When to Switch from Hand Wrapping to Machine Wrapping

When to make the switch

Do you feel that you are spending more on stretch film and labour than you should be? Our automated form below can help you uncover how much you could save by switching to machine film. In just a few quick steps, you’ll see whether your operation has reached the tipping point where automation makes financial and operational sense.

Note: These figures are based on optimal hand wrapping conditions. In real operations, film waste is often higher due to inconsistent tension, overlapping, and operator variability, meaning your actual savings from switching to machine wrap could be even greater.

Hand Wrap to Machine Wrap Calculator

Answer a few quick questions about your current hand-wrap process. We’ll estimate weekly savings, payback period, and a general recommendation. You can save a PDF of your results.

Current Hand-Wrap Profile

Pallets wrapped per day

Days per week

Minutes per pallet (hand-wrap) Walking time + wrapping time

Operator loaded wage (CAD $/hr)

Film cost per roll (CAD $) Enter your average roll price (e.g., $22–$28)

Average pallets per roll How many pallets do you typically get from one roll?

Estimated machine investment (CAD $) Leave blank to use $14,000

Benefits of machine film

Reduced
Film Usage

Pre-stretch up to 300% allows you to use less material per load without sacrificing performance.

Consistent Load Containment

Delivers uniform tension and wrap patterns to prevent load shifting and product damage.

Lower
Labour Costs

Reduces manual wrapping time and operator involvement, freeing staff for other tasks.

Improved
Operator Safety

Reduce operators’ strain and injuries by removing the need to walk around pallets.

Let's Connect

Request a Free Visit from a Stretch Wrap Expert

Learn how to cut film usage, increase throughput, and improve load security. Available to Canadian companies.

Impak Packaging
110A Iron St, Etobicoke, Ontario M9W 5L9
Phone: 416-299-0960 | Fax: 416-299-0961 | Email: info@impakpackaging.com

Find the Right Stretch Film for You

Experience the quality yourself—optimize load security while reducing film usage.

Request a Free Sample

IN Packaging Solutions

How we reduced a Companies stretch film usage by 68% while improving their containment force

Many assume that using more film means better containment. But in reality, piling on extra layers often leads to waste, higher costs, and little improvement in load stability.

At Impak, we have a team of experts who can conduct stretch wrap audits with cut & weigh tests, tilt and vibration tests, and more, to help you optimize your stretch wrapping operations.

In this case study, we will go over how we optimized a customer’s stretch wrapping operations with the AXIS Lean 80 Gauge Stretch wrap, in turn reducing their total stretch film usage by 68%, while improving containment strength, lowering costs, and future-proofing their stretch wrapping operations.

Challenge: Improving the stretch wrapping process for damage-free shipping

Two pallets with very different load profiles were delivered to our warehouse for our team of experts to test. The first pallet was tall and irregular, holding products of varying sizes, and the second was shorter and more uniform, with evenly stacked products. These pallets were being wrapped with a semi-automatic stretch wrapper at nominal tensions. Both pallets looked to have been poorly wrapped, with numerous punctures and tears in the film. . This was due to an excessive amount of stretch wrap applied, combined with significant inboard distance between the pallet edge and the product, which left the loads unstable, wasteful, and vulnerable to damage during transit.

OPTIMIZE

We needed to find a way to optimize their stretch wrapping operations, from the type of stretch wrap they should use to and any additional materials needed.

PALLET 1 - TALL & IRREGULAR

PALLET 2 - SHORT & UNIFORM

Our Approach: Testing, Auditing & Process Optimization

To start, we needed to know all we could about the load containment so that we could provide a solution. That meant measuring the weight of the pallet overall, and each section of the pallet, as well as the cut & weigh.

A cut & weigh test measures exactly how much film is being used to wrap a load. When a pallet is wrapped, a section of the film is cut off and weighed, which reveals the true film consumption in ounces. These tests are used to identify waste and to set a baseline for improvement.

Pallet 1 – SPECIFICATIONS
Gross Pallet Weight	1436 lbs
Top	4.62 lbs
Middle	14.88 lbs
Bottom	9.25 lbs
Cut & Weigh	25.07 oz

Pallet 2 – SPECIFICATIONS
Gross Pallet Weight	1226 lbs
Turntable Speed	7.25 lbs
Turntable Size	N/A
Weight Requirements	5.10 lbs
Maximum Load Size	7.7 oz

The next step was a tilt and vibration test to see how both pallets would currently hold up in transport. The current methods of stretch wrapping proved to be insufficient. Both pallet tests resulted in containment failure. If the load had been exposed to any additional forces, damage to the product was certain, and the potential for injury may have been possible.

Pallet 1

<br />

The stretch film tore at the pallet corners on the side opposite the tilt.
The wrap pulled up one of the pallet boards, which exposed nails and a sharp edge.
Inside the load, the products weren’t tight; there were gaps and movement, which caused the load to shift.

Pallet 2

<br />

The film tore at the pallet corners and continued ripping during the test until it completely detached from the pallet.
Once the film failed, the load slid off the pallet, and only the sled kept the products from fully separating.
The load shift was caused by three main issues: the film failure at the punctured corners, low friction between product layers that caused uneven sliding, and the load being positioned too far in from the pallet edges, which amplified the movement once it began.

Axis Lean 80 GaugeAnti-Slip SheetsStrappingOptimized Wrap Pattern

Our team of experts reviewed our lineup of stretch wrap and decided that the best course of action was to switch the customer’s current conventional 80 gauge stretch wrap to our
Axis Lean 80 Gauge high-performance stretch film known for its:

High Load Containment
High Puncture Resistance
Excellent Clarity with High Cling
Lowest Cost Per Load / Wrap

We also added to both pallets anti-slip sheets to inhibit movement, strapping to unitize the load, and optimized the wrap patterns for consistency and efficiency.

Pallet 1 – SPECIFICATIONS
Gross Pallet Weight	1436 lbs
Top	4.62 lbs
Middle	14.88 lbs
Bottom	9.25 lbs
Cut & Weigh	25.07 oz

Pallet 2 – SPECIFICATIONS
Gross Pallet Weight	1226 lbs
Turntable Speed	7.25 lbs
Turntable Size	N/A
Weight Requirements	5.10 lbs
Maximum Load Size	7.7 oz

Pallet 1

The stretch film tore at the pallet corners on the side opposite the tilt.
The wrap pulled up one of the pallet boards, exposing nails and a sharp edge.
Inside the load, there were gaps and movement, which caused the load to shift.

Pallet 2

The film tore at the pallet corners and continued ripping until it fully detached from the pallet.
Once the film failed, the load slid off the pallet, and only the sled prevented full separation.
The load shift was caused by low friction between layers, the film failure, and the load being set too far in from the pallet edges.

Axis Lean 80 Gauge
Anti-Slip Sheets
Strapping
Optimized Wrap Pattern

High Load Containment
High Puncture Resistance
Excellent Clarity with High Cling
Lowest Cost Per Load / Wrap

We also added to both pallets anti-slip sheets to inhibit movement, strapping to unitize the load, and optimized the wrap patterns for consistency and efficiency.

Results: Reduced film used while improving load stability

The final stage of our stretch wrap optimization was to validate the improved setup in real-world conditions.

We rewrapped both pallets using AXIS 80 Gauge high-performance film, added the strapping, and anti-slip sheets to stabilize the loads.

Since the customer used a Wulftec SML-150 Turntable Pallet Wrapper, we replicated their setup in our warehouse. With the same machine on-site, our team performed multiple in-house test wraps to ensure the updated process delivered consistent, failure-free results.

After numerous tests, we visited the customer’s warehouse to have them try out this new stretch wrapping process on their machine, and it performed flawlessly. The results were consistent, stable, and fully aligned with their operational needs.

Pallet Comparison — Collapsible

Pallet 1 Comparison

Gross Weight: 1,436 lbs

Film ↓ ~84% (25.7 oz → 4.1–4.4 oz) Top Containment ↑ >3× (4.62 → 15.5 lbs)

Containment & Film Use
Metric	Before	After
Top Containment (lbs)	4.62	15.5
Middle Containment (lbs)	14.88	15.6
Bottom Containment (lbs)	9.25	9.00
Cut & Weigh (oz)	25.7	4.1–4.4

Optimized with AXIS 80ga, strapping on both axes, anti‑slip sheet, and a shaped top sheet.

Pallet 2 Comparison

Gross Weight: 1,226 lbs

Film ↓ ~52% (7.7 oz → 3.7–3.9 oz) Top Containment ↑ >2.7× (7.25 → 20.15 lbs)

Containment & Film Use
Metric	Before	After
Top Containment (lbs)	7.25	20.15
Middle Containment (lbs)	—	—
Bottom Containment (lbs)	5.10	10.50
Cut & Weigh (oz)	7.7	3.7–3.9

Optimized with AXIS 80ga, strapping on both axes, anti‑slip sheet, and a shaped top sheet.

Reduced Film Usage

Film consumption dropped significantly on both loads, Pallet 1 was reduced by over 84% (from 25.7 oz to just over 4 oz), while Pallet 2 saw a 52% reduction (from 7.7 oz to 3.9 oz). In turn reducing their overall film usage by 68%.

Heightened Load Security

By adding strapping, anti-slip sheets, and custom top sheets, internal shifting and product separation were completely eliminated. As a result, both pallets moved from being classified as unstable (C-load) to fully secure and transport-ready.

Increased Containment Force

Containment strength increased by 247% on Pallet 1 and by 30% on Pallet 2, despite both using dramatically less film than before. Not only were the loads more stable, but the improvements were achieved without added material, labour, or equipment changes.

Improved Safety & Performance

The optimized wrap process eliminated film tearing, corner punctures, and shifting altogether. The loads remained fully intact with no sliding or separation, reducing damage risk, improving safety, and ensuring more reliable pallet transport.

416-299-0960

Contact Us Today!

Looking to Improve your Stretch Wrapping Operations?

Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.

Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries

info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

IN Automation, Uncategorized

Why Food Manufacturers are Moving to the
HDX 250A Combo Shrink Wrapping System

Compact, fully electric shrink wrapping system with built-in sealer and tunnel—cutting costs, saving space, and eliminating compressed air.

In the food manufacturing industry, shrink wrapping is a widely used packaging method trusted for extending shelf life, providing tamper-resistant protection, reducing food waste, and enhancing visual appeal with the option of printed shrink film.

To achieve this in the smartest and most cost-effective way possible we step in with the Automatic Combo Shrink System HDX-250A. An all-in-one unit combining a high-speed L-bar sealer with a built-in shrink tunnel, built to eliminate the need for separate machines and slashing equipment costs by up to 40%.

This combo machine is fully electric with zero air requirements and offers plug-and-play convenience, fast tool-free changeovers, and intuitive touchscreen controls. With speeds up to 35 packs per minute, it’s engineered for high-throughput production without sacrificing quality or floor space.

416-299-0960

COMPACT FOOTPRINT

Combines an automatic L-Bar sealer and shrink tunnel into one unit.

FULLY ELECTRIC

100% electric for easy installation and hassle-free operation.

HIGH-SPEED OUTPUT

Achieve up to 35 packs per minute with minimal operator input.

COST SAVINGS

Up to 40% Cost Savings – eliminates need to purchase separate equipment.

Why choose the Automatic Combo Shrink System HDX-250A?

A space-saving, food-industry workhorse designed for fast, clean, and efficient shrink wrapping.

Shrink wrapping plays a huge role in the frozen food industry as it is integral in securing products in a way that maintains freshness and security. This is done by protecting the product during transit and serves as a barrier against moisture and freezer burn, extending the product’s shelf life. The shrink film combines with heat and seals around the product, fully enclosing it.

The HDX-250A Automatic Combo Shrink Wrapper is specifically built to excel in these high-demand settings. It’s all-in-one, fully electric design combines an automatic L-Bar sealer and a built-in shrink tunnel into one compact, efficient system. This makes it faster, cleaner, and simpler to operate than traditional two-machine setups, while still delivering tight, consistent wraps on a wide range of frozen formats.

Most importantly, the HDX-250A delivers the level of seal integrity and package durability that frozen foods require. With features like precise film control, automatic feeding, and high-speed operation, the HDX-250A keeps your line running smoothly and your products looking flawless, right from the freezer to the shelf.

Maximize ROI with the HDX-250A

The HDX-250A replaces two machines with one compact, fully electric system, cutting floor space, energy use, and maintenance costs – maximizing your return on investment!

Impak Packaging leads the industry in ROI-focused solutions. We help manufacturers lower packaging costs, boost efficiency, and get faster payback with expert support and flexible purchase options.

BUYING

Avoid long lead times and get your fully electric, all-in-one shrink system delivered fast. Perfect for food manufacturers who need a turnkey solution without delays.

FINANCING

Upgrade your packaging line without the upfront investment. Flexible financing plans are available to match your budget and cash flow with full ownership at the end of the term.

RENTALS

Rent the HDX-250A on a monthly or yearly basis, ideal for managing seasonal demand, capacity surges, or pilot programs before committing to a purchase.

BUYBACK

Using older shrink equipment? We’ll buy it back and apply the value toward your new HDX-250A, helping you modernize while minimizing waste and upfront cost.

Shrink Smarter: Unlock Better Results with Cryovac® Shrink Wrapping Materials

As the exclusive distributor of Cryovac® shrink film, Impak delivers high-performance materials perfectly matched to the HDX-250A. From trays and cartons to retail-ready packs, our film is engineered for optimal results backed by expert support tailored to your product and equipment.

416-299-0960

SPEAK WITH A Shrink Wrapping system EXPERT TODAY

Looking for a Shrink Wrapping System?

Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.

Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries

info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

IN Case Study

Packaging Innovation in Action: How a Growing Craft Distillery Transformed Their Packaging Process with Automation

How Impak Streamlined Willibald Farm Distillery & Brewery's Packaging Operations

Discover how Impak Packaging helped Willibald Farm Distillery & Brewery optimize its packaging line using a Refurbished Damark B180 Shrink Bundle Wrapper and S34T Shrink Tunnel.

As demand for their canned spirits and cocktails surged, Willibald’s manual packaging process struggled to keep up, leading to inefficiencies, increased labour hours, and fulfilment bottlenecks. Recognizing the need for a better solution, one of the owners began exploring automation options, and that’s when they connected with us.

Impak Packaging stepped in as a trusted partner to streamline Willibald’s end-of-line operations. After assessing their workflow/growth trajectory, Impak recommended the B180 Shrink Bundle Wrapper and S34T Shrink Tunnel combo – an automated shrink bundling system designed to replace manual boxing and reduce packaging time significantly.

USED EQUIPMENT

Willibald scaled with a refurbished Damark system – lower cost, same performance.

WHAT WE INSTALLED

Damark B180 + S34T: A high-speed shrink system for mid- to high-volume canning.

READY TO SCALE?

Willibald’s growth won’t stop with one machine, and yours shouldn’t either.

Enter Willibald

Located in Ayr, Ontario, Willibald Farm Distillery & Brewery has become one of Ontario’s most recognized names in craft beverages. What began as a dream between two brothers and a close friend has grown into a thriving, 100-acre, farm-based operation, blending small-batch distilling, brewing, and farm-to-table dining.

Founded by Nolan, Jordan, and their longtime friend Cam, Willibald took shape on Nolan’s family farm. With no formal background but a deep passion for the craft brewery scene, they dove in headfirst starting with a single canning line. What started with a few curious visitors has transformed into a true destination, with a full-service restaurant, a vibrant taphouse, and a growing line of craft spirits, seasonal beers, and ready-to-drink canned cocktails.

From a first-time visitor to a loyal regular, everyone who steps onto the farm gets a taste of what Willibald is all about: community, creativity, and care in every pour.

We’re proud to support innovative producers like Willibald who are redefining what it means to be craft, without ever losing sight of where they started.

THE CHALLENGE: MANUAL BOTTLENECKS SLOWING DOWN GROWTH

Manual Packaging vs. Modern Demand: Willibald’s Challenge

One of Impak’s Sales Representatives reached out to assess their current operations and explore opportunities for improving their packaging line. They concluded that as their product line continued to grow, their packaging process wouldn’t be able to keep pace. Manual boxing and bundling required an entire day of labour for each production run, making it increasingly difficult to meet rising demand. The manual bundling of cans and bottles created several bottlenecks in their workflow, ultimately limiting their overall efficiency.

We were just spending so much time packing, the orders kept getting larger and larger… we literally couldn’t handle it unless we bought some automated equipment.

Nolan – Willibald Farms

INEFFICIENCIES

The manual process was time-consuming, impacting their ability to scale production effectively.

PRODUCTION LIMITS

With products reaching hundreds of LCBO outlets, meeting the growing demand of 40,000–50,000 cans per week had become an increasingly daunting task.

LABOUR COSTS

They relied heavily on family and friends to keep up with demand, a costly and unsustainable solution as their orders grew.

The Solution: Finding the Right Fit with Impak

Strategic Selection: How Willibald Landed on the Ideal Bundle Wrapper

After they had figured out the main challenges they were facing, they began to evaluate their options. Nolan began researching what would work best for them and viewed many Bundle Wrapping options. When asked about this process – Nolan explained that the main criteria they were looking for were timing and availability. They needed a new system in place and set in the wintertime that was effective and not costly.

Next, through a consultative process, Impak worked closely with them to identify the right equipment that could improve efficiency, reduce manual labour, and support their scaling production. We provided a dependable solution and decided that a Refurbished Damark B180 Shrink Bundle Wrapper and S34T Shrink Tunnel combo was the perfect fit for their operations.

REFURBISHED
PRODUCTS

Looking for a cost-effective packaging solution? Join Willibald Farms and other growing brands in choosing quality used equipment.

Damark B180 Shrink Bundle Wrapper
and S34T Shrink Tunnel

The B180 Shrink Bundle Wrapper and S34T Shrink Tunnel combo is a powerful, cost-effective solution for bundling multipacks with speed and consistency. Ideal for medium- to high-volume production lines, this system efficiently wraps and shrinks products without the need for compressed air.

"It’s really helped simplify and streamline things… being able to send it through, wrap it, shrink it, it just made the whole process easy for anyone to jump on and do."

Nolan – Willibald Farms

Features

Built for reliable, high-output bundling, perfect for growing operations ready to replace manual boxing with consistent, professional-grade shrink wrapping.
Compact Footprint, High Output: Designed to maximize floor space without sacrificing performance.
With a tunnel opening of 32” W x 16” H, the S34T can handle various multipack sizes: Ideal for cans, bottles, and boxed items.

RESULTS

Impak Packaging stepped in as the solution provider, taking on the task of modernizing Willibald’s manual packaging process to meet rising production demands. The upgrade included the installation of the Damark B180 Shrink Bundle Wrapper and S34T Shrink Tunnel, an automated bundling and shrinking system designed to streamline multipack handling and eliminate the need for manual boxing.

With increased efficiency, lower labour dependency, and the capacity to bundle up to 50,000 cans weekly, Willibald found the right partner in Impak Packaging.

The bundler is big. Before we were putting everything in boxes. That was like a whole extra day just to box up what we can. Now we just send it to the bundler and that’s a huge opportunity.

Nolan – Willibald Farms

Lower Operating Costs

By replacing manual labour with automation, Willibald significantly reduced labour expenses and minimized overtime, freeing up resources to reinvest in growth.

Simplified Workflow

Easy to operate and train on, the new setup allows any team member to jump in, streamlining packaging and reducing training time.

Faster Throughput

The new bundling system matches Willibald’s high-volume canning (up to 40 loads/hour), boosting speed and efficiency without compromising quality.

Built to Scale

As demand continues to grow, Willibald is now equipped with an automated system that supports larger orders and future production increases.

Looking Ahead: Automation as a Foundation for Growth

As Willibald continues to expand across Ontario and beyond, with some products already in 300–400 LCBO stores, automation remains a key part of their strategy for sustainable growth.

They’re already looking into future upgrades like carton erectors to build their boxes and further improve their can packaging operations. Impak will be there to help in this venture along the way.

416-299-0960

Have a question about our equipment or service?

Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.

Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries

info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

Year: 2025

When to Switch from Hand Wrapping to Machine Wrapping

When to make the switch

Hand Wrap to Machine Wrap Calculator

Current Hand-Wrap Profile

ROI Snapshot (weekly)

Recommended Approach

Profile

ROI Snapshot

Recommendation

Benefits of machine film

Request a Free Visit from a Stretch Wrap Expert

Find the Right Stretch Film for You

How we reduced a Companies stretch film usage by 68% while improving their containment force

Challenge: Improving the stretch wrapping process for damage-free shipping

OPTIMIZE

PALLET 1 - TALL & IRREGULAR

PALLET 2 - SHORT & UNIFORM

Our Approach: Testing, Auditing & Process Optimization

Step 1: Baseline testing

Step 2: Stress Simulations

Step 3: Process Optimization

Step 1: Baseline testing

Step 2: Stress Simulations

Step 3: Process Optimization

Pallet 1

Pallet 2

Results: Reduced film used while improving load stability

Reduced Film Usage

Heightened Load Security

Increased Containment Force

Improved Safety & Performance

Contact Us Today!

Looking to Improve your Stretch Wrapping Operations?

Why Food Manufacturers are Moving to the HDX 250A Combo Shrink Wrapping System

Compact, fully electric shrink wrapping system with built-in sealer and tunnel—cutting costs, saving space, and eliminating compressed air.

COMPACT FOOTPRINT

FULLY ELECTRIC

HIGH-SPEED OUTPUT

COST SAVINGS

Why choose the Automatic Combo Shrink System HDX-250A?

A space-saving, food-industry workhorse designed for fast, clean, and efficient shrink wrapping.

Maximize ROI with the HDX-250A

Shrink Smarter: Unlock Better Results with Cryovac® Shrink Wrapping Materials

Looking for a Shrink Wrapping System?

Packaging Innovation in Action: How a Growing Craft Distillery Transformed Their Packaging Process with Automation

How Impak Streamlined Willibald Farm Distillery & Brewery's Packaging Operations

USED EQUIPMENT

WHAT WE INSTALLED

READY TO SCALE?

Enter Willibald

THE CHALLENGE: MANUAL BOTTLENECKS SLOWING DOWN GROWTH

Manual Packaging vs. Modern Demand: Willibald’s Challenge

The Solution: Finding the Right Fit with Impak

Strategic Selection: How Willibald Landed on the Ideal Bundle Wrapper

Damark B180 Shrink Bundle Wrapper and S34T Shrink Tunnel

RESULTS

Lower Operating Costs

Simplified Workflow

Faster Throughput

Built to Scale

Looking Ahead: Automation as a Foundation for Growth

Have a question about our equipment or service?

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Why Food Manufacturers are Moving to the
HDX 250A Combo Shrink Wrapping System

Damark B180 Shrink Bundle Wrapper
and S34T Shrink Tunnel