Manual pallet wrapping remains a common practice in many logistics operations – yet it’s often the source of unnecessary cost and risk. In this case, a new automated wrapping solution helped our partner significantly cut packaging expenses while boosting transport security.
The Challenge: Inconsistent Film Usage and Unstable Loads
At our partner’s logistics warehouse, wrapping pallets by hand led to several interrelated problems:
- Inconsistent film consumption: Each employee wrapped pallets differently, using between 250 and 400 grams of stretch film per pallet. This led to inefficiencies and unpredictable material costs.
- Insufficient holding force: Manual wrapping didn’t consistently secure the loads. Pallets occasionally shifted or collapsed during transport – a major risk, especially when handling fragile goods.
- Uncontrolled packaging costs: Due to the inconsistency in film usage and product damage, packaging costs were difficult to plan and often higher than expected.
The partner sought a solution that would provide more consistent, efficient, and cost-effective pallet wrapping.
The Solution: Introducing the Sféra Automated Wrapping Robot
After an on-site consultation and testing session with our specialists, the Sféra wrapping robot was selected as the ideal fit for the warehouse’s standardized pallet types.
Key benefits of the new system:
- Automated process: The robot applies the same amount of stretch film each time, based on pre-set parameters.
- Reliable load stability: Every pallet is wrapped with consistent holding force, reducing transport risks.
- Predictable unit costs: Controlled film usage enables accurate packaging cost planning.
- Improved operational efficiency: Staff time is no longer tied up with manual wrapping, allowing them to focus on other tasks.
The Result: 2,100 kg of Film Saved per Year
The investment produced fast and measurable results:
- Film consumption per pallet:
- Manual wrapping: approx. 285 g
- Sféra robot: approx. 90 g
- A 68% reduction in film used per pallet
- Monthly film savings: ~175 kg
- Annual film savings: ~2,100 kg
In addition to material savings, the partner experienced greater pallet stability, fewer product damages, and a packaging process that is more transparent, faster, and sustainable.
With a single, well-chosen equipment investment, our partner reduced costs and improved load security – through an automated, environmentally conscious, and long-term sustainable packaging solution.
