The upsides of downgauging

The evolution of industrial packaging, like that of other forms of packaging media, continues apace with manufacturers investing considerable time, effort and resources into developing new and innovative solutions to the sector’s needs.

One concept in particular that remains a key focus for the sector is that of packaging downgauging. As Dave Khanna, Sales Director at bpi.visqueen (one of Europe’s leading manufacturers of polyethylene-based industrial packaging), points out, downgauging allows suppliers to develop products that are perfectly suited to the challenges of the times.

“Downgauging is like the best ideas – simple and yet highly effective. In essence, it entails the creation of packaging that offers more from less. More performance but from less material, meaning major reductions in the volume of packaging used and subsequent waste created,” he says.

“Downgauging also provides additional benefits from a commercial, operational and cost perspective. As such, it provides users with a ‘win-win’ situation - the opportunity to boost both their green credentials and their packaging efficiency in one swoop.”

While the principles behind downgauging packaging may be simple, the actual process of creating downgauged packaging is anything but. In order to develop these solutions, bpi.visqueen draws on its extensive experience spanning more than two decades, the very latest polymers and cutting edge extrusion technology – including equipment housed at its Ardeer site in the UK, the recent focus of a £7 million investment.

By combining these factors, the manufacturer is able to produce polyethylene (PE) film for conversion into pallet stretchhoods, sheeting, open mouth sacks and tubular sacks on the reel which offer all the performance of conventional products but from a film profile that’s as much as 25% thinner.

And bpi.visqueen’s downgauged products are also 100% recyclable. Best of all, the green benefits don’t stop there. As downgauged films are thinner, manufacturers like bpi.visqueen can also accommodate more product on a standard reel. This greater yield per reel reduces delivery requirements and as a result, associated vehicle emissions.

Aside from their improved environmental credentials, there are other major attractions driving the popularity of downgauged packaging films. Most notably, they also have the ability to deliver genuine commercial advantages.

“Downgauged packaging’s capacity to deliver more from less is as beneficial from a commercial point of view as it is for the environment,” explains Mr Khanna.

“For instance, the greater yield of film offered allows users to create more packaging with fewer stoppages for reel changes. Not only does this maximise machine and operator time, but the improved efficiency also tends to lower per unit packaging costs. Also, the need for fewer film deliveries reduces associated administrative demands.”

Stretching the limits

At the recent easyFairs exhibition in Birmingham, UK, bpi.stretchfilms was promoting a new blown pallet stretchwrap known as Bontite. The Bontite range draws on a proprietary blend of polymers to offer the benefits of blown film (such as a high level of strength and tear resistance) but with the added advantages of films produced using cast technology (low noise levels and good presentation qualities).

The film’s load holding forces are said to surpass those of typically heavier gauge cast films, and at lower stretch levels. It can be used to wrap heavy, irregular or awkward loads (for example loads with sharp edges) as well as on lighter and easily crushable goods.

Bontite offers a flexible choice of cling configurations that include inside or outside cling, and with the option of a high slip level on the non-cling face to help prevent inter-pallet adhesion.