Retrofit Efficiency: Replacing an outdated Inline Stretch Wrapping Machine

Replacing and retrofitting outdated equipment is a common challenge amongst long running and well established businesses. At times, enhancing a packaging process for better reliability and productivity is necessary; however, budget constraints may prevent the replacement of all components. 

Our multinational customer's Victorian warehouse faced this challenge with outdated stretch wrapping machinery and the inability to justify the costs of a full upgrade. The existing wrapping machine and safety system were no longer functional, creating production inefficiencies and increased safety hazards.

FROMM identified the key areas requiring 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 FS580 series system to enhance performance while ensuring the safety system met current Australian standards. The FS580 automatic pallet wrapping machine provides a perfect entry point into full automation without requiring substantial financial investment. 

The planning for this project involved FROMM creating a comprehensive engineering scope and securing loan equipment for the customer to minimise downtime. 

Our scope for this project included installing new cabling for each conveyor section, integrating the cabling into a modern electrical cabinet, and replacing the Lantech wrapper with a FROMM FS580 Arm Stretch Wrapping Machine. Additionally, we introduced a new pallet lifter to provide greater flexibility in film application and installed a state of the art production safety cell to ensure workplace safety. 

Previously, an employee monitored the wrapping process, identifying pallets that were not wrapped to standard, which contributed to inefficiencies. With FROMM's FS580 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, saving on packaging costs and waste disposal. 

The integration and installation of all project elements was carried out by our committed FROMM service technicians and occurred onsite over the course of about seven days. Upon completion of the project, 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 retrofitted solution not only maximised the use of existing equipment but also delivered measurable improvements in operational efficiency and costs.

Our FROMM technicians and project teams have completed many retrofit installations, and their knowledge and experience are key to each project's success. If you have outdated equipment that needs replacing, reach out to our expert team and we can tailor a solution for your business.