The Benefits of Automated Pallet Wrapping: 3 Real-World Examples That Showcase Its Impact

Exploring The Benefits Of Automated Pallet Wrapping Systems 

In today's fast-paced industrial landscape, many companies are grappling with the challenge of meeting soaring production demands. Whether they are importers navigating a flood of incoming containers or manufacturers racing to keep pace with high production rates, the quest for efficient and reliable packaging solutions has never been more crucial. Enter automated pallet wrapping systems - a technology that has evolved dramatically in recent years, offering one of the most effective ways to secure palletised cargo. These systems do more than just simplify operations; they elevate the safety and integrity of your goods while in transit. This makes them an essential asset for boosting business efficiency and ensuring peace of mind. 

Automated Pallet Wrapping Benefits 

Stretch wrapping remains the fastest and most cost-effective way to secure goods for storage and transport. With advancements in plastic technology, businesses can now use considerably less one way plastic compared to just five years ago. By pairing high-quality stretch films with the right wrapping machines, companies can achieve impressive outcomes that align with their sustainability goals while also enhancing production efficiency. Moreover, automation reduces the need for human involvement in the wrapping process, allowing staff to focus on other critical areas of the operation. 

Let's explore a few recent examples of how FROMM automated pallet wrapping systems have improved our clients packaging process and productivity.

1.)  High speed automated solution for a brand new facility

When starting designing a system to be integrated into a brand new facility, the possibilities are almost endless. At a newly established greenfield site in Victoria, a client sought to enhance their production capabilities by implementing a high-speed advanced FROMM automated pallet wrapping system. With the remarkable demand to secure up to 100 pallets per hour, the system was required to streamline the stretch wrapping process and efficiently apply the necessary stretch film in approximately 26 seconds per pallet. The solution for this client was FROMM's FA8 Series; an ultra high speed stretch wrapping machine, which can handle up to 120 pallets per hour in its optimum configuration. The installation also included an optional pallet lifter so the film could be applied accurately and meet the requirements of Coles and Woolworths incoming goods protocol. 

As as result of this automation, the final customer benefits from a much smaller waste footprint compared to previous operations. They are now able to collaborate with recyclers to recover the used stretch film, facilitating its transformation into new resin for second processing. Such partnerships not only enhance sustainability but also optimise the supply chain, making it more efficient and environmentally friendly. 

2.)  Automated pallet wrapping solution for fragile and  unstable loads 

In another recent installation in Victoria, our customer was searching for a standalone solution that would allow their staff to be redeployed to other important tasks. The task only demanded that capability to stretch wrap and secure 35 pallets per hour; however, it currently necessitated more staff involvement due to the fragile nature of the pallet contents. A benefit of FROMM automated pallet wrapping systems is that they can be engineered to cater to light or fragile loads with little human involvement and deliver consistent and efficient results. In this case, it was crucial that the cartons remained intact to meet the struct load containment guidelines set by major retailers like Coles and Woolworths. 

The FROMM FA7 Series arm wrapper was perfectly designed for this application, integrating an optional pallet lifter and platen that work together to keep the loads stable throughout the stretch wrapping process. The FROMM designed and engineered pre-stretch film carriage also converts one metre of stretch film into three metres of finished product on the pallet. This overall system allows for the stretch film to be applied in a way that significantly reduced the risk of carton crush whilst still ensuring clear visibility for labelling. Moreover, it minimised the amount of stretch film required to secure the cargo safely. 

The benefits of automated pallet wrapping were very clear in this case. It not only increased the speed of wrapping process but also lowered the overall cost of ownership. By reducing one-way plastic usage and providing consistent, repeatable results, the return on investment is immediately noticeable. Ultimately, the implementation of this automated solution led to positive outcomes for the customer, streamlining their operations and enhancing efficiency in their despatch processes. 

3.) Integrating automated pallet wrapping machines with existing equipment 

At times, enhancing a packaging process for better reliability and productivity is necessary; however, budget constraints may prevent the replacement of all components. 

A warehouse in Victoria faced those challenges with an outdated packaging line and the inability to justify the costs of a full upgrade. Their production demand were not exceptionally high-speed, but the layout prohibited reintroducing human intervention. To secure funding for improvements, we conducted a thorough analysis of their existing equipment, focusing on maintenance and downtime costs. 

By examining data of the old system, we identified key areas of improvement, particularly regarding safety compliance and efficiency. Our recommendation involved a partial upgrade that would utilise the existing conveyors, which had proven to be reliable with minimal maintenance and downtime. Our proposal included replacing the wrapper arm with a FROMM FS550 series system to enhance performance while ensuring the safety system met current Australia standards. The FS550 automatic pallet wrapping machine provides a perfect entry point into full automation without requiring substantial financial investment. 

Previously, an employee monitored the wrapping process, identifying issues of the pallets not up to standard, which contributed to inefficiencies. With FROMM's FA5 Series solution, the quality control system is inbuilt to ensure consistent and predictable outcomes. This transition led to a significant reduction in stretch film consumption, cost saving on packaging and waste disposal. 

As a result of this enhancements, uptime increased, eliminating production bottlenecks. Staff could confidently turn their backs to the packaging line, knowing that the upgrade system was reliable and efficient. This integrated approach not only maximised the use of existing equipment but also delivered measurable improvements in operational efficiency and cost-effectiveness. 

Maximise Efficiency With A FROMM Automated Pallet Wrapping Solution Today! 

FROMM Packaging Australia have been providing automated pallet wrapping solutions to the Australian market since 1977 and we have built a strong reputation for providing expert advice, reliable equipment and tailored solutions. Smart automated solutions can elevate your packaging line into seamless operation. Modern automated wrapping delivers consistent stretch, precise film usage, and perfect load containment. Every time. No exceptions. Australian businesses trust our technology because it works - simple as that. From providing a cutting edge high speed solution for a brand new facility to working with difficult loads or integrating with existing equipment, we've got solutions that match your exact needs. 

Ready to save time, film and frustration? Let's talk. Our packaging specialists can help you crunch the numbers and see exactly how automation could transform your operation. Because efficiency isn't just about wrapping faster - it's about wrapping smarter.