Two approaches, one goal: significant stretch film savings in the food industry
Two different packaging strategies at a food manufacturing company, the same objective, different solutions, outstanding results.
In the operation of food manufacturing plants, stretch wrapping often receives little focused attention, even though significant hidden losses occur within this process on a daily basis. Wrapping takes place at the end of the production line and does not directly influence production output, which is why non-optimized material usage can become embedded into everyday operations unnoticed over time.
Two different packaging interventions were implemented at the same site
The objective on both packaging lines was identical: to reduce material usage without compromising pallet stability or operational safety. In one case, optimization was carried out while retaining the existing machine. In the other, a new machine was introduced to unlock a higher level of savings.
Savings on machine 1
Achieved through film change and machine-setting optimization, without capital investment.
Reduction with the new machine
Major material savings while pallet stability and transport safety remained unchanged.
Annual savings
Delivered through a self-financing model based on lower packaging material usage.
Optimization of an existing stretch wrapping machine
Both machines had been operating reliably for more than twenty years, so the partner did not initially consider investing in new equipment. The clear expectation, however, was to reduce packaging costs while maintaining the existing infrastructure and pallet stability.
Initial state and audit findings
- Applied film: 13-micron stretch film
- Average film consumption: 227 g per pallet
- Film pre-stretch: low relative to machine capability
- Film tension and wrapping pattern: set with excessive safety margins
- Pallet stability: adequate, but achieved with unjustified material usage
The solution
Based on the recommendation of our expert team, the partner was transitioned to Manustif 9-micron stretch film, and the film pre-stretch settings were adjusted on both existing machines.
- Gradual testing with continuous monitoring
- No production risk or downtime
- Pallet performance checked after wrapping and during transport
What the project proved
Packaging safety did not deteriorate, film breakage did not increase, and no pallet stability complaints were reported on either machine.
The case clearly showed that substantial savings can be achieved on older-generation equipment as well, without a new machine investment.
Wrapping machine 1
Original consumption: 227 g per pallet
New consumption: 141 g per pallet
Film savings: 38%
Pallet stability: unchanged
Wrapping machine 2
Original consumption: 227 g per pallet
New consumption: 148 g per pallet
Film savings: 33%
Pallet stability: unchanged
Why this route worked
Both lines kept their existing machines, but film choice and machine settings were finally aligned with each other.
- No CAPEX required
- Fast implementation on site
- Stable pallets without excess film usage
The savings delivered not only cost benefits, but sustainability gains as well
Reducing film consumption delivered not only cost benefits, but also direct environmental advantages. By lowering the specific film usage per pallet, a considerable amount of plastic use became unnecessary on an annual basis.
Lower film usage meant reduced raw material demand and lower manufacturing and logistics-related environmental impact, while packaging safety and pallet stability remained unchanged. The savings were therefore achieved in full alignment with sustainability goals, without compromise.
Replacement of the stretch wrapping machine: major material reduction with a self-financing investment
On the second packaging line, the partner's objective was no longer limited to fine-tuning material usage, but rather to achieving the maximum possible savings. The on-site assessment showed that, in this case, the desired results could only be achieved by introducing new equipment.
Initial situation
- Average film consumption: 750 g per pallet
- Pallet stability was acceptable, but only with extremely high material usage
- The existing machine’s pre-stretch capability limited efficiency
- Further savings were not feasible without technical intervention
Interim solution before investment
Because the new machine’s lead time was several months, we installed a warehouse-available stretch wrapper as a temporary step.
- Optimized packaging started immediately
- Film consumption dropped before final installation
- Production continued without downtime
Results and ROI
Film consumption before changeover: 750 g per pallet
Film consumption after changeover: 215 g per pallet
64% reduction in material usage
Pallet stability and transport safety remained unchanged
Investment payback within 3 to 4 months
Financing model
In this project, a 66% reduction in film usage made it possible for half of the savings to cover the machine cost through the film price, while the other half appeared immediately as net cost savings.
Annual savings: HUF 10 million
When replacement is the better option
Here, the largest savings potential was on the machine side, so equipment replacement unlocked the result that optimization alone could not deliver.
- Self-financing structure
- No compromise on transport safety
- Manupackaging supported both technology and financing
The foundation of measurable savings
Every optimization begins with a detailed on-site packaging audit. The objective of the audit is to identify savings potential in film usage and the packaging process based on real measurements.
Decision support
Cost-effective decisions based on real data.
Speed
Immediate on-site results, no post-analysis waiting time.
Sustainability
Less film, lower environmental impact.
Safety
More stable loads, fewer transport-related damages.
Areas examined during the audit
- Technical condition and settings of the stretch wrapping machines
- Type, thickness, and performance of the applied film
- Suitability of film pre-stretch, tension, and wrapping pattern
- Pallet stability after wrapping and during transport
- Specific film consumption per pallet
- The gap between the current state and the achievable optimized state
Why the audit matters
If you would like to understand where and how much savings can be achieved in your own packaging processes, apply for our on-site packaging audit.
The purpose of the audit is not sales, but measurement and well-founded decision support.
If you want to understand where and how much can be saved, apply for our on-site packaging audit
The purpose of the audit is not sales, but measurement and well-founded decision support. We help you determine whether optimizing the existing machine or introducing new equipment will deliver the best return in your operation.