Situation
A high-volume consumer packaged goods manufacturer was looking for ways to reduce packaging costs while advancing sustainability goals across its stretch hood film application. The company ships heavy palletized loads of pet care products and continuously evaluates packaging materials that can improve efficiency without compromising load stability or product protection.
With approximately 474,000 pallet loads annually and each pallet weighing about 2,200 pounds, even small improvements in film usage had the potential to create significant operational and environmental impact. The existing stretch hood film was a 5.5 mil material, and the goal was to determine whether a lighter-gauge PCR film could deliver comparable performance while reducing material consumption and total annual film spend.
Solution
Group O partnered with the manufacturer to evaluate a 30% post-consumer recycled content stretch hood film. The recommended solution was a 4.5 mil stretch hood film designed to help reduce plastic usage while maintaining the containment force needed for heavy pallet loads.
Group O supported the process through material recommendation, testing support, on-site trial management and performance analysis. Across four trials, the film was evaluated for operational fit, load containment, transportation performance and sustainability impact. As part of the validation process, product was shipped to multiple production facilities to assess performance in transit and sent to an ASTM-certified packaging lab to support approval of the change.
While no major equipment modifications were required, the trial process also created an opportunity to make adjustments that improved how the equipment was operating.
Results
The trial data showed that the recommended 4.5 mil PCR stretch hood film delivered similar performance capabilities while using less material per pallet. Film usage decreased from 22.9 ounces per pallet to 18.9 ounces per pallet, creating an estimated annual reduction of 118,500 pounds of plastic.
The lighter-gauge material also reduced the estimated cost to wrap each skid from $3.22 to $2.49. Based on annual pallet volume, the projected annual film cost decreased from approximately $1.53 million to $1.18 million, resulting in estimated annual savings of $345,013 and a 22.6% reduction in annual film costs.
From a sustainability perspective, the reduction in plastic usage is estimated to be equivalent to more than 5.2 million plastic water bottles. The initiative also supports improved sustainability reporting by helping the manufacturer document reduced virgin plastic usage and progress toward packaging optimization goals.
Key Outcomes:
- 30% PCR stretch hood film solution
- 5.5 mil to 4.5 mil film downgauge
- 22.6% estimated annual film cost savings
- $345,013 estimated annual savings
- 118,500 fewer pounds of plastic used annually
- More than 5.2 million plastic-water-bottle equivalent reduction
