Client: Hungarian Detergent Manufacturing Company
Sector: Chemical Industry – Household Cleaning Products
Technology: Pre-stretch Pallet Wrapping (Synthesi Rotary Turntable Machine)
Challenge: High Unit Packaging Costs and Rising EPR Fees
For years, the client had been using standard stretch film for pallet wrapping, handling around 60 pallets per day. On average, 530 grams of film were used per pallet – a practice that resulted in high packaging costs and increasing EPR (Extended Producer Responsibility) fees year over year.
The company had two clear goals:
- To drastically reduce per-pallet film usage and packaging costs
- To minimize the financial burden of EPR-related environmental fees
Solution: Pre-stretch Wrapping Robot – On-Site Testing and Deployment
The Manupackaging expert team provided a test-driven approach by demonstrating the benefits of pre-stretch technology using a mobile wrapping robot directly at the customer’s facility.
The results spoke for themselves:
- Film usage per pallet dropped from 530 g to just 133 g, resulting in a 75% reduction
- Pallet stability remained excellent, and the robot consistently applied the same amount of film, delivering full cost predictability
- Following the successful demonstration, the company invested in a Synthesi rotary turntable pre-stretch wrapping machine
Results in Numbers
The investment brought tangible benefits from the very first months:
| Metric | Result |
|---|---|
| Film per pallet | 530 g → 133 g |
| Daily pallets wrapped | 60 pcs |
| Monthly film savings | 596 kg |
| Annual film savings | 7,152 kg |
| Film reduction rate | 75% |
| Machine ROI | 7 months |
In addition, the company achieved:
- Lower environmental impact thanks to less packaging waste
- Reduced unit cost, as each pallet receives the same amount of film
- Decreased EPR-related fees, supporting sustainability efforts
Key Takeaway
This case study is a clear example of how a single strategic investment can bring substantial cost savings and environmental benefits. The automated pre-stretch wrapping technology not only improves packaging efficiency but also supports sustainable operations – which is no longer an option, but a modern-day expectation.
