Recently we were asked to evaluate a consumer product that was flow wrapped for overwrap. We carefully undid the wrapping, so that we could see how much material was being used to flow wrap. We laid that film out flat against what we cut to do the overwrap; then we measured the difference.  The difference in square inches was 14% less for the overwrap. That means a 14% film savings over the life of the machine.

We then went on to look at the case pack. Because the excess film took up so much space in the box, there was an extra inch along one side of the box. We cannot do the calculation of what that might mean over a pallet load but we believe that one inch might be huge when looked at over a truck load, or many truck loads. We see sustainability written all over it.

Flow wrapping is a great choice for airtight sealing. You can use clear or printed film and have a total barrier seal. Some candy companies have switched to flow wrapping their candy bars because the candy lasts longer in vending machines.

So what is flow wrapping? Think of a tight fitting bag that your product is slide into and sealed. That is not quite how it happens but that is the net effect. The product ends up with tails and flap of long seam on the back/bottom. For larger products, there is also a tucking action that makes the flow wrap conform better to the product, like a gusseted bag.

Overwrap, like a neatly wrapped gift, is not as complete a barrier wrap, since it uses a tuck and fold to more tightly hug the product with sealing centered on the bottom seam and the tuck and fold, but it commonly considered to be a more attractive wrap.

Flow wrap and overwrap both use polypropylene film (BOPP) to create the wrap. Both can use printed film. Overwrap offers the versatility of wrapping with other materials such as paper, waxed paper or cellophane.

We cannot be sure that every package would show this difference in film consumption, but we now know that there are opportunities for material savings between flow wrap and overwrap.

In the past year, we have had two customers shift from shrink wrap to overwrap for their candy boxes.  In one case, it was to achieve costs savings in wrapping material. This customer is now looking at the energy savings that accompany getting rid of a shrink tunnel. Oddly though, the energy savings seem less important than the upscale look of their overwrap packaging  which they find more attractive than the shrink wrap.

What is the difference in the two processes?  Shrink wrap uses polyethylene film which is fitted around a package loosely, crimp-sealed around the edges and the excess cut off. It is then shrunk 20% in a heat tunnel to fit the package. The excess film that was cut off is sometimes recycled.

In contract, there is no excess film with overwrap. The tuck and fold is neat to the package with no windows in the wrap. Heat is used for spot welding of the long seam and the tuck and fold.  Overwrap uses polypropylene film which is less expensive pound for pound than polyethylene of the same gauge. Because polypropylene film is crisper, you can fold it like paper and achieve that high end gift wrapped look. Because it is not shrunk, you can use registered film and have artwork on it.

We had one customer who achieved a 3 month payback on his switch to a high-end registered polypropylene laminate overwrap on a bundle rather than a shrink wrapped box with smaller boxes inside. He had additional savings in corrugated box costs, since his packages were smaller without the box.

So when do we recommend you use shrink wrap? Use it for ultra- low volume runs where the cost to set up or changeover is too high. Use it for oddly shaped packages that are not suitable for a tuck and fold wrap/ gift wrap. If you want your package to be neat, and have a high end appeal, look at overwrapping it. Package can offer some low volume overwrap solutions.

The SUSTAINABLE word is now so heavy with meaning that it seems scary to say out loud. So let’s just talk about it as that spot where preserving our planet and making a profit meet.

I don’t think we have a single wrapping customer who does not want to achieve both of those goals but they sometimes feel stymied by the conflicting priorities and the how -
• how to reduce costs,
• how to look at greener processes,
• how to evaluate what their vendors are doing,
• how to keep their customers happy,
• how to get the consumer onboard,
• how to control any of these variables.

It makes herding cats look easy.

After a business has looked at gaining efficiency through Lean techniques and implemented Kaizens, the opportunities are still often ones that involve people and institutions outside the facility gates. Just as looking at the timing of vendors deliveries played into a lean project, looking at what and how those vendors provide to you can play into a life cycle analysis.

Wikipedia defines Life Cycle Analysis or Assessment as “the investigation and valuation of the environmental impacts of a given product or service caused or necessitated by its existence.” It goes on to write, “The goal of LCA is to compare the full range of environmental and social damages assignable to products and services, to be able to choose the least burdensome one.

Most Life cycle analyses are done using cradle to grave. That means looking at a product from the raw material to the post-consumer disposal of all the parts. There are many directories that help with calculations for transportation, energy use, and common metrics but some of the information comes from within your own processes. It is possible to do a life cycle analysis gate to gate that looks only at what happens inside your facility, but logically that is only a baby step toward the bigger goal.

Total Cost Assessment is a newer concept now getting a lot of play. According to Lise Laurin of EarthShift, “Total Cost Assessment is the consideration of all environmental and health (E&H) costs associated with a decision, including direct costs, risks and liabilities, and costs borne by others.” It looks not simply at the cost to produce and deliver a product but the costs born by the business, employees, vendors and by society and tries to quantify all the costs. This notion behind this is that some costs are born by society and some by employees that might at some point be born by the business. Think of the number of environmental clean ups that many companies did not expect to pay for when they made the mess, or the clean water costs of making paper or beer, or the healthcare costs for cigarette users or asbestiosis.

You may think LCA and TCA are the same thing but Total Cost Assessment is not designed to have you change anything simply to recognize all the costs associated with a good regardless of who pays it.

After doing a TCA, the alternative costs of changes that are suggested by an LCA might not look too high.

You might think of the as complements, just as a screwdriver and a wrench are often used together.

Industry Buzzing Over New Wrapster

Chicago, IL - Package Machinery Company, Inc is excited to announce the release of its new WRAPSTER semi-automatic wrapping solution to the marketplace. Customers can get a glance of this new wrapping innovation at PACK EXPO, Chicago 2006.

Designed to replace hand wrapping, the Wrapster reduces the need to hire large temporary or seasonal workforces without the large capital outlay required for fully automatic wrapping machines. One worker can easily and efficiently “cello or gift” wrap 300-400 cartons per hour using either unregistered BOPP film or standard size rolls of gift wrap paper.

“Market interest has been very strong across all industry segments!” notes Jonathan Viens, National Sales & Marketing Manager at Package. “There is nothing else like it on the market. We conceived, designed, and priced the Wrapster with entry level users, co-packers, and those with small production runs in mind.”
Customers can choose from 2 machine frame sizes that accommodate everything from small cosmetics boxes, media products, and confectionery boxes to large gift basket boxes. “We’ve spent the past year refining the machine design with our Beta test customers,” adds Viens. “The wrap quality is exceptional. More importantly, you will see savings of up to 50% per wrap versus shrink wrap.”

Savings and wrap quality aren’t the only keys to the Wrapster’s market momentum. The machine handles a variety of sizes and comes with a standard kit of size parts. “It’s tremendously versatile and super easy to changeover,” sites Wrapster inventor John Bernet, “Size parts aren’t an issue. You can even gift wrap department store shirt boxes on the larger model.”

The WRAPSTER supplements PACKAGE’s growing line of new, hi-tech, and easy to use wrapping equipment including the industry leading FA-ST Servo wrapper. Launched in 2001, the FA-ST is the first all servo tuck and fold overwrapper on the market, featuring 35% fewer components than competing mechanical wrappers and offers 5 minute changeovers with throughput rates up to 150 boxes per minute.

“Our goal is to be the Wrapper of Choice in North America,” adds Katherine Putnam, Package President. “Customers have been asking us for a simple, affordable, entry level overwrapper and we want them to know; we heard you loud and clear!”

For more information on the Wrapster or other wrapping solutions, please contact sales@packagemachinery.com.

Joint Press Release

Econocorp Inc. Randolph, MA and Package Machinery Co. Inc. West Springfield, MA

Two Massachusetts companies, both members of the Packaging Machinery Manufacturers Institute, were awarded training grants by the Commonwealth of Massachusetts for lean education. Econocorp, Inc and Package Machinery Company, Inc. were recently awarded $50,000 and $20,000 respectively from the State to support a comprehensive lean training program.

“Both our companies will be using the grants for a lean manufacturing training program to eliminate waste in our respective production efforts,” notes Mark Jacobson, vice president of Econocorp Inc. “We’ll have our own tailored training program to meet our unique manufacturing needs.” Katherine Putnam, President of Package Machinery Company Inc of West Springfield adds, “And we can send our employees to each other’s sites since our training will be complementary.

Econocorp and Package Machinery will be working with the Greater Boston Manufacturing Partnership (GBMP), a Massachusetts-based program that is based at U-Mass Boston, to deliver a full array of lean enterprise training to all employees of both companies. “GBMP made the grant application process simple and convenient,” says Jacobson.

“GBMP is walking us through all aspects of lean manufacturing including helping us focus our efforts on areas that will benefit each of us most, as well as training our people,” adds Putnam. “They have a strong process that will keep us on track as we tackle the opportunity of changing how we produce our machines and create cost savings from our current processes.”

To support this effort, both companies applied for grants through the Commonwealth of Massachusetts. It is a matching fund grant. The match is made in terms of the employees’ time and normal compensation and the grant must be used over a period of two years.

“The single most important advice I can impart to any company looking to do something similar is this: DO IT!” exclaims Jacobson.

“I learned about the GBMP from work we’ve done in the past with the New England Trade Adjustment Assistance Center,” adds Putnam. ” I really respect how helpful and thorough GBMP has been throughout the process. Last year, we were approved through NETAAC to receive grant money in support of some product development, process improvement and marketing efforts we needed to help us improve our competitive position. We will be working with the NETAAC grant, which matches every dollar we spend, for the rest of this year and into 2007. This has been a great start for any company looking for both state and Federal programs to help it develop and be more competitive.”

Econocorp Inc of Randolph MA is a recognized worldwide leader in cartoning and casepacking for moderate and lower production volumes.

Package Machinery of West Springfield MA is a manufacturer of custom wrapping machinery for consumer products companies. Having been first to market with an all servo wrapping machine, it is a global leader in wrapping technology and is certified as women-owned by WBENC.

To learn more about these companies, contact:
Mark Jacobson at 781.986.7500 mark@econocorp.com, or
Katherine Putnam at 413.732.4000 kputnam@packagemachinery.com

Package Machinery Company, Inc. Receives Certification for Women’s Business Enterprise National Council

May 30, 2001, West Springfield, MA - Package Machinery Company, Inc. has received certification from the National Women’s Business Enterprise Council (WBENC), a national organization dedicated to enhancing opportunities for women’s business enterprises in America’s major business markets. WBENC offers a thorough, standardized national certification process for businesses owned and operated by women. Through its Internet database of certified firms, WBENCLink, corporations and government agencies can find women-owned and operated firms from which to purchase goods and services.

“I’m very proud that Package has received certification,” said Katherine E. Putnam, President. “It means we are part of a network of companies that are helping to open new doors for women in business. It expands our horizons for contracts for our business. WBENC is a national leader in promoting diversity and best practices in corporate America. We are the first company in western Massachusetts to be granted such certification.”
WBENC also conducts training programs for its organizational partners, conducts surveys on important issues concerning women’s business ownership, and designs and implements comprehensive research projects aimed at expanding supplier diversity programs. The organization annually compiles a list of top corporations supporting women-owned businesses in purchasing.

Package Machinery Company, Inc. is a manufacturer of plastic and paper wrapping and bagging machinery for food and other consumer products. The Company supports existing machinery with parts, service, technical advice, and provides rebuilds of machinery made by its predecessor company going back to its origins in 1913. Its customers include most major consumer products companies as well as many regional consumer products manufacturers. “Many of our larger customers have supplier diversity programs which we hope will open doors to new business,” said Ms. Putnam.

Package Machinery Company, Inc. is also a member of the Packaging Machinery Manufacturers Institute (PMMI), a major trade association for packaging machinery manufacturers. Its predecessor company was one of the founding members of the PMMI. The Company has been headquartered at 380 Union Street, West Springfield, MA since 1996 when it moved from Connecticut. The original company was headquartered first in Springfield MA until 1947 and then in East Longmeadow MA until 1986. Ms. Putnam, a resident of Whately MA, is the successor to her grandfather and great grandfather at Package.

For more information, please contact Katherine E. Putnam, President at 413.732.4000 x 100 or visit the following web sites.

Package Machinery Company, Inc.
Women’s Business Enterprise National Council
Center for Women and Enterprise
Packaging Machinery Manufacturers Institute