The European Aerosols Group is the market leader in the development of spray solutions for paints, varnishes, and technical products, and is primarily active in the automotive, DIY, and industrial segments. European Aerosols has three production locations in Europe, with its headquarters in Wolvega. In addition to the annual production of more than one hundred million spray cans, European Aerosols also produces fillers. The spray cans are packed in boxes, palletized, and then automatically wrapped. Some of the pallets receive one or more additional stacked layers. These pallets are moved to another hall, where they are semi-automatically wrapped.

The Challenge

The pallets must be wrapped tightly and professionally, and because of the high volume, the process must be flawless—without interruptions due to film breakage. European Aerosols challenged Cyklop to reduce costs while also decreasing plastic usage in the wrapping process.

The Solution

A test was set up using a thin wrapping film. In this case, a 12mu nano film. This is a multi-layer film, specially developed to deliver high performance with a relatively small amount of film. The machine settings were not adjusted (pre-stretch, wrapping pattern). It was not necessary to deploy new pallet wrappers; the existing ones functioned properly. Then it was tested whether the process continued to run smoothly, whether employees were satisfied, and what European Aerosols' customers thought of it. At the end of the test, a savings measurement was conducted on-site.

The Result

The new film was tested for several weeks, with visual inspections, employee feedback, and customer responses collected.The measurement at the end of the field test showed significant savings. Switching to the 12mu wrapping film immediately resulted in a 55% weight reduction. On an annual basis, this means that approximately 20,000 kilos less plastic is used in the wrapping process. The cost per pallet decreases by more than 35%, as the type of film has a slightly higher price per kilogram. On an annual basis, this translates into savings of nearly 25,000 euros. Furthermore, the same film is now used on the fully automatic wrapper. As a result, the purchasing process is simpler, additional cost advantages can be achieved (e.g., lower transport and storage costs), and it is easier to ensure there is always stock available.

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5 useful tips to save costs when wrapping pallets.

1. USE A GOOD PALLET WRAPPER. By using a good pallet wrapper, you can save a significant amount of money!

A good pallet wrapper can pre-stretch up to 300% (turning 1 meter of film into 4 meters). In practice, an operator achieves only about 20%, and most pallet wrappers do not exceed 150%.

Pallets are often still wrapped manually. This is heavy and physically demanding for workers (leading to absenteeism) and can take up to 3 minutes per pallet. By switching to a machine, output is significantly increased, and the operator can focus on other tasks or may no longer be needed.

A machine wraps each pallet in the same, consistent manner every time. The result is increased stability, reducing the risk of damage.

Less plastic around the pallet also means lower waste disposal costs, both for you and your customers!

2. USE A GOOD FILM. A good film should be highly stretchable and have a high puncture resistance. The price per kilogram is often slightly higher, but this will always pay off because consumption can be up to 65% lower.

3. CONDUCT TESTS. It is useful to test different pre-stretch percentages, film tension, wrapping patterns, and other machine settings. Measure how this affects tension and how much plastic is used per pallet. This way, you get real insights. An expert can assist in this process.

4. CHECK, CHECK, DOUBLE-CHECK. Regularly check that the pallet wrapper settings have not been changed (accidentally), leading to reduced pre-stretch.

5. MAINTENANCE. Plan regular maintenance on the machine. This prevents downtime and unnecessary costs due to malfunctions.

Just get started: Deciding whether to make your packaging process more efficient is not difficult. The 'how' is often the real challenge. Start by identifying your needs and requirements. Cyklop can assist you in this process. Together, we will explore the possibilities and benefits our products can offer. Our experienced specialists are ready to help!

Step 1: Get in touch. Our specialists are ready to assist you.

Step 2: Determine your needs. We will assess the situation and help you identify your requirements.

Step 3: Find the solution. List the available options and make your decision.