Packaging efficiency today is no longer just a cost issue – predictable, safe and sustainable pallet stabilization has become a strategic priority for companies. At one of our plastic product manufacturing partners, we carried out a comprehensive audit that included an M StableSite test audit and an on-site FEF200 measurement. The goal: to identify the problems arising from manual wrapping and to find the most economical and safest solution.
Initial situation: fluctuating film consumption, weak load stability
The company previously used manual stretch film to secure the pallets, which caused several issues:
- Each employee used a different amount of film, averaging around 400 g per pallet
- Wrapping technique varied from person to person, resulting in inconsistent load security
- Load stability was often insufficient, and pallets frequently tipped over during transport
- Damaged goods led to regular customer complaints
- Film consumption was unpredictable and wasteful
The on-site M StableSite test audit clearly showed that manual wrapping does not provide the required holding force and stability level for the company.
The FEF200 measurement also demonstrated significant differences in strength and consistency between pallets wrapped manually by different operators.
The solution: switching to automated wrapping with the Sféra robot
Following the detailed audit, the company invested in a Sféra wrapping robot, which:
- uses the same amount of film every time, making costs predictable
- ensures uniform and strong pallet stability
- significantly reduces required film quantity through optimized pre-stretch
- eliminates the errors and risks associated with manual wrapping
Results in numbers
After the machine installation, the consumption data improved dramatically:
- Manual film usage: 400 g/pallet
- Sféra robot usage: 120 g/pallet
→ This means 70% film savings per pallet.
This not only leads to substantial cost reduction but also provides environmental benefits by reducing several tonnes of plastic waste annually.
Audited safety and sustainability
The new packaging process was tested again with the M StableSite audit and the FEF200 measurement, which confirmed:
- Pallet stability meets international standards
- Holding force is consistent and safe
- Film usage is optimized and repeatable
As a result, the company not only saves costs and film but also ensures damage-free transport with a high-quality, audited packaging system.
