Shrink Wrap Packaging Experts - We Do It Right!

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.

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."

Features

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.

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. 

Contact Us Today!
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 Gertex Group Logo
Impak Packaging
Inquiries
Parts and Service

416-299-0960

flow wrap solution for salad kits

Overview:

A Toronto-based fresh fruit and vegetable processor and repackaging company wanted to enhance their existing operations, particularly in serving retail and foodservice clients through salad kit offerings. They wanted to improve the presentation of their product by introducing more effective packaging machine.

To address their needs, Impak technical expert closely examined the company’s requirements and proposed a highly efficient solution: a Flow wrapper equipped with a built-in printer. Printing ink directly onto plastic film can be a complicated task, as the type of film used can impact ink drying time and adhesion.

A flow wrapper sealing salad kits with Best-by date printed film

Impak’s expert not only suggested the perfect blend of film and inkjet technology for the best outcome but also proposed a cost-effective solution by recommending a well-maintained, gently used machine at a more budget-friendly price point. Additionally, this expert customized the pre-owned equipment to align seamlessly with the client’s specific requirements and expectations for salad kits.

Since the implementation of the new flow wrapper, the customer has reduced its packaging cost by 15% and can print best-before dates without any further configuration.

a flow wrapper with a PRinter attached

Challenge:

The customer had a multifaceted challenge on their hands: they needed to package various items like cheese, nuts, and dressing of varying sizes simultaneously while ensuring the Best by dates were accurately printed on each package. Their goal was to achieve higher packaging speeds without any issues of smudged printing. Additionally, they aimed to reduce their packaging costs and sought a solution that would streamline their processes, minimizing labor-intensive tasks and improving overall efficiency.

After (Salad dressing with 'Best By' printed on)
Best-by salad dressing
After (Salad dressing with 'Best By' printed on)
Process & Solution:

A previous customer referred the customer to one of Impak’s Technical Applications Experts. He worked alongside the customer and proposed a flow wrapper(IMPAK AHP 450 Servo) with a built-in printer. The flow wrap machine is fully adjustable to cater to the specific needs of products with a memory of 20 different recipes. All the controls are centrally located with HMI full-color touch screen so it’s easier for the operators to set up. The system cut the packaging by bag lengths setting and print registration setting can be added with additionally installed printer as well. Servos are utilized on the drives for minimal maintenance and long-term reliability.

The people working in the plant are very happy with the ease of system operation and the fact that it is much quieter than the old system. The customer has increased their production and reduced their cost. They are now able to provide safe and secure packaging for a broader range of customers in the food industry with compliance across all sectors.

results

Lowered Cost

Since the introduction of the new system, the customer has reduced overall cost by 25%. Less material is being used resulting in a 15% savings on packaging costs.

Reduced Labour

The system works on demand and only one operator is required to put products on the machine, the customer has reduced labour by 30% and reallocated employees to other key areas in the business.

Increased Production Speeds

Overall production has been increased as the machine runs 30% faster than the previous system.

THE EQUIPMENT USED FOR THIS SOLUTION

  • Impak AHP450
AHP-450 Flow Wrapper
  • Conveyor
  • Hx Nitro Thermal Inkjet

Get a flow Wrap Consultation Today!

Have a question about 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 Gertex Group Logo
Impak Packaging

400 Flint Rd.
North York, Ontario
M3J 2J4
Phone: 416-299-0960
Fax: 416-299-0961
Email: [email protected]

Inquiries

416-299-0960

Parts and Service

416-299-0960

FDA Approved Shrink Packaging Solution for Cake/Pizza Cartons

Overview:

A large manufacturer of cake cartons, pie cartons & pizza boxes in Toronto wanted to upgrade their existing process, and incorporate a faster and effective way to wrap cake and pizza boxes. They were wrapping on a sleeve wrapper which left open holes on each side of the package. Their customers needed a fully enclosed package to comply with food packaging guideline’s under CFIA (Canadian Food Inspection Agency) & FDA food & safety regulations.

An Impak technical application expert worked with this company to get a better understanding of their expectations and recommended a highly efficient Automatic Side Sealer for Cake Cartons, Pie Boxes & Pizza Boxes. Since the implementation of the new shrink wrapping system, the customer has reduced its packaging cost by 15% and can run different sized boxes at the required speeds without having to change the film.

Automatic Side Sealer with Shrink Tunnel

Challenge:

The customer wanted a complete enclosure due to CFIA and FDA regulations. They wanted to wrap big and heavy stacks of cake and pizza boxes at higher speeds. They wanted to cut their packaging cost and wanted a solution that was less labour intensive and more efficient.

Before (Cake Boxes on a Bundle Wrapper)

Process & Solution:

A previous customer referred the customer to one of Impak’s Technical Applications Expert. He worked alongside the customer and recommended an Automatic Side Sealer capable of running several sizes of cartons. The machine has a larger range of sizes and is fully adjustable with unlimited length. All the controls are centrally located so it’s faster and easier for the operators to set up. Since the introduction of the new side sealing system, less material is being used. The system works on demand and no operator is required. Servos are utilized on the drives for minimal maintenance and long-term reliability.

The people working in the plant are very happy with the ease of system operation and the fact that it is much quieter than the old system. The customer has increased their production and reduced their cost. They are now able to provide safe and secure packaging for a broader range of customers in the food industry with compliance across all sectors.

After (Pizza Boxes on the Automatic Side Sealer)
After ( Pizza Boxes on the Skid)

results

Lowered Cost

Since the introduction of the new system, the customer has reduced overall cost by 25%. Less material is being used resulting in a 15% savings on packaging costs.

Reduced Labour

The system works on demand and no operator is required, the customer has reduced labour by 30% and reallocated employees to other key areas in the business.

Increased Production Speeds

Overall production has been increased as the machine runs 30% faster than the previous system.

Side sealer sealing and shrinking pizza boxes, cake boxes with complete enclosure

Get a shrink Wrap Consultation Today!

Have a question about 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 Gertex Group Logo
Impak Packaging

400 Flint Rd.
North York, Ontario
M3J 2J4
Phone: 416-299-0960
Fax: 416-299-0961
Email: [email protected]

Inquiries

416-299-0960

Parts and Service

416-299-0960

Lowest Cost Beer Can Packaging: No Corrugated!

Overview:

A craft brewer wanted to reduce their material costs by 60%, increase production by 300%, and eliminate manual labour. They were wrapping cans in a printed cardboard case and were looking to wrap both supported and unsupported cans in clear or printed shrink film with or without trays.

An Impak technical application expert worked with the craft brewer to get a better understanding of their expectations and recommended a highly efficient automatic shrink wrapper with an automatic infeed.

Since the implementation of the new shrink wrapping system, the brewer has reduced their packaging cost by 60% and reallocated labour to other key areas of their operation.

Challenge:

The Brewer had a tight budget and needed the equipment quickly. They wanted to cut their packaging costs by replacing printed cardboard cases with printed film while at the same time increase their production speeds. Their current process was very labour intensive. Production was under significant pressure from sales to deliver more product immediately.

Looking to Reduce Material Costs of Beer Can Packaging?

Process & Solution:

The craft brewer and Impak’s applications expert worked together to find the best solution. Three different options were considered. Impak combined several configurations and then proposed a system that ran at 30% over the required speeds and fit within the customer’s budget.

The solution enabled the craft brewer to shrink wrap their unsupported cans in 6 packs, 12 packs or 24 packs in printed or clear shrink film. With a quick changeover, the system can also wrap printed or clear shrink film around trays OR run trays through without wrapping them. The automatic bundle wrapper was delivered on time. To help the customer get through their immediate production surge Impak was able to supply a semi-automatic bundle wrapper on a rental basis until the system ordered was delivered and installed.

Before (4 Cans in a Cardboard Sleeve)
After (6 Cans in Printed Shrink Film)
Before (24 Cans in a Cardboard Box)
After (24 Cans in Shrink Film Supported)

results

This packaging solution has helped the brewer to reduce their overall costs by 50% and given them the ability to wrap cider, beer or other beverage products in printed or clear film. It has also enabled them to do extra profitable work as a contract packager for several of their smaller and larger competitors.

Lowered Cost: The brewer reduced its packaging cost over 50%.

Reduced Labour: With an automated system the brewer reduced labour by 60% and reallocate employees to other key areas in the business.

Increased Production Speeds: The implementation of an automated system has also increased production speeds by 50%.

Increased Product Offering: With the ability to use high quality printed graphics the customer has now begun producing higher margin products in convenient 4 packs, 6 packs, 12 packs and 24 packs and also expanded their product range.

Watch the automatic system in action wrapping 6 cans as well as 24 cans of beer!

Get a Bundle Wrapper Consultation Today!

Have a question about 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 Gertex Group Logo
Impak Packaging

400 Flint Rd.
North York, Ontario
M3J 2J4
Phone: 416-299-0960
Fax: 416-299-0961
Email: [email protected]

Inquiries

416-299-0960

Parts and Service

416-299-0960

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