Packaging machines for structured insulation panels such as XPS, EPS, PIR and PU have for years been dominated by energy consuming heat shrink systems. This is changing now since new and energy friendly alternatives have proofed to be a strong alternative. There are convincing evidence that manufacturing companies are also eager to benefit from other advantages like high waterproof packaging, high repeatability and low plast film consumption.
Film can be delivered locally (Tentoma does not deliver film but has a range of approved suppliers and others can be approved as well)
UV blocking/protection possible with the film
Film strength: If your customer has double packs (600+600) in his packs then he will be able to lift and manoeuvre the packs after packaging with RoRo StretchPack
For other products and dimensions please check out the possibilities in this video.
Structured insulation panels can have various dimensions. Consult with Tentoma www.tentoma.com in order to define the exact machine that can cover your product dimensions. Following span of dimensions can be covered.
W: 600, 1200 (including 600+600) Max width is 1350 mm
L: Max 8000 mm
H: Max 1400 mm
In order to reach industry required capacities the machine series Duplex and the SemiFlow function is required. The SemiFlow function is briefly explained a multiple packaging sequence function where no time is wasted during the packaging process. The film being prepared at one of two film stations is sufficient to cover a series of products. This reduces the time spent going back and forth between film stations and packaging position at the conveyor.
Top view of machine – Semiflow, Duplex D2 machine in operation mode showing a multiple packaging sequence with minimum waste and high repeatability
Top view of machine – SemiFlow, Duplex D2 machine in stand-by or product By-Pass mode
RoRo StretchPack machines ensure high repeatability since full control is maintained of the film during the whole process
~ 6 km film available times 2 (due to Duplex system) meaning 12 km film available on the machine
Easy to exchange film (2-4 minutes) and no machine stops are required
Few moving parts
Standard globally available products
Benefits of Applying Tubular Stretch Hood
100 % sealing (option to choose 4 sided)
Total of 12 km film available (40 micron)
Protection of L-shaped products
Corner protection (film pressure on corners in can be controlled)
High seal strength and stretchability (particularly important if 2 board layers per pack (600+600)
UV protection of film and product an option
At the final customer: Film is easier to remove from product, easier to minimize and occupy less space than heat shrink film on a construction site (roof area)
Energy Consumption Savings
A RoRo StretchPack machine of the type above will consume between 4,5 and 5 kW/h during operation. During ramp-up and ramp-down there is no energy consumption. In comparision to heat shrink systems there is a significant energy consumption saving during full operation, during production stops and during ramp-up and -down times. Energy consumption in heat shrink systems is typically 40 kW/h excluding ramp up and down times. In addition: The fire insurance costs can be reduced!
ROI – Customer Example
Our customers (when comparing to Heat Shrink Systems) typically see a film consumption saving of 20-60% which corresponds to a film cost saving of 10-50%.
An XPS customers with full year production has calculated a return of an investment of 1,3 years including a capacity increase of 20%. The yearly cost savings amount to 200.000 Euro compared to an existing heat shrink machine. The major costs saving points are film saving (154.000 euro) and energy saving (36.000 euro) and the maintenace saving of 6.200 Euro. Then of course the packaging quality is higher due to a complete control of the packaging film.
Annual euro savings with Tentoma RoRo Duplex D2 at an XPS Manufacturer
Come Meet Tentoma
We always welcome existing and new customers to come and see some of the most advanced machinery in the packaging industry in our facilities in Denmark. We also appreciate meeting you during on of the following upcoming events:
Watch the full Geosynthetic Packaging Machine Video by Tentoma about:
4 Ways to reduce PE plast film consumption
100% sealing of roll materials
Ease of machine Operation & Maintenance
Naue Geosynthetics Invest in RoRo StretchPack Machine
The leading manufacturer of geosynthetics in Germany called NAUE GmbH & Co. KG has invested in an XL-S2 machine from Tentoma A/S. The purpose of waterproof packaging for the high value geosynthetic rolls has been a key driver in choosing machinery from Tentoma.
Another driver was to implement a fully automated packaging process in an existing production set-up with limited floor space. The full RoRo StretchPack machine portfolio is characterized by occupying minimal space in the machine length direction. This makes it possible to integrate the machines in existing in-line and off-line packaging areas in an easy way.
NAUE – A RECORD OF INNOVATION:
NAUE GmbH & Co. KG has been part of the history of geosynthetics since the very beginning;
NAUE introduced the first nonwoven filter material for use in hydraulic engineering applications;
Those products are still fully meeting their designated purpose today – for example, on the embankments of the Mittelland Canal, the only East-West waterway in Northern Germany;
NAUE of today became an independent company in 1984 under the name of Naue Fasertechnik GmbH & Co. KG.;
Geosynthetics | Geomembrane | Geotextile
Product protection of rolls
In this chapter you will see more examples on packaging of rolls. But first, let’s look at some of the typical problems we experience that Geotextile manufacturers are struggling with today:
Seals on the length of the reels and on the ends are opening;
Water comes in the reel;
Film needs to be as slippery as possible on the outside for storage reasons;
Labels don’t stick well on sides of reels, because of “folds” in the film;
Film tears when handling in stock situations;
Branding is not satisfactory;
How to solve Geosynthetics | Geomembrane | Geotextile packaging problems?
Example 1 is from a customer in Spain that has requested to encapsulate 100% the product. The reason is that the cloth needs to maintain a controlled state of moisture level.
Note: Quite the opposite really of what is normally the task in packaging. With RoRo you can keep moisture in or out.
Example 2 is not only to show a potential customer that the rolls are 100% tight but also to enable a test of:
Film has high enough tear and puncture resistance to withstand normal logistic handling of geotextile rolls
Insertion of plugs in the end while ensuring 100% tight packaging
Example 3 – Close-up of a strong and controlled sealing!
Example 4 will show you that rolls can have up to 8 meter lengths. Watch This 40 Second packaging sequence of an automated geotextile packaging process.
Product Protection of Outdoor Stored Products
Outdoor storage of products is a topic Tentoma is receiving positive feed-back since the high quality film material applied in RoRo machinery allows safe outdoor storage of up to 24 months.
The film can be specified with UV protection and UV blocking in order to protect the film and the goods.
Besides protecting the goods from moisture, contamination, dust and alike the film also has excellent capabilities in being a low-friction film. When products are stored tightly together (e.g. geotextile rolls) it is a requirement that the film doesn’t get damaged when placing and removing the products.
Easy transport due to low friction between goods and thus no sticking Low friction film (COF < 0,2)
Lower friction between products makes handling easier (gliding) Low friction film is a clear advantage in transport and storage handling when products are placed tightly together
Welcome to this blog about packaging machinery for wood blocks, panels, furniture, sofas, plaster boards and all larger products that need reliable packaging.
The blog is accompanied by a series of Youtube videos.
You can follow the machine from assembly, FAT (Factory Acceptance Test), Installation, SAT (Site Acceptance Test) & Commissioning through final and running production finalizing with an interview with the President or a representative in order to learn how they have experienced the whole process.
Part 1 – Tentoma Packaging Machine - Assembly
In the first video you will see the Simplex XL-S2 machine in state of assembly and thus only partly finished. You will hear about:
Packing machine XL S2
How you can reduce film consumption
Before and after stretch capability of a LD PE-Film
How to exchange a 500 Kg. film roll in 2-4 minutes
Packaging material savings
MMI – Man Machine Interface (Standard and detached control system)
Tentoma scope of supply
Reduce Film Consumption
Tentoma can assist in reducing packaging material consumptions. When calculating and performing test packaging you typically reduce the consumption with 20-60% leading to a cost saving between 10-50%. Additional cost reductions can be realized and in general we see consumption savings related to:
In this part 2 blog you will besides the FAT info of the XL-S2 machine also get a full introduction to the RoRo packaging technology and the Step-Change in machine design. Finally, you will learn how to choose the right packaging machine whether needed for packaging of wood blocks, panels, furniture or other longer products.
Packaging Machine FAT (Factory Acceptance Test)
We are ready to perform the FAT for our customer Dekker Hout from Holland. Dekker Hout will be using the XL-S2 machine to pack long wood blocks.
CLICK IMAGE TO WATCH VIDEO
Part #1 in the Factory Acceptance Test;
The machine in the video above is a Simplex XL-S2 machine (picture of XL-S1) and will be tested for packaging a woodblock with 6-sided-sealing. This will consist of a front- and a back sealing. The packaging sequence must live up to the specified packaging output requirements of the customer.
The proper function of the 2 film stands containing each one film roll will be controlled. This includes that the correct film is being selected depending on the pre-set product dimension recipes which are unique for each product size.
Part #2 in the Factory Acceptance Test;
The purpose of the applied 3D Measuring Bridge which can be seen in the video is to identify the dimensions of the incoming product:
After proper identification of the incoming product, the machine will be notified about this product’s recipe. The recipe contains pre-set parameters in order to execute the packaging process described later in the Step-by-Step guide of RoRo StretchPack.
Part #3 in the Factory Acceptance Test;
Fully automated woodblock packaging solution with full integration between the packaging machine and conveyor system with a 3D measuring bridge installed.
About Dekker Hout (Holland):
Producer of end products and semi-finished products for constructional retail;
Supplier of the Elephant® brand, known for quality and reliability;
Manager of FSC® forests, sawmills and factories in Europe, South America and Asia;
More than 600 qualified wood lovers;
RoRo StretchPack Step-by-Step Guide
In order to understand how the RoRo packaging technology works you can watch this step-by-step guide and gain a fully understanding.
Reach out to us in order to learn if the RoRo technology is ideal for you to. Just drop an e-mail to firstname.lastname@example.org. In addition to the Step-by-Step guide, please also find 2 short video introductions to the horizontal tube stretch process in the following:
Introduction Video #1: Roll-on and Roll-off (RoRo Packaging Principle);
Introduction Video #2: RoRo Packaging Example (Gypsum boards);
Which Packaging Machine to Choose?
The RoRo machines all apply the same packaging technology and the selection of an appropriate machine will depend on mainly 3 things:
Required packaging output / cycle;
Ad 1 - Product dimensions;
Products within e.g. wood (wood blocks, wood building materials, furniture, panels, tables etc.) and within rolls geotextile, geosynthetics, geomembranes, geofabrics) can typically be covered within the max 8 meter length that is possible with RoRo machines. The maximum height is 1,4 meters and width 1,35 meters.
Ad 2 – Required packaging output /cycle;
The packaging cycles of the Simplex XL machine series are fit to cover most output challenges. So, a wood block of e.g., 6 meters, 0,6 meter high and 1 meter in width can be packed with a cycle of <65 packs per hour based on the length (follow the red arrows in the figure below.). See the cycle information here for XL-S2.
Ad 3 – Product Variance;
An often asked question when we get involved in a new packaging project is: How can the product variance be covered?
The versatility of the RoRo machines makes it possible to cover a variance of products. One film roll can as a starting point cover various product dimensions since the film can be stretched from 0% to e.g. 75%. Products that can fit into this range can be packed with this same film roll.
Now, products outside this range will then need to be covered by a second film roll with other dimensions meaning that we are in S2 solution mode. If this is not enough, we can apply 3 different dimensioned film rolls.
Step-Change in Stretch Hood Machine Design
The founder of Tentoma, Frank Bruhn, has a long track record as service technician at a leading manufacturer of vertical stretch hood machines. This know-how was extended to other vertical stretch hood brands when he started his own technical service company with global reach.
He noticed that the same problems occurred again and again, and this vast know-how was key when developing the new generation of packaging machines based on already proven key technological elements back in 2010. The goal was to eliminate the weak elements he experienced with the vertical stretch hood machines.
Step-Change with RoRo Machine Design
Opening wedge without any moving parts (avoiding suction cups, etc.);
Belts and no roller chains (which require maintenance);
Few moving parts;
Standard and acclaimed components used (SEW, SICK, FESTO);
PLC: Siemens Serie 1500 with safety module integrated (programmed in TIA portal);
Product Protection of Outdoor Stored Products
Tentoma is receiving positive feed-back on the RoRo machines because of the outdoor storage capability of the packed products. The high quality film material applied allows safe outdoor storage of even up to 24 months. The film can be specified with UV protection and UV blocking in order to protect the film and the goods. Besides protecting the goods from moisture, contamination, dust and alike the film also has excellent capabilities in being a low-friction film. When products are stored tightly together it can be a requirement that the film doesn’t get damaged when placing and removing the products.
Welcome to this Tentoma Horizontal Packaging Machine blog which is accompanied by a video called Tentoma Horizontal Packaging Machine (2018) found below in the image link.
PE Stretch Film Cost Savings
The stretch film packaging enables a process where packaging film savings can contribute to a very attractive ROI. Typically film consumption savings between 20% and 60% corresponding to film cost savings between 10% and 50% can be achieved.
Improve- Environmental impact
- Working environment
- Carbon footprint
- Green image
PE-Film Cost Savings
The PE-Film cost savings are achieved with the RoRo StretchPack technology by stretching a tubular Low Density PE-film before applying it on a product. The stretch film will then retract and protect the product. The fact that the film is stretched enables the savings since a reduced amount of film can be applied compared to the size of the product.
10-50% Film cost savings 20-60% Savings in film consumption!
Vertical Stretch Hood (Machine) Experience
Tentoma has accumulated more than 20 years of experience within vertical stretch hood technology from development, service and industrial machine operation activities. This know-how has been converted into a game changing new packaging technology called Horizontal Packaging with the use of Low Density PE-Stretch Film.
The horizontal packaging technology is significantly different from vertical stretch hood which is an EOL packaging technology used for pallet wrapping giving load stability and a 5-sided sealing to protect against contamination.
The RoRo StretchPack technology is targeted for BEOL as well as EOL packaging processes of products that are longer (typically not palletized products) since the stretch film technology from Tentoma allows up to 8 metres long products to be packed with 4-, 5- or 6 sided sealings.
Waterproof Packaging100% sealed against
6 sided sealing corresponds to 100% waterproof packaging including full protection against humidity, dust and other form of contamination.
Tentoma can also offer 4- or 5-sided sealing.
Heat Shrink- versus Stretch Film Packaging
When applying stretch film the starting point is to use an amount of film which is smaller than the actual product dimensions. The film is then stretched to cover the product with an adequate stretch percentage depending on the product characteristics such as sharp corners (hard versus soft materials).
In heat shrink the principle is to apply to much film and remove excess PE-film applying heat in a heat shrink tunnel. Apart from applying excess film there is also a high energy consumption since heat shrink systems work continuously whether products are coming or not.
Product segments ideal for horizontal stretch film packaging can be products like building materials, building plates, geotextile or geomembrane rolls, wood blocks, gypsum boards XPS-, EPS plates and other insulation materials.
These products are carefully assessed in a dialogue between Tentoma and the customer in terms of desired outcomes with respect to e.g. sharp corners, ventilation (4- or 5-sided sealing or even perforated PE Film) branding engagement, load stability, film puncture requirements.
The products can then be test packaged to see how the desired outcome is achieved for the customer in order to move forward implementing the machine in either in-line or off-line operation.
BEOL Packaging Machine
BEOL Tentoma packaging machines provide new opportunities for stretch film suppliers and also system integrators/OEM's. These new opportunities can be discovered when looking beyond the traditional applications where PE- film is already being applied. According to CEO Henrik Raunkjaer a film supplier can look for additional supply opportunities to their existing customers “Just because deliveries are made to one EOL process doesn’t mean that there are not opportunities to deliver more film in BEOL packaging processes”. Manufacturers are challenged with new upcoming EUMOS standards and need to improve the way they create load stability in their packaging. This is an opportunity to carefully study new opportunities in BEOL processes and implement module packaging processes using technologies such as RoRo StretchPack by Tentoma.
Module packaging can increase the load stability significantly before the final EOL vertical stretch hood or similar packaging machinery. Watch an example wrapping of the load stability when applying high quality stretch film.
Branding on Industrial Packaging
When the stretch film is applied on a product it will be smoothly closed around the product which enables vast branding opportunities from e.g. logo placements and text messages. Options include:
RoRo StretchPack machines come with different capabilities depending on the size of e.g. building materials. Please, refer to Downloads in order to learn detailed machine details and find here a quick introduction to the building material products sizes:
Lengths: 200-8.000 mm
Widths: 300-2.200 mm
Heights: 10-1.400 mm
Product Circumference: max 5.500 mm.
The PE-Film suppliers must deliver a Low Density Poly Ethylene Stretch Film with proven stretch capabilities. Tentoma has approved various PE-film suppliers similar to vertical stretch hood film suppliers. They serve their markets locally as well as globally depending on the brand. If in doubt, don’t hesitate to contact email@example.com for further information.
Operational Packaging Costs and ROI
The ROI (Return-on-Investment) will always be a determining factor when comparing heat shrink packaging to Tentoma Horizontal Stretch Packaging. In the accompanying video in the top, a case study is introduced in order to give a detailed insight of the potential ROI depending on volumes and product sizes. The major savings when implementing Tentoma machines are within the packaging material costs and energy. In many cases the ROI is also affected by improvements in operational activities. A closer look can be taken on issues related to:
Reduce- Operational costs - Energy consumption - Fire risk - Film cost by 10 – 50% - Film waste
Extraordinary handling including manual labour
Excess quality inspections
Tentoma is a Manufacturer of Packaging Machines
Tentoma was originally founded by Frank Bruhn in 2011 as a service- and specialist company within vertical stretch hood technology. In 2014 Mr. Bruhn developed the horizontal stretch film technology and launched the first Tentoma machines early 2015. In 2017 a AAA+ rated investor, Danish Growth Fundjoined Tentoma in order to support a strategic global expansion with a unique new packaging technology based on a solid machine installation references all over Europe across various segments.
Tentoma, a new strong player within sawmill packaging of wood and also building materials, insulation materials, geosynthetics, is presenting an exciting machine that can automate and offer clear benefits including removing ergonomic stress for employees.
Watch the video and see the machine working already now before it is being shipped to our partner in Finland. Here:
The machine that can be seen at our Finnish distributor Jartek on stand B-240 is an XL packaging machine for large wood blocks. On the exhibition representatives from Tentoma in Denmark will go into detail on some of the benefits when implementing the machine.
How did the 25 years experienced specialist in stretch films create a game changer with Horizontal Stretch Packaging? An Interview about Horizontal Stretch Packaging with founder of Frank Bruhn ApS in Denmark. As of Sept 1st. the company name is Tentoma ApS (now Tentoma A/S).
How did you start with Horizontal Stretch Packaging?
Jensen: Hi Mr. Bruhn, let’s jump right into this. Why did some large building material manufacturers contact you? How did the Horizontal Stretch Packaging journey start? Bruhn: I guess they knew me well enough to seek some advice on how to solve some specific problems. You know, I haven’t been doing anything else for more than 2 decades. But you know what, this time I didn’t have any solution to their problem so hang on.
You see, existing packaging technologies like stretch hood, heat shrink hood, heat shrink tunnel and pallet shrink wrapping couldn’t solve the problem they challenged me with.
Customers wanted to know if it was possible to change existing stretch technology from vertical to horizontal and at the same time solve some of the more critical problems they were experiencing.
Founder Photography, 2011: Frank Bruhn (lower left side) and his brother Gunnar Bruhn (lower right side) founded the company Frank Bruhn ApS in Denmark several years ago. Today Frank Bruhn ApS has gained an international foothold with an established brand based on the horizontal stretch packaging equipment RoRo StretchPack
It all started with a fire in a Heat Shrink Tunnel packaging line
The initial reason was a fire in a factory packaging line caused by a heat shrink tunnel machine. You have a lot of heat exposure in a shrink tunnel and in the worst case it can cause a fire.
This constant fire risk explains the higher insurance costs you pay to protect against potential losses. So, the manufacturer wanted me to explore the possibility of making a machine which could package long products and to get well known problems solved. Also he wanted to get rid of the heat tunnel risk.
Difference between Horizontal Stretch Packaging and other technologies
Jensen: Okay, and in, and before this process, I know, that you have collaborated with both manufacturers like Nordfolien (Stretchfolie - Nordfolien in Germany) and also market leader ExxonMobil Chemical (PFFC-online ) in a collaboration between ExxonMobil Chemical and Frank Bruhn ApS.
I also understand that you later will explain some challenges in going from vertical to horizontal in stretching of PE-films.
But first, please clarify what the difference is between vertical and horizontal stretch packaging equipment.
Bruhn: Sure. We can also later talk about why applying stretch film in general can cause challenges when packaging. Okay, let’s start by taking a look on the difference between the vertical and horizontal technologies. These following pictures illustrate it quite well.
Movie 1: How does the horizontal stretch packaging equipment work? Compared with Heat Shrink Tunnel there are significant savings on PE-Film and Energy.
The horizontal stretch technology is one of a kind compared to vertical stretch hood solutions, pallet wrapping (spiral- or ring wrap) and significantly different to the heat shrink process.
Once the PE-film has been captured by the grabbing unit, it is led to the product lane where components or products will be stretch packed.
When comparing to heat shrink tunnel machines the significant difference is the energy- and film savings that can be achieved. A saving impact can also be seen in the reduced insurance costs to protect against losses in case of a fire due to heat exposure.
Figure 6: Example of long textile component packed horizontally with RoRo StretchPack
Source: Frank Bruhn ApS
Comment on complimentary packaging technologies
Bruhn: So, the heat shrink tunnel and our horizontal stretch packaging equipment both operate in a horizontal way. The stretch hood and spiral/ring-wrap technologies internally have their differences which you can read about on-line on Foodprocessing Technology & Manufaturing.
The traditional vertical stretch hood technology is an excellent end-of-line packaging solution which our customers typically have. Our Horizontal Stretch Packaging machine will often be located as primary packaging before-end-of-line. You can say, that RoRo StretchPack helps to feed the final packaging station.
Some products, e.g. larger building material components and larger insulation material components are today typically running through a manual process or a heat shrink tunnel. Here our customers see the unleashed cost saving potential when replacing these with the RoRo StretchPack. For such larger components or products a traditional vertical stretch hood cannot be applied.
Looking at the performance criteria for horizontal stretch and heat shrink tunnel below, it is obvious that there are some significant differences when comparing for instance operational costs and optical features. Let’s go into this right away.
Performance comparison between Heat Shrink Tunnel and Horizontal Stretch Packaging
Bruhn: If we talk about comparing performance on horizontal stretch technologies it would make sense to compare the newest technology, our horizontal stretch, with the widely applied heat shrink tunnel technology.
We can define various relevant performance criteria that we know are important to our customers including operating costs and savings on energy and film consumption. However, never forget the packaging speed as well as the optical features. Let’s have a look at an extract of a comparison.
Table 1: Performance comparison between Heat Shrink Tunnel and Horizontal Stretch Packaging (RoRo StretchPack) Source: Frank Bruhn ApS
Comments to the comparison Bruhn: Obviously, a comparison between different technologies and equipment’s is not always easy and can even vary from customer case to customer case. We did this comparison in the beginning and included, I think more than 80 parameters. We did it in order to verify that we could introduce a solution to the market that would be extremely competitive. And at the same time be disruptive in comparison with at least heat shrink tunnels.
Challenges in going from vertical to horizontal stretching
Jensen: What were the most critical challenges in going from vertical stretch to horizontal? Bruhn: There were many and once we solved them we also applied for several patents right away to protect these innovations.
When thinking back, I would mention three things in particular; firstly, it’s about controlling the winding and un-winding process 100%. My experience from vertical stretch hood technology has taught me that you need to be focused on these two processes if you want a smooth and reliable end result. The second challenge was huge in the industry and about controlling the film opening problematic. How to smartly open or separate the PE-film coming from the film roll? This has for everyone been the big question. Actually we can write a whole book about this issue.
The problem is that 2 PE-film sides stick together and must be turned into a PE-stretchfilm-tube in order to be stretched. As the film roll gets rolled off you will find that the it gets harder and harder to open or separate. We have now found a way to solve this by introducing a more stationary tool which enables us to operate with a more static film. Now you know what the problem was and I think it would be an idea to take up this topic separately later on in a separate post.
The third critical challenge was to adapt our technology into a horizontal mode. Let’s talk about the winding process first.
100% control of the film-winding and film-unwinding process Bruhn: The winding and un-winding process we can also call film roll-on and film roll-off. This, by the way, led to the name of our final packaging equipment solution; RoRo StretchPack.
It is critical to master this film-winding and film-unwinding process in order to tackle the well-known challenges from all technologies, such as film-wrinkles, holes in the PE-film, precise film positioning and finally the important optical features.
The principle in doing it horizontally is to create a horizontal tube and pull it tightly over the component which is fed-in on a conveyor belt. Well, it is principally a kind of stretch hood in horizontal mode. The components, and not the people, are moving which frees up resources that can be dedicated to other value-added activities.
Jensen: Maybe it is a good time now to watch the video showing the actual roll-on and roll-off process in the RoRo StretchPack solution (Horizontal Stretch Packaging). Let’s see it now.
Movie 2: Horizontal Stretch Packaging - How the innovative roll-on and roll-off process of PE-Film takes place avoiding wrinkles, holes and packaging damages
Bruhn: As you could see in the video our patented roll-on and roll-off process enables us to 100% control the winding and un-winding of the film-material. So we can deliver a 100% sealing proof packaging if this should be required. If not, you still get all the other benefits mentioned during our talk.
PE-Film Savings with Horizontal Stretch Packaging compared to Heat-Shrink-Tunnel
Now, the principle in a heat shrink tunnel concept is that an excessive amount of film is being shrinked. We instead offer an optimized, and much smaller film that is being stretched. Do you see the saving potential here?
We achieve a much lower film consumption and most importantly we can reduce the energy consumption bill and improve the CO2 foot-print of our customers. Most customers care a lot about green packaging and have fixed KPI’s on improving this. In fact, just the energy savings and the film consumption savings, compared to heat shrink tunnel packaging, can give you a very, very interesting ROI besides reducing the CO2 emission.
Jensen: And the challenge in creating a solution that made it possible to operate horizontally?
Bruhn: We needed to focus on as few machine part movements as possible between the actual PE-film-roll, film-feed-in point and the component to be packaged. The thing to know was; where does the product come from and where must it depart after the packaging. We decided to position the PE-film-roll unit right next to the horizontal stretch packaging operation point in order to increase the feed-in-efficiency and packaging speed.
Competitive package speed
In this way we can achieve as a minimum, the same speed, compared to heat shrinking machines. Today we also offer several options, like a duplex PE-film-feed-in or semi-flow packaging. It all depends on what our customers need and want. Today it is no problem to reach an even higher speed. Jensen: I understand that you have had to study intensely whether it makes sense for a customer to change from heat-shrink-tunnel into horizontal stretching. What 1 or 2 things would you recommend to look at here?
Bruhn: Hmm, well, I did mention the energy savings, green packaging and improved CO2 foot print. What many customers also look at is their own value proposition. See, if your products can live up to the value proposition when considering for instance logistics and do a simple 3-step-test yourself.
How to choose the correct packaging solution fit for your logistic
Bruhn: When deciding on your packaging solution you should consider the whole outbound logistic journey. Think about it; you often will have several intermediate loading and unloading points within your own manufacturing facilities, at the logistic forwarder, 1 or 2 logistic international transportation hubs with loading and unloading, unloading at customer, storage, new shipment and then unloading at the final end customer.
All these loading and unloading points calls for well-considered package solutions to sustain them. And, don’t forget the always changing weather elements during the whole journey.
What we see is also that customer geographies and destinations are not static. The packaging should be adopted to always more and more global supply chain developments. Your film-supplier can surely advise you based on their vast experience.
How to check for potential savings and quality improvements on your packaging
Bruhn: My close collaboration for many years with various PE-film manufacturers and distributors has made clear to me that the choice of PE-film, is not where you want to compromise on quality. But be aware. You may need to drive down costs continuously and at the same time ensure excellent quality. Certainly. But what I have seen again and again is that lack of know-how in choosing the appropriate PE-film for the packaging process leads to unnecessary high costs.
Start by making sure, that your machinery is adjusted precisely. Whatever machine we are talking about. Whatever logistic challenges you have. This can lead to significant savings on consumption.
As to the quality improvements, there are certainly a lot of parameters to be aware about and we cannot cover them all here so let me show you just one 3-step-test that you can do yourself without being an expert.
Go to your end-of-line packaging point, or even better, to the last in-house intermediate storage point. Pick out a packaged product and do these 3 steps:
Your 3-STEP-GUIDE to check packaging quality
Video 3: How to check your packaging quality fast and easy. Go to your end-of-line packaging point, or to the last in-house intermediate storage point. Pick out a packaged product and do these 3 steps shown in the video
Source: Frank Bruhn
1. Check the optical features!
Does it live up to your value proposition and your customers’ expectations? Will your brand be represented the way you want it to at the final destination?
Will it sustain, without any doubt, the outbound logistic journey towards all your customers considering all geographic destinations? Should it, and is it, 100% sealed against moisture and dirt
2. Make a punctual resistance test!
Is hardly no pressure needed to break the film material? If easy punctured; is it realistic that it will sustain all customer destinations with all loading and unloading points?
3. Test the tearing resistance!
Does the PE-film-material easily tear down/up/sidewards when tearing in the point where you made a hole in step 2? How will it affect the load resistance of multiple packaged products after several unloading and loading points? Does it imply risks to be aware about for your valued customer?
Bruhn: So, this easy do-it-yourself-test will often give you a good indication whether you should improve something or not. Taking it to the next level will of course mean to carry out the same test at maybe 3 or 4 different customer destinations in different geographic locations.
Jensen: I’m sure there are many other quality check points we can address like the above. However, here at the end, maybe it’s time for you to tell a little bit about the company today.
Bruhn: For me, and my brother who is the co-founder, it is important that the original company values are the same today as when we started years ago. Also after we have grown together with our international oriented customers. To see, that everyone in the company lives up to these same values when performing their jobs, whether in our supply chain, service, sales or management, really makes us proud.
And what really makes me excited is that our RoRo StretchPack solution opens up the minds of our customers. Again and again I hear that they, much better than us, can see the vast opportunities in our solution and the packaging contexts it can be used in.
It’s very simple. At the end of the day they know their supply chain better than any outsiders.
Jensen: Thanks for taking the time for this internal company interview. I also look forward to working together on our upcomming webinars where we will go into detail with the RoRo StretchPack technology and adress savings on film and energy and much more.
PS: If you are interested in learning more about Horizontal Stretch Packaging for e.g. building materials (wood/timber, insulation products in roll/batch, gipsonite etc,) or, you want to participate in a Webinar to get deeper insight, then please send an e-mail to firstname.lastname@example.org.
The geotextile industry sees innovative automation in packaging Automation in packaging in the geotextile and geomembrane industry is now seeing an innovative move by Frank Bruhn ApS. The proven horizontal stretch packaging technology - RoRo StretchPack - originates from decades of experience in the vertical stretch hood industry. Frank Bruhn ApS is now introducing a rock solid value proposition to the textile manufacturing industry as well as for geotextiles, fabrics, membranes including geomembranes when it comes to automation in packaging? See the short video and learn how!
Geotextile and Geomembrane WEBINAR Are you interested in more details ? Then please drop an e-mail to email@example.com and you will receive an invitation to our upcoming webinar about going from manual packaging of textile, various, fabrics, geotextile, membranes, geomembrane in rolls and alike to a fully automated packaging process.
Savings in packaging of geotextiles The savings are attractive in respect to considerable plastic packaging material (PE-film) savings, FTE reduction and on top of that? With the RoRo StretchPack horizontal packaging equipment you get a 100% water resistant packaging.
100% water resistant geotextile packaging One challenge in the textile industry is to succeed with a packaging that doesn't need to be overpacked in order be 100% water resistant which is critical in order to keep the rolls and alike fully intact. With RoRo StretchPack you obtain a 100% water resistant packaging (6-side closed) in a maximum 40 seconds automated packaging process with a minimal use of packaging material.
Drop an e-mail right away to firstname.lastname@example.org and you will be invitated for our Geotextile and Geomembrane WEBINAR