{"id":8306,"date":"2026-01-24T10:32:34","date_gmt":"2026-01-24T10:32:34","guid":{"rendered":"https:\/\/manupackaging.hu\/?p=8306"},"modified":"2026-01-24T10:38:59","modified_gmt":"2026-01-24T10:38:59","slug":"31-film-savings-in-a-flour-mill-when-accurate-measurement-leads-to-real-cost-reduction","status":"publish","type":"post","link":"https:\/\/manupackaging.hu\/en\/31-film-savings-in-a-flour-mill-when-accurate-measurement-leads-to-real-cost-reduction\/","title":{"rendered":"31% Film Savings in a Flour Mill \u2013 When Accurate Measurement Leads to Real Cost Reduction"},"content":{"rendered":"\n

In many industries, packaging is often treated as a given: \u201cthis is how we\u2019ve always done it,\u201d \u201cit works well enough.\u201d
However, the case of one of our flour mill partners<\/strong> once again proved that data-driven packaging optimisation delivers tangible business results<\/strong> \u2013 even in highly automated environments.<\/p>\n\n\n\n

Industry and activity<\/h3>\n\n\n\n

Our partner operates in the milling industry<\/strong>, where pallet stability, product safety, and cost efficiency are all equally critical factors.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

Why did the collaboration start?<\/h3>\n\n\n\n

The starting point of our cooperation was a classic, yet highly relevant challenge:<\/p>\n\n\n\n

    \n
  • high packaging material costs<\/li>\n\n\n\n
  • unnecessarily high specific film consumption<\/li>\n<\/ul>\n\n\n\n

    The objective was clear: cost reduction<\/strong>, while maintaining packaging safety.<\/p>\n\n\n\n

    Initial situation \u2013 when \u201creported data\u201d differs from reality<\/h3>\n\n\n\n

    Before testing and on-site measurements, the partner indicated that:<\/p>\n\n\n\n

      \n
    • they were using\u00a017 micron (\u00b5m) stretch film<\/strong><\/li>\n\n\n\n
    • film consumption per pallet was\u00a0233 grams<\/strong><\/li>\n<\/ul>\n\n\n\n

      However, during the on-site audit it became clear that:<\/p>\n\n\n\n

        \n
      • a\u00a020 micron film<\/strong>\u00a0was actually in use<\/li>\n\n\n\n
      • meaning the basic data itself was inaccurate<\/li>\n<\/ul>\n\n\n\n

        Once again, this highlighted a key principle:
        without accurate measurement, real optimisation is impossible.<\/strong><\/p>\n\n\n\n

        Was packaging machine replacement necessary?<\/h3>\n\n\n\n

        The partner currently uses an automatic stretch wrapping machine<\/strong>.
        During the project, no machine replacement or new investment was required<\/strong>.
        Switching to a more suitable film and optimising machine settings proved sufficient to achieve the desired results.<\/p>\n\n\n\n

        Scope of the assignment<\/h3>\n\n\n\n

        The task was straightforward:<\/p>\n\n\n\n

          \n
        • reduce film consumption<\/li>\n\n\n\n
        • lower packaging costs<\/li>\n\n\n\n
        • maintain pallet stability and load safety<\/li>\n<\/ul>\n\n\n\n

          The result \u2013 measurable success<\/h3>\n\n\n\n

          After optimisation and testing:<\/p>\n\n\n\n

            \n
          • the operation was switched to\u00a015 micron stretch film<\/strong><\/li>\n\n\n\n
          • film consumption per pallet was reduced to\u00a0162 grams<\/strong><\/li>\n<\/ul>\n\n\n\n

            In practical terms, this means:<\/p>\n\n\n\n

              \n
            • 31% film savings<\/strong><\/li>\n\n\n\n
            • 71 grams saved per pallet<\/strong><\/li>\n\n\n\n
            • approximately\u00a02,500 kg of film saved annually<\/strong><\/li>\n<\/ul>\n\n\n\n

              What does this mean from a business perspective?<\/h3>\n\n\n\n
                \n
              • lower packaging material costs<\/li>\n\n\n\n
              • reduced raw material usage<\/li>\n\n\n\n
              • more sustainable operations<\/li>\n\n\n\n
              • significant savings without capital investment<\/li>\n<\/ul>\n\n\n\n

                Summary<\/h3>\n\n\n\n

                This project clearly demonstrates that:<\/p>\n\n\n\n

                \n

                packaging decisions should be based on measurements, not habits.<\/strong><\/p>\n<\/blockquote>\n\n\n\n

                Even in automated packaging systems, there is often substantial hidden potential in film selection and machine parameter optimisation.<\/p>\n","protected":false},"excerpt":{"rendered":"

                In many industries, packaging is often treated as a given: \u201cthis is how we\u2019ve always done it,\u201d \u201cit works well enough.\u201dHowever, the case of one of our flour mill partners once again proved that data-driven packaging optimisation delivers tangible business results \u2013 even in highly automated environments. Industry and activity Our partner operates in the milling industry, where pallet stability, […]<\/p>\n","protected":false},"author":5,"featured_media":6075,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_seopress_robots_primary_cat":"129","_seopress_titles_title":"","_seopress_titles_desc":"","_seopress_robots_index":"","footnotes":""},"categories":[157],"tags":[],"class_list":["post-8306","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-studies"],"acf":[],"_links":{"self":[{"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/posts\/8306","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/users\/5"}],"replies":[{"embeddable":true,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/comments?post=8306"}],"version-history":[{"count":2,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/posts\/8306\/revisions"}],"predecessor-version":[{"id":8308,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/posts\/8306\/revisions\/8308"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/media\/6075"}],"wp:attachment":[{"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/media?parent=8306"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/categories?post=8306"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/manupackaging.hu\/en\/wp-json\/wp\/v2\/tags?post=8306"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}