Client Profile:
A major automotive logistics provider, responsible for packaging and shipping approximately 200 pallets per day across the country.
The Challenge: Unpredictable Packaging Costs and Load Stability Issues
Previously, the client relied on manual pallet wrapping, which resulted in several recurring problems:
- Inconsistent film usage: Each employee applied a different amount of stretch film, ranging from 300 to 400 grams per pallet.
- Insufficient load stability: Manual wrapping often failed to secure the pallet properly, causing load shifts or collapses during transport.
- No bottom wrap coverage: The lower part of the pallet was frequently left unwrapped, further compromising transport security.
The Solution: Implementation of a Sfera Robotic Wrapping Machine
Working with Manupackaging, the client invested in a Sfera wrapping robot and integrated it into their packaging process. Given that they handle standardized unit loads, the transition to automated wrapping was a perfect fit.
The Results: Film Savings, Load Stability, Fast ROI
Once the machine settings were optimized, the new system delivered immediate and measurable benefits:
- Consistent film usage: Each pallet is now wrapped with an exact and optimized amount of film – on average, 115 grams.
- 60% reduction in stretch film usage: Previously, the manual process consumed around 279 grams per pallet.
- Improved transport safety: The robot ensures full bottom wrap coverage every time, significantly enhancing load stability during shipment.
- Quick return on investment: With 200 pallets wrapped daily, the machine paid for itself in just 6 months.
Savings in Numbers:
| Metric | Manual Wrapping | Sfera Robot | Savings |
|---|---|---|---|
| Avg. film per pallet | 279 g | 115 g | -164 g |
| Monthly film usage | ~1,325 kg | ~530 kg | 795 kg |
| Annual savings | – | – | 9,540 kg of film / year |
Summary
This machine investment brought more than just cost-efficiency – it delivered predictability, sustainability, and safety. With consistent wrapping quality and substantial material savings, the company significantly improved its packaging process and reduced its environmental footprint.
“The usefulness of packaging is unquestionable, as it ensures that products, goods and food can be transported over longer distances and have a longer shelf life. However, we believe it is important to do this with as little packaging as possible and to protect our environment from unnecessary packaging pollution – this is our mission statement” – Gábor Arató, Managing Director of Manupackaging Hungary Kft.
