A partner in the bottled-beverages sector approached us with the question:
“Is it possible to safely reduce the stretch-film thickness used on pallets from 23 microns to 17 microns?”
The goal was clear: to achieve material and cost savings, while ensuring the pallets remain stable and safe throughout the entire logistics chain.
The challenge
In beverage manufacturing and bottling, pallet stability is a key issue. With high, heavy loads, every vibration, acceleration or deceleration places increased stress on the film. An incorrect setting or excessive thinning of the film can lead to film rupture, and ultimately to damage to the shipment.
Our partner therefore wanted to find out whether the film thickness could be reduced without compromising safety.
The investigation – Manupackaging M StableSite Test
We conducted an on-site trial at the partner’s own plant using the M StableSite Test methodology, and measured the pallet stability in a real packaging environment with the FEF 200 measuring instrument.
During the measurements:
- We wrapped the same pallets that the partner uses in daily production,
- Packaging parameters (tension, rotation speed, overlap etc.) were not changed,
- First we used the 23 µm film, then a 17 µm film with the same settings.
Even from the static measurements it became clear that the packaging performance of the thinner, albeit same-quality film, was reduced. In the top third of the pallet the restraining force dropped significantly, increasing the risk of film rupture – in practice this could cause serious problems during loading and transport.
The solution – 17 µm Manustar® special-property film
Next we tried out a specially designed high-elongation 17 µm Manustar® film, which has been engineered so that despite its thinner gauge it still ensures higher restraining force and a more even tension distribution. The wrapping parameters remained unchanged, so the results remained objectively comparable.
The M StableSite Test – FEF 200 measurements showed that with this Manustar film:
- The pallet stability returned to its previous level,
- The film’s restraining force became more even across the entire height,
- The safety profile was slightly even better than that of the 23 µm conventional film,
- All this whilst the amount of film used dropped drastically.
The comparison showed: reducing film thickness alone is not enough – the film’s material structure and mechanical properties are crucial for maintaining safety.
Expected savings
Expected annual film usage reduction: 30,338 kg (–50.32%)
Expected annual packaging cost reduction: EUR 50,000
These figures are not estimates, but come from on-site M StableSite Test measurements and real calculation results.
Benefits achieved for the partner
After the investigation our partner:
- Received proof that thinner film can indeed be safe – if its structure is appropriate,
- Achieved film and cost savings without compromise,
- Reduced their EPR fee and environmental burden,
- And packaging became measurably more efficient and sustainable.
Conclusion
The on-site Manupackaging M StableSite Test with the FEF 200 measuring instrument clearly proved that film thickness reduction only works if the selected film has advanced mechanical properties. With such investigations, our customers can make data-based decisions, minimize risks, and maximize savings.
Would you like us to carry out the on-site assessment at YOUR plant or logistics warehouse too?
Contact our expert:
Gyökér Péter
Packaging-technology consultant
+36 70 584 2277
gyoker.peter@manupackaging.hu
If, like our partner, your business could also benefit from packaging-process optimization, please call +36 30 682 60 50 or write to iroda@manupackaging.hu!
Arató Gábor
