A leading FMCG food manufacturer identified an opportunity to reduce plastic consumption while improving pallet load stability across its distribution network. The business required a partner capable of delivering a comprehensive supply chain assessment, proven load stability testing, and a measurable strategy for reducing stretch film usage without compromising product protection during transit.
The manufacturer contacted Samson Pallet Stability to evaluate its existing pallet wrapping processes, minimise transit damage, lower operational costs, and improve supplier performance metrics.
Objectives
Working in partnership with Samson Pallet Stability, the manufacturer sought to:
Upgrade pallet wrapping equipment
Reduce operational and film costs
Lower stretch film consumption
Improve pallet load stability
Eliminate product damage during transit
Reduce supplier fines and penalties
Improve vendor performance ratings
The Challenge
The manufacturer was operating multiple pallet wrapping machines with varying capabilities across its production facilities. As a result, the stretch film being used was not optimised for the machinery or load requirements, leading to inconsistent wrap patterns and pallet instability throughout the supply chain.
To compensate, the business adopted a double-wrapping process to improve load security. While this reduced load displacement, it significantly increased film consumption and introduced a new challenge. Excessive containment forces were contributing to crushed and damaged products during transport.
As the products involved were food items that could not be reworked or returned to stock, the manufacturer faced substantial financial losses through damaged goods, supplier penalties, declining vendor performance scores, and increased packaging costs.
The current machines consistently would breakdown, calling for additional maintenance costs alongside prolonged sessions of downtime, reducing the site’s overall efficiency, increasing costs and introducing avoidable health and safety hazards.
The Solution
Samson Pallet Stability conducted a detailed assessment of the manufacturer's supply chain, pallet configurations, and wrapping operations to identify opportunities for improvement.
Following the evaluation, the manufacturer introduced a Samson Nano system on a three-month trial to validate the proposed performance improvements. Through precise load testing, machine optimisation, and the implementation of a high-performance stretch film specifically matched to the application, Samson Pallet Stability was able to significantly reduce film usage while maintaining and improving load stability.
The trial demonstrated measurable reductions in packaging costs, improved transit performance, and enhanced load containment. Following the successful outcome, the manufacturer rolled out a further five Samson Nano systems across its operations.
The solution also delivered the benefits of a guaranteed cost per wrapped pallet, fully maintained equipment, no additional servicing costs, and a no-capex model, enabling the business to achieve immediate operational savings without upfront investment.
Results
Following the full implementation of the Samson Nano solution, the manufacturer achieved:
75% reduction in stretch film consumption (64 tonnes to 16 tonnes)
150.7 tonnes reduction in CO₂ emissions associated with pallet wrapping
Over 55% savings vs their previous film
Additional savings in maintenance and servicing
Eliminated transit damage and associated product losses
Improved supplier performance and vendor ratings
By combining proven pallet stability testing, with a fully managed wrapping solution, Samson Pallet Stability helped the manufacturer reduce costs, improve sustainability performance, and eliminate recurring transit damage issues.
The result was a long-term, scalable solution that delivered safer loads, lower operating costs, exact packaging spend visibility, fully maintained equipment, and consistent pallet performance across the entire supply chain.
"After delivering on all promises, it was a breath of fresh air that pricing was fixed and not 'estimated' like everyone just trying to sell a machine. The team are hands on and proactive. We can concentrate on our business instead of worrying about loads failing on vehicles or even placing orders for film, as the machines do it for you". - Operations Manager
In-House Stability Solutions for your Business
One issue with pallet wrapping is that every pallet loads perform differently during transit. With Samson Pallet Stability's in-house pallet testing facility, we can scientifically measure load stability, identify weaknesses, and recommend proven improvements before costly damage occurs.
Want to see how stable your pallets really are? Contact Samson Pallet Stability to arrange a pallet stability assessment and discover opportunities to reduce product damage, improve safety, and optimise your packaging performance.