The Customer’s Brief
The solution will be capable of providing shrink wrap material to the rolls of fabric to protect them against ingress of dust whilst in storage and transit. The shrink wrap will cover the entire roll.
The equipment will be fully automated with zero or minimum change over times, it will require low levels of supervision and minimal manning levels including, where appropriate, design & specification to minimise the necessary maintenance.
The machine was required to fully enclose and shrink wrap rolls of fabric varying in length from 1.4 metres to 1.7 metres and from 100mm diameter to 450mm diameter
Rolls of fabric are placed onto the shrink wrap machine infeed belt (approx 2 metres in length) narrow edge leading. These fabric rolls are placed randomly and vary in length and diameter from 1.4 metres to 1.7metres in length and 70mm diameter to 450mm diameter. As the rolls are fed into the machine, parallel to the seal bar, the rolls are measured and the seal bed automatically adjusts to cut and seal on the centreline to ensure the film is tightly packed around the differing diameters. Once the roll is transferred and pushed through the film wall the machine senses the rear of the pack and then the seal bar seals and cuts in one operation. As soon as the seal is made the head retracts ready for the next roll. The seal jaw vertical stroke is 0 – 480mm.
As the rolls progress through the sealing section, side sealers seal the ends of the pack, and the roll then exits narrow edge leading towards the tunnel exit conveyor.
The shrink tunnel consists of a heat chamber system with heater banks mounted in the side of the machine. As the roll passes through the tunnel the heat shrinks the film leaving an enclosed pack ready for stacking.
We have tried over the years, at great expense to find a packaging solution for our vast array of products and failed. We approached Shrinkwrap and through their hard work and knowledge, they have developed a truly remarkable solution. This has been achieved by their professionalism and dedication to deliver the solution we require. We did look at overseas suppliers but none of them could offer a bespoke machine to cope with the diversity, all they could offer were “Off the shelf” products that would cope with 40% of our products.
The machine has given us a 20% increase in production, 45% saving in Polythene usage and a 35% saving in Polythene costs but most importantly it has improve the aesthetics of the finished product going to our customers.
The Shrinkwrap team have been very helpful and very professional.
What impressed me the most? The fact that they never gave up on solving 100% of our requirements, even when we thought we could not package the lighter rolls, the team worked hard brainstorming and coming up with various solutions before eventually find the best solution.
Camira Fabrics Ltd