Inconsistent wrapping
The customer wrapped windows manually in stretch film. The process was time-consuming, and the appearance and amount of film varied with the operator, making consistent quality and film cost per window difficult to control.
POLPACK ZEUS / Installation case study
Window wrapping: 50% shorter wrapping time
Custom fixtures. One operator to position and secure the window.
For a window manufacturer preparing export batches, POLPACK ZEUS supplied a Wrapper SA with dedicated fixtures, a pneumatic top press and a 3,000 mm column. Matching the machine, stretch film and programme improved packing speed and the consistency and appearance of window protection.
50% shorterWrapping time: about 3 minutes to 90 seconds
Approx. 35% lowerFilm cost, down to about PLN 1.20 per window
One operatorTo position and secure the window
The challenge
Manual wrapping under export deadlines.
Batch preparation
Export batches had to be prepared within short timeframes. Higher volumes increased the burden of manual wrapping and made completion times harder to predict.
The solution
Wrapper SA configured for windows.
Dedicated fixtures and pneumatic top press
Following an on-site process assessment, we proposed Wrapper SA with specially designed window fixtures and a securing system. The configuration included a 3,000 mm column and a pneumatic top press. Column height is a machine dimension, not a stated maximum window height.
Suspended press controls
The operator places the window in the fixtures and activates the press using a suspended pendant controller on a support arm. This arrangement allows one person to position and secure the product before wrapping.
Semi-automatic working sequence
The operator positions, secures and removes the window. The machine applies the film automatically according to the selected programme, reducing work with a manually carried roll and improving repeatability.
Machine and material
17 µm film and motorised pre-stretch.
Film selected for the process
We selected 17 µm stretch film with a declared stretch capability of up to 300%, working with the motorised pre-stretch system. The film rating is not a statement that this machine was set to a 300% pre-stretch ratio.
Settings and wrapping programme
Film selection was combined with machine settings and programme optimisation to reduce material use and produce more consistent, neatly wrapped windows.
Commissioning
Trials, adjustments and operator training.
Tested with the customer's products
After delivery, POLPACK ZEUS conducted a series of trials with the customer's windows, adjusted the operating settings and refined the wrapping programme.
Preparing the team
We trained the operators before the machine entered regular production. The project brought together the wrapper, window fixtures, stretch film and working method.
The results
About 90 seconds per window.
50% shorter wrapping time
Reported wrapping time fell from approximately 3 minutes to 1 minute 30 seconds per window, a reduction of 50%. This concerns the wrapping stage; it does not establish the total cycle time including positioning, securing and removal.
Approximately 35% lower film cost
Average stretch-film cost fell by approximately 35%, to around PLN 1.20 per window. The amount covers film only, excluding operator labour and other workstation costs. Film consumption and manual work also decreased, without a separate percentage claimed for film weight.
More consistent packaging
The repeatable programme improved the appearance of the protection and helped plan the time and material required for batches. Operators spent less effort wrapping by hand.
Results specific to this installation
The outcome reflects the customer's products, previous process and selected settings. We assess the potential for another window manufacturer through trials and workstation analysis.
Window production / Wrapper SA
Project facts
These parameters describe this particular installation and do not establish the specification or results of every project.
| Machine | Semi-automatic Wrapper SA |
|---|---|
| Application | Stretch-film wrapping of windows |
| Column height | 3,000 mm; not a specification of maximum window height |
| Product securing | Dedicated window fixtures |
| Top press | Pneumatic |
| Press controls | Suspended pendant controller on a support arm |
| Film system | Motorised pre-stretch |
| Selected film | 17 µm stretch film, declared stretch capability up to 300% |
| Positioning and securing | One operator |
| Reported wrapping time | Approximately 3 minutes before; 1 minute 30 seconds after |
| Reported film cost | Approximately PLN 1.20 per window after optimisation; around 35% lower |
Original installation photographs
See the equipment and layout.
Project lead: Tomasz Siwiaszczyk, Sales Manager, POLPACK ZEUS
Frequently asked questions
Can one person prepare the window for wrapping?
In this installation, the fixtures and suspended press controller allow one operator to position and secure the window. Handling arrangements for other windows depend on their dimensions, weight and the workstation.
Is 300% the machine's pre-stretch setting?
The source specifies film with a declared stretch capability of up to 300%. It does not state that the machine operated at that ratio.
Does PLN 1.20 represent the full packing cost?
No. It is the reported average stretch-film cost per window after optimisation. Labour and other workstation costs are excluded.
Machines and installations
Explore the equipment and project examples.
The model used in this project
Wrapper SA pallet wrapping machine
Explore equipment options, film systems, technical specifications and manufacturer support.
Explore Wrapper SA in English ↗
Logistics / Wrapper SA
Oversized pallet wrapping: 35% lower film cost
Large loads. A workstation built around the process.
Explore in English ↗Installation results are specific to the described process, loads and comparison conditions. We assess the potential for your factory through trials.
Selection and operation
Useful before choosing your machine.
Pallet wrapper selection guide
Compare machine types, film systems and the questions to ask when planning a workstation.
Read the English guide ↗What determines the price?
Consider the machine configuration, installation and support when comparing quotations.
Read the English price guide ↗Pallet-wrapper safety guide (Polish) · Semi-automatic wrapper operating tips (Polish)
Talk to POLPACK ZEUS
Tell us about your pallets and process.
Send load dimensions and weights, required throughput, loading method, available space and operating conditions. Photographs or a short video help us assess the application.
info@polpack.pl · Bukowiecka 75, Warsaw, Poland