Wrapping, packaging speeded up for furniture

A packaging company studied a furniture factory's existing packaging methods and reduced manual handling by introducing a rotary turntable pallet stretchwrapper.

Invited to a furniture factory, a packaging company studied the host's existing packaging methods to find ways to reduce produce manual handling and speeded up the wrapping process.

Aetna UK exhibited at a very small Business Exhibition in Exeter in 1997.

On show was a rotary turntable pallet stretchwrapper manufactured by Robopac.

Only a few enquiries were taken but one of them was for Bisley Office Furniture, Newport.

This enquiry asked Aetna to visit their factory in Newport to study their packaging methods and to find ways to reduce produce manual handling, speeding up the wrapping process, reduce damage in transit and find worthwhile material cost savings.

Working with the Bisley production engineers, Aetna put forward proposals and suggestions to achieve all of the original objectives over a period of time.

In principle, the use of stretch film was introduced instead of corrugated board and applied either vertically or horizontally using a number of different Robopac systems.

The first systems introduced were semi auto rotary stretch wrappers and indeed over the four years some eight are now in use in the two Bisley production plants in Newport and Bisley.

Subsequently, Robopac Spiror horizontal systems were introduced for suitable products and as higher speeds were required the fully automatic Robopac rotary arm Helix and the high speed Genesis ring system were also introduced.

After the four years of development, Bisley are now using a total of eight semi automatic rotary systems, two horizontal Spirors and three fully automatic systems.

Moving from corrugated board to stretch film has made dramatic cost savings in the region of 40%.

Apart from the direct material cost savings, there have been significant reductions in indirect costs associated with handling and storage of bulky pallets of corrugated board.

Far less manual handling is needed within the packing department and in fact damage in transit has also been reduced by as much as 26% largely because more care is taken in handling because the product can be seen.

Packing speeds have been increased by 23% whilst labour has been reduced.

The whole process continues and it will be several more years before the exercise is completed.

Throughout the four years, Aetna have provided the very highest level of advice and service, providing 24h call out, on site spares, quarterly maintenance and regular training visits, and a true partnership has been created.

Part of the ongoing plan is to provide regular machine upgrades to ensure the very best product presentation and maximise film cost savings.

Bisley have at all times applied their best practice business experience to the project and Aetna have worked closely with the Bisley management team to develop their people, improve efficiency and reduce costs to ensure the most environmentally friendly package to suit al their customer requirements.

Bisley are delighted with the support and advice Aetna have provided over the years since they first met in that tent near Exeter, and are delighted with the technical abilities and reliable performance of all the ROBOPAC systems in operation in their two manufacturing plants.

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