before stretch wrapping can begin, the load must be placed on a pallet. Once the goods are on the pallet, the entire unit is wrapped together.

Properly arranging the load on the pallet is essential. The load should not extend beyond the pallet edges or sit more than four inches inside. The pallet itself should be in good condition.

Three methods for applying pallet wrap

There are three main ways to apply pallet wrap to a loaded pallet:

1. Manual application
2. Using a semi-automatic stretch wrap machine
3. Using a high-speed automatic stretch wrap machine

Manual wrapping requires an operator to secure the wrap to the pallet and walk the film around the load.

Manually pulling a heavy roll of wrap around a pallet is physically demanding, especially in a hot warehouse. Manual wrapping usually results in the highest material costs due to inconsistent film use and lack of pre-stretch. Achieving a consistently secure load is also challenging.

Semi-automatic stretch wrap machines are available in two main designs: turntable and rotary arm. The load is placed in the wrapping zone, and the film is applied. Turntable models rotate the pallet, while rotary arm wrappers move the arm around the stationary load to apply the wrap.

High-speed automatic stretch wrap machines operate similarly to semi-automatic models, but typically include infeed and outfeed roller conveyors to automatically move pallets through the machine.

The importance of containment force

Whichever type of stretch wrap machine you use, achieving the correct containment force is crucial. Containment force determines whether a load arrives safely or is damaged in transit. But what exactly is containment force?

Containment force is what keeps the load secure. It is calculated as the wrap force multiplied by the number of film layers. Wrap force measures how tightly each layer is applied, while the number of layers refers to how many times the wrap is wound around a specific point.

Advantages of pallet wrappers

Pallet wrappers are a valuable investment for any business using wrap to secure and protect palletised goods. They are widely used in manufacturing, logistics, and transport sectors. The main benefit of a new stretch wrap machine is that it eliminates the need for manual wrapping, increasing productivity and reducing labour costs. Modern pallet wrappers are made from highly durable materials, offering long service life, ergonomic operation, reliability, and stability. Another key advantage of the latest stretch wrap machines is their comprehensive safety systems, which include fall prevention, film break alarms, safety sensors, bottom pressure, and injury prevention features. This allows for fully automated pallet wrapping with peace of mind.

Choosing between automatic and semi-automatic pallet wrappers

Automatic pallet wrapper

The automatic pallet wrapper operates without the need for an engineer to intervene, either at the start when attaching the film or at the end when removing the pallet. The pallet is brought to the wrapping area by a roller conveyor, positioning it precisely in the centre of the platform. The machine then wraps the pallet according to the pre-set programme, and once finished, the pallet is automatically removed.

There are several types of automatic pallet wrappers, each distinguished by the wrapping technology they use:

• Turntable pallet wrapping equipment
• Rotary arm wrapper machines

Semi-automatic pallet wrapping machine

With a semi-automatic pallet wrapper, the operator is required to supervise and assist with the application of the film. The worker must position the pallet and manually attach the film. The machine then completes the programmed wrapping cycle, after which the operator cuts the film and removes the pallet from the machine.

Semi-automatic pallet wrappers are further classified by their operation and design as follows:

• Rotating turntable pallet wrapping machines
• Rotary arm pallet wrapping machines
• Mobile pallet wrapping machines

Semi-automatic pallet wrappers apply a stretch film (plastic film) around the pallet to protect it during transport, stabilise the load, and keep it secure in storage. These machines use a stretchable plastic film, which allows for stable wrapping of pallets without risk of tipping or difficulties in movement.

The use of film in semi-automatic pallet wrappers must be overseen by the operator or supervisor. As these machines are semi-automatic, placing the pallet on the turntable and securing the film must be done by an employee. The machine then completes the programmed wrapping cycle. Once finished, the employee must cut the film and remove the pallet from the pallet wrapping machine to complete the wrapping process.

Benefits of Using Pallet Wrapping Equipment

A pallet wrapping machine is designed for wrapping pallets, large boxes, containers, and other items for storage or transport. Using stretch wrap machine technology offers several benefits, including:

1. Protects Goods from Damage, Scratches, Dust, and Moisture

Choosing the right pallet wrapping machine ensures your goods are securely wrapped, helping to prevent damage from dust, dirt, or moisture.

2. Improved Safety for Employees

A stretch wrap machine keeps operators on the forklift, which is a safety advantage. A recent survey found that 20 percent of forklift accidents involve pedestrians in the warehouse. Keeping operators on the forklift reduces this risk. Manual wrapping can also cause repetitive strain injuries, so switching to an automatic stretch wrap machine helps protect staff.

Automatic pallet wrappers require minimal operator involvement. The operator simply pulls a cord from the forklift to start the wrapping process, and the machine wraps the pallet or goods automatically. This ensures consistent and secure wrapping, reducing the risk of pallets toppling and protecting both goods and staff compared to manual wrapping.

3. Time Savings

Investing in a pallet wrapping machine saves significant time. Manually wrapping pallets and boxes is labour-intensive and slow. Using an automatic stretch wrap machine for storage or transport streamlines the process, freeing up time for other important business activities.

4. Reduced Film Costs

Both semi-automatic and automatic stretch wrap machines help reduce film usage and costs compared to manual wrapping. Automatic machines use two film threading rollers, with the second roller rotating faster to stretch the film. This increases the film’s tensile strength and lowers overall costs. Rotary tower automatic pallet wrappers are especially efficient.

5. Faster Packing Process

An automatic stretch wrap machine with PLC control speeds up the packaging process and helps meet high-volume packing needs. This is more effective than using a standard machine with basic features.

6. Consistent Product Wrapping

Using a stretch wrap machine for bulk packaging ensures consistent wrapping with the same stretch and efficiency every time, which is difficult to achieve with manual wrapping. Manual processes often result in variations, but an automatic pallet wrapping machine delivers uniform packaging for your boxes, pallets, and goods.

7. Higher Productivity

Increasing productivity is always beneficial. An automatic stretch wrap machine boosts efficiency by eliminating the need for operators to start and stop wrapping cycles manually. Placing a pallet on a conveyor or pulling a cord starts and stops the process automatically.

8. Better Inventory Management

Keeping similar products together makes stocktaking easier and reduces the risk of items being separated, which can slow down inventory counts. Clear, consistent stretch wrapping also allows for easy scanning if you use a scanning system.

A stretch wrap machine brings consistency and safety to your production line, regardless of your warehouse’s size or location. If you are interested in the many advantages of a pallet wrapping machine, please view our full range of automatic wrapping systems or contact one of our product experts.