A Success Story of Partnership
Sometimes, everything is in place for substantial cost savings in packaging — all that’s needed is the right expertise to unlock the potential. This was exactly the case with one of our printing industry partners. By fine-tuning their existing wrapping machine and selecting the ideal film, we achieved a 61% cost reduction!
The Mission: Cost-Effective Optimization with Minimal Disruption:
Our client aimed to reduce packaging costs through process optimization — but without any major changes or investments. We conducted an on-site packaging test to assess both the weaknesses and untapped potential of their current setup. It quickly became clear that using a 23 μm film to wrap relatively lightweight pallets (200–300 kg) was entirely unnecessary.
The Results: Smarter Film, Smarter Savings:
Simply replacing the 23 μm film with a thinner, better-suited alternative allowed us to reduce the cost per pallet significantly.
But we went even further: by activating the previously unused pre-stretch capability of the existing machine, we maximized the potential of a 17 μm high-stretch power film. Using 160% pre-stretch and the same number of wraps (6) as before, we achieved an almost 70% material reduction.
Where previously 254 grams of film were needed per pallet, our solution brought that number down to just 84 grams. Even considering the higher unit price of the higher-quality film, this translated into an impressive61% cost saving for the company!
This means that — without any major investment, reconfiguration, or new equipment — the company can now convert nearly two-thirds of its former packaging costs into profit, while also significantly reducing the amount of waste generated on-site.
Additional Benefits: Less Waste, Greater Safety, Lower Fees
Thanks to the optimized packaging method, the company’s EPR (Extended Producer Responsibility) fees were also reduced, as less packaging material is used. At the same time, pallet stability and load retention improved, ensuring safer transport and storage.
Let’s Make Your Business More Efficient – Together!
“The value of packaging is beyond question – it enables the safe transport and extended shelf life of products, goods, and food items over long distances. However, we believe this should be done with minimal packaging material to protect our environment from unnecessary waste. This is the mission we’ve committed to.”
– Gábor Arató, Managing Director, Manupackaging Hungary Kft.
