In manufacturing plants handling a wide and rapidly changing product range, the efficient securing of finished goods is crucial to the efficiency of the entire logistics process. Masterchem Logoplaste, a manufacturer of PET and rPET packaging for various industries, decided to further automate its internal logistics. A key element of this modernization was the implementation of an automated pallet-securing system at the end of the production line. The new solution improved the consistency of the wrapping process, streamlined the preparation of diverse loads for storage and transport, and optimized the use of consumables.
Various pallets and dimensions – the challenge of flexible production
The nature of production at Masterchem Logoplaste involves handling loads of varying dimensions. Products arriving at the packaging station differ in height, weight, and pallet arrangement. The project aimed to increase the level of automation at this stage while ensuring a repeatable process for securing various types of loads. The solution proposed by Lintegra – featuring an automatic load detection system – addressed these requirements. The system identifies the parameters of the incoming pallet and automatically adjusts the machine’s operating settings, including wrapping height and the method of film application.
Signode Technology – stability and sustainability in one
The implemented solution utilizes technology from Signode, a manufacturer of machinery and materials for securing industrial loads. The project employs the POWER FLEX T1 system, which automatically adjusts the wrapping process to accommodate diverse pallet loads. A key feature of the solution is the precise control of film application, enabling tension management and efficient material usage while ensuring the stability of the secured pallet. The technology also supports the use of films containing recycled content – such as PCR – aligning with sustainability initiatives.
POWER FLEX T1 Technical Specifications
- Throughput [loading capacity] – up to 100 loads per hour
- Machine footprint [length] – 1620 mm (63.8 in)
- Machine footprint [width] – 2250 mm (88.6 in)
- Machine height – 4430 mm (174.4 in)
- Pallet size [min.] – 1000 mm L x 800 mm W (39.4 x 31.5 in)
- Pallet size [max.] – 1400 mm L x 1200 mm W (55.1 x 47.2 in)
Professional pallet wrapping in practice
The process, which previously required constant operator supervision, has been fully automated. The automatic wrapping machines we offer apply stretch film with precision, creating a compact structure resistant to external factors.
Key phases of automatic film wrapping:
- Load dimension detection – scanning the pallet profile before the cycle begins.
- Optimal pre-stretch – precise film stretching, reducing consumption by up to several tens of percent.
- Base and top reinforcement – additional wrapping at points most susceptible to stress.
- Automatic film cutting and sealing – a clean finish with no loose ends that could cause jams in high-bay warehouses.
Customer benefits and measurable gains
The implementation of an automated film-wrapping system marks another step in the development of Masterchem Logoplaste’s production and logistics processes. The solution supports end-of-line automation and ensures the consistent securing of diverse pallet units.
The key benefits of the implementation include:
- Increased productivity – maximum throughput of up to 100 pallets per hour (45-second cycle), elimination of downtime, and seamless product take-off from the production line.
- Consistent quality – every pallet, regardless of dimensions, is secured with the same optimal tension.
- Material savings – significant reduction in stretch film consumption thanks to the pre-stretch function.
- Transport safety – compatible with 1200×800 Euro pallets and adaptable for industrial pallets; elimination of claims related to goods damaged during logistics.
Grow your business with Lintegra
Are you looking for a way to streamline packaging processes and reduce costs at your facility? Let’s discuss tailored solutions for your company.
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