If you are responsible for a pallet wrapping operation, you’ll know only too well that your choice of machinery can make an enormous difference to your operational efficiency and costs, the amount of plastic film you use, and the load stability and safety standards you achieve.

With competitive price and timely delivery, Mastek sincerely hope to be your supplier and partner.

However, the wide choice of automatic and semi-automatic pallet wrapping machines available on the market today, and the huge amount of information provided by their manufacturers, can make it very challenging to identify the pallet wrapping machine that best meets your needs. This short guide aims to help you through the selection process by suggesting the questions you should consider and providing some of the information you’ll need to help answer them.

WHAT IS A PALLET WRAPPING MACHINE?

So what is a pallet wrapping machine? In essence, it is a machine that holds a roll of plastic film and applies it to a pallet, either by circling around the pallet, or by rotating the pallet on a turntable. Pallet wrappers can be loosely divided into 2 main categories – Core Brake machines and Power pre-stretch machines. You can read a lot more about their differences, and the pros and cons of each in our pallet wrapping guide.

WHAT TYPE OF PALLET-WRAPPING MACHINE DO I NEED?

Every pallet wrapping situation has its own challenges and nuances which, combined with the variety of different machines on the market, can make it hard to know where to start. We recommend that you begin by considering the following points:

1. Stability of load before wrapping. Can your load be moved at all before it is wrapped?  If not, you’ll need to choose a pallet-wrapping machine that can handle this
2. Load stability. Can you be confident that the machine will keep your load secure and safe on its pallet from the time it is wrapped until the time it’s unwrapped, no matter how it is treated during handling, transit and storage?
3. How much will it cost you to wrap each pallet, once you’ve taken all costs into consideration?
4. Plastic waste. How much single-use plastic will the machine use to wrap a pallet?
5. How much available space do you have in which to wrap the pallets?
6. Can you wrap all your pallets in fixed locations, or will you need to move your pallet wrapping location around?

THE MOST COMMON PALLET WRAPPING MACHINES WITH ADVANTAGES AND DISADVANTAGES

MANUAL PALLET WRAPPING MACHINE

Generally the cheapest pallet wrapping machine type, this option is entirely mechanical and requires no electrical supply.

ADVANTAGES

• Low initial outlay
• No requirement for electrical supply
• Very easy to use

DISADVANTAGES

• No Power Pre-Stretch System (which means a higher cost of wrapping)
• Uses a lot more plastic than necessary to wrap pallets
• Still requires operative to walk around the pallet

TURNTABLE SEMI-AUTOMATIC PALLET WRAPPER – CORE BRAKE

The most basic of all motorised pallet wrapper machines, this option has a couple of advantages but many drawbacks – as you can see below:

ADVANTAGES

• Low initial outlay
• Can be moved using a fork lift truck

DISADVANTAGES

• No Power Pre-Stretch System (which means a higher cost of wrapping)
• Ineffective when wrapping light items, as load stability is gained by increasing the tension as the film is applied to the pallet
• Uses a lot more plastic than necessary to wrap pallets
• Although it can be moved, it’s not designed to be moved on a regular basis

TURNTABLE SEMI-AUTOMATIC PALLET WRAPPER – POWER PRE-STRETCH

These are often the most efficient, and therefore popular, machines on the market. When optimised properly these machines take some beating – as  you can see from the pros and cons below:

ADVANTAGES

• The power pre-stretch head stretches the film in the head before it is applied to the pallet, creating better load stability when optimised.
• Minimises film used per pallet
• Easy to set up and use
• Can be moved with a fork lift truck
• Low maintenance
• Can be set up with many different programs to meet the needs of different pallet load types

DISADVANTAGES

• Has a large footprint so needs more space than some other types of machine
• Can generally only be used in one location.

LOW PROFILE TURNTABLE SEMI-AUTOMATIC PALLET WRAPPER – POWER PRE-STRETCH

These machines have all the advantages of the Turntable Semi-Automatic Pallet Wrappers, but with the added benefit of having a very low profile, meaning that pallets can be placed on the turntable very easily.

ADVANTAGES

• The power pre-stretch head stretches the film in the head before it is applied to the pallet, creating better load stability when optimised
• Low profile enables loading using pump trucks or PPTs
• Minimises film used per pallet
• Easy to set up and use
• Low maintenance
• Can be set up with many different programs to meet the needs of different pallet load types

DISADVANTAGES

• Has a large footprint so needs more space than some other types of machine
• Can generally only be used in one location
• Can not be moved easily once installed

ROTARY ARM MACHINES – CORE BRAKE

These models feature a machine head that circles the pallet, rather than the pallet turning on a turntable, so are great for situations in which pallets are transported on powered pallet trucks or when loads are very unstable prior to wrapping.

ADVANTAGES

• Allow easy access when using PPTs
• No base at all – so pallets can stay on the floor
• Small footprint

DISADVANTAGES

• No Power Pre-Stretch System, which means a higher cost of wrapping
• Not effective at wrapping light items as load stability is gained by increasing the tension as the film is applied to the pallet

ROTARY ARM MACHINES – POWER PRE-STRETCH

With Rotary Arm machines, a machine head circles the pallet rather than the pallet turning on a turnable, which means they are great for situations in which pallets are transported on powered pallet trucks or when loads are very unstable prior to wrapping. The power pre-stretch head also delivers excellent load stability, but these machines do still have their pro’s and con’s:

ADVANTAGES

• Allow easy access when using PPTs
• No base at all – so pallets can stay on the floor
• The power pre-stretch head stretches the film in the head before it is applied to the pallet, creating better load stability when optimised.
• Minimises film used  per pallet
• Easy to set up and use
• Can be set up with many different programs to meet the needs of many different pallet load types

DISADVANTAGES

• Large base footprint
• Often a more expensive option
• Cannot be moved once installed

ROBOT PALLET WRAPPER

The latest in the pallet wrapping innovation – the Robot follows the contours of the pallet and literally ‘runs’ round the pallet wrapping it as it goes in much the same way as a human would. Robot pallet wrappers have a lot more advantages than disadvantages.

ADVANTAGES

• Easily movable, so can be used anywhere that pallets need wrapping
• Battery operated, so don’t need a local power supply
• Wraps pallets of any shape and size as the robot follows the contours of the pallet
• Power pre-stretch head ensures that film usage is minimised when optimised

DISADVANTAGES

Contact us to discuss your requirements of Carton Erector. Our experienced sales team can help you identify the options that best suit your needs.

Pallet Wrapping Machine: Types, Features, and Buyer’s Guide

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Pallet wrapping machines are essential for automating the packing of palletized loads. They ensure the goods on pallets are protected and stabilized during shipping or storage by using stretch film to secure them. 

In this blog, we will explore what pallet wrapping machines are, why they are used, and their benefits. We will also delve into the different types of pallet wrapping machines, their features, and what to consider when buying one.

What is a Pallet Wrapping Machine?

A pallet wrapping machine, also known as a pallet stretch wrapper, is a specialized piece of equipment designed to secure and stabilize palletized loads by wrapping them with stretch film. 

This process is essential for protecting goods during transportation and storage, ensuring they remain intact and free from damage, dust, and moisture. The machine wraps the stretch film tightly around the products on the pallet, creating a secure and tamper-evident package.

The Different Types of Pallet Wrapping Machines

Automatic Pallet Wrapping Machine

Automatic pallet wrappers are designed for high-volume operations. They offer significant benefits, including:

• Lower Labor Costs: Automation reduces the need for manual labor.
• Less Film Waste: Pre-stretching functions allow for efficient use of film.
• Better Safety: Modern automatic wrappers have advanced safety features to protect operators.

Semi-Automatic Pallet Wrapping Machine

Semi-automatic pallet wrappers are a hybrid between manual and automatic machines. They are suitable for medium-volume operations:

• Manual Loading and Unloading: Operators must position the pallet, attach the film, start the wrapping process, and remove the wrapped pallet.
• Automatic Wrapping: The wrapping process itself is automatic, providing efficiency while still requiring some manual intervention.

Comparison of Automatic vs. Semi-Automatic Pallet Wrapping Machines

Feature/Aspect

Automatic Pallet Wrapping Machine

Semi-Automatic Pallet Wrapping Machine

OperationFully automated, minimal human intervention requiredPartially automated, requires some manual handlingLabor RequirementsSignificantly reduces labor needsRequires an operator for loading, starting, and unloadingSpeed and EfficiencyHigh-speed operation, wraps pallets quicklyModerate speed, faster than manual but slower than automaticConsistencyEnsures uniform and consistent wrapping every timeProvides more consistent wrapping than manual methodsSafetyEnhanced safety features, keeps operators on forkliftsImproved safety over manual methods, but still requires manual stepsCostHigher initial investmentLower initial investment compared to fully automatic machinesFilm UsageOptimizes film usage with pre-stretch capabilitiesUses more film than automatic machines without pre-stretch capabilitiesMaintenanceRequires regular maintenance of more complex systemsEasier maintenance due to simpler mechanismsIdeal ForHigh-volume operations with frequent pallet wrappingMedium-volume operations with moderate pallet wrapping needsFlexibilityBest for standard and repetitive tasks, can be less flexible for custom needsOffers more flexibility for varying loads and custom wrapping requirementsProductivityMaximizes productivity, allows operators to focus on other tasksIncreases productivity but still requires manual intervention at key pointsSpace RequirementsRequires dedicated space for setup and operationCan be more compact, suitable for smaller spaces

How Does a Pallet Wrapping Machine Work?

Step 1: Loading the Pallet

The pallet, loaded with goods, is placed onto the machine. Depending on the type of machine, this can be done manually, semi-automatically, or fully automatically.

Step 2: Applying the Film

The stretch film is attached to the pallet, usually at the base. The film can be applied either manually or through an automated system, depending on the machine type.

Step 3: Wrapping Process:

The machine wraps the film around the pallet. This can be done in various ways:

• Turntable Machines: The pallet sits on a rotating turntable, and the film is wrapped as the table spins.
• Arm Wrapping Machines: A rotating arm moves around the stationary pallet, wrapping the film around it.
• Ring Wrapping Machines: The pallet remains stationary while a ring wraps the film around it vertically.

Step 4: Securing the Film

Once the pallet is fully wrapped, the film is cut and secured. In automatic machines, this is done by the machine itself. In manual or semi-automatic machines, an operator might need to cut and secure the film.

Step 5: Unloading the Pallet

The wrapped pallet is then removed from the machine, ready for storage or transportation.

Why is a Pallet Wrapping Machine Used?

Pallet wrapping machines play a vital role in modern logistics and packaging operations. Here are several key reasons why these machines are crucial:

Protection from Damage

• Environmental Protection: Pallet wrapping machines ensure that goods are tightly wrapped with stretch film, which acts as a protective barrier against environmental factors such as dust, dirt, and moisture. This is especially important for products that need to maintain their quality and integrity during long periods of storage or transport.
• Physical Protection: The stretch film provides an additional layer of cushioning that helps protect products from physical damage such as scratches, dents, and breakage. This is particularly beneficial for fragile or delicate items.
• Tamper Evident: The tight wrapping makes it immediately evident if the package has been tampered with, adding an extra layer of security during transport and storage.

Increased Safety

• Operator Safety: Automatic pallet wrapping machines keep operators on the forklift, reducing the need for them to manually handle the wrapping process. This minimizes the risk of accidents, such as trips and falls, which can occur when walking around the pallet to wrap it manually.
• Consistent Application: By automating the wrapping process, the risk of repetitive strain injuries, which are common with manual wrapping, is significantly reduced. This contributes to a safer working environment.

Uniform Wrapping

• Consistency: Automatic and semi-automatic pallet wrapping machines ensure that each pallet is wrapped uniformly, regardless of who operates the machine. This consistency is crucial for maintaining product quality and stability during transport.
• Efficiency: Uniform wrapping reduces the likelihood of load shifting and instability, which can cause damage to products during transit. It also improves the overall appearance of the wrapped pallets, making them more presentable and easier to handle.

Labor Cost Reduction

• Automation: By automating the wrapping process, companies can significantly reduce the amount of manual labor required. This not only lowers labor costs but also frees up employees to focus on more critical tasks that require human intervention and critical thinking.
• Time Savings: Automated pallet wrappers can wrap pallets much faster than manual methods. This increase in speed and efficiency allows companies to process more pallets in less time, improving overall productivity and throughput.
• Material Savings: Modern pallet wrapping machines often include features like pre-stretching, which optimizes the use of stretch film. This reduces the amount of film needed per pallet, resulting in cost savings on packaging materials.

Enhanced Load Stability

• Load Containment: Properly wrapped pallets are more stable and secure, reducing the risk of load shifting during transport. This is particularly important for heavy or irregularly shaped loads.
• Minimized Waste: Securely wrapped pallets reduce the likelihood of product loss or damage due to instability, which can significantly impact a company’s bottom line.

To conclude, pallet wrapping machines are indispensable tools for any business that needs to package and transport goods efficiently and safely. 

They offer numerous benefits, including enhanced protection, increased safety, uniform wrapping, and labor cost reduction, making them a valuable investment for improving overall operational efficiency.

Features of a Good Pallet Wrapping Machine

When selecting a pallet wrapping machine, consider the following features:

• Adjustable Tension Control: Allows for precise control over the film tension.
• Pre-Stretch Function: Maximizes film usage, reducing waste and cost.
• Safety Features: Includes sensors, photocells, and safety interlocks to protect operators.
• Ease of Use: User-friendly controls and interfaces for easy operation.
• Durability: Built to withstand harsh industrial environments.
• High-Speed Operation: Suitable for high-volume applications, ensuring efficiency.
• Versatility: Ability to handle different pallet sizes and shapes.
• Energy Efficiency: Reduces operational costs and environmental impact.

Consult with Flexipack for Your Pallet Wrapping Needs

Choosing the right pallet wrapping machine for your packaging needs can be complex, given the variety of options and specific requirements of different industries. 

At Flexipack, we understand the importance of selecting the most suitable machine to ensure optimal protection, efficiency, and cost-effectiveness for your products. Our team of packaging specialists is here to help you navigate through the different types of pallet wrapping machines and determine the best solution for your unique requirements. 

Schedule a Free Consultation Today