POLPACK ZEUS / Installation case study
Two pallet formats. One automatic wrapping line.
For a pet-food producer handling bagged products, POLPACK ZEUS supplied a complete Wrapper VO line with conveyors and a pallet lift. The installation brings pallet transport and wrapping into one process, handling Euro pallets and DHP half pallets without stopping the line to change formats.
The challenge
Standard pallet wrappers were served individually by a forklift. Repeated journeys to separate wrapping stations occupied operators and interrupted material flow. The customer also needed repeatable load protection for two pallet formats.
Bring feeding, transfer and wrapping together while accommodating bagged products on Euro pallets and DHP half pallets. The project had to fit the plant's handling process and provide consistent wrapping.
The solution
A forklift or electric pallet truck feeds pallets at floor level. A pallet lift raises them to conveyor height. The subsequent transfer and wrapping stages run automatically; operators still feed the line.
The lift, conveyors and automatic wrapper form a common system for Euro pallets and DHP half pallets, without stopping for a format change. This reduces the forklift operator's involvement in transfers between separate stations.
The film carriage provides pre-stretch up to 300%. Film tension can be adjusted continuously from the panel. Pre-stretch and tension are selected together to control material use and protect the bagged load.
POLPACK ZEUS supplied and commissioned the complete installation, including fencing, photocells and light curtains. Equipment, controls and safeguarding were integrated as one line.
Measured result
Compared with the previous process, the reported film cost fell by 45%: from PLN 2.85 to approximately PLN 1.57 per pallet, a saving of approximately PLN 1.28 per pallet. Values are rounded.
The comparison concerns film cost only. It excludes labour, energy and capital costs. A lower film cost does not by itself establish an identical percentage reduction in film weight.
The installation improved wrapping repeatability and load stability and shortened wrapping time. No separate numerical time reduction is claimed.
The result belongs to this installation and its comparison conditions. For another plant, we establish the potential through trials with its loads, film and settings.
Pet-food production
These parameters describe this particular installation and do not establish the specification or results of every project.
| Customer sector | Pet-food production |
|---|---|
| Load type | Bagged products |
| Pallet formats | Euro pallets and DHP half pallets |
| Load height | Up to 2,300 mm |
| Pallet weight | 200–1,000 kg |
| Throughput | Up to 25 pallets/hour |
| Film system | Two-motor pre-stretch, up to 300% |
| Feeding | Forklift or electric pallet truck at floor level |
| Equipment | Wrapper VO, conveyors and pallet lift |
| Safeguarding | Fencing, photocells and light curtains |
Original installation photographs
Project lead: Tomasz Siwiaszczyk, Sales Manager, POLPACK ZEUS
Machines and installations
Wrapper VO
Pallet transport and wrapping in one process.
Explore in English ↗
Petrochemical industry
A defined machine area. Access planned around the operator.
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
Compare machine types, film systems and the questions to ask when planning a workstation.
Read the English guide ↗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
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