Packaging strapping with built-in carrying handle

Shrink packaging is the most used secondary packaging for PET containers. Today this already has a market share of more than 30 per cent, with a growing trend. All other types of packaging such as open or closed cardboard boxes, baskets, trays of high rim, plastic or wood and other Multipack boxes are solutions with minor to pack PET bottles. However the shrink films are produced with fossil raw materials, and during the process of shrink tunnel of shrink occurs, in addition, high energy consumption.

Why Krones development aimed to create an alternative to shrink-wrapped film packaging to save resources, a packaging system complete with packaging as such and the respective technique of machinery. So Krones took advantage of the technique of strapping widely proven in other sectors and applied it to the packing containers. Thus was born LitePac, a design of completely new packaging for PET containers.

The most varied concepts of packed with strapping to packaging technology were developed in numerous workshops. The diagonal arrangement of carrying handle packaging achieved the best results and reached maximum stability under different test conditions.

Configuration of test for stability of the packaging tests performed comparative tests between shrink packaging and packaging flejados. Shrink packaging broke after just 15 runs. This was the reference. During testing it was found that the stability of flejados packaging strongly dependent parameters such as the temperature of the product, loss of CO2, the storage time and content of CO2 of the bottled product. The results were amazing. LitePac packaging with diagonal carrying handle they totalled up even 250 runs, i.e. a much higher number than that of the packaging under film. Under all conditions, even the most unfavourable, LitePac packaging was the most resistant.

The horizontal strap is a highly resistant PET of 8 mm wide tape. It has a wide Reed of quick opening to facilitate its opening. Easy opening is guaranteed through a Reed of destensado applied in two points of welding with the tape loop. The strapping vertical way of carrying handle is willing diagonally between the bottles. It consists of a Ribbon of polypropylene soft and comfortable of 15 millimeters wide, with good transport characteristics. The carrying handle focus and at the same time reinforces the horizontal strapping tape. A bar code can be applied with adhesive tape on the strapping tape, optionally also externally. On the vertical transportation, optionally on a previously equipped tape loop, you can print a code of numbers.

The stability of the packing was also checked tests on the conveyor. So Krones performed cycles of testing on different transport systems, from the packer to the Palletiser machine. They were also evidence of stacking with bottles of 1.5 litres on half pallets and during loading trucks, with positive results: the bottles were not damaged.

Developing packaging strapping for packaging innovation attention focused especially on the reduction of energy consumption. The Elimination of the tunnel of shrink represents a clear reduction in operating costs for the operator. Also the amount clearly minor required packaging material contributes uniquely to lower operating costs: while in the LitePac package (in the case of bottles of 1.5 litres in composition 3 x 2) they require about 3.5 grams per unit of packaging for strapping tapes, in shrink packs are required about 13 grams per unit of packaging. This also significantly reduces the waste of the consumer. The Elimination of the applicator of handles in the line of packaging contributes to a lower power consumption, reduces the number of transporters and the required installation area. In the end also here: lower costs.

Another important advantage for the user is the increased use of pallets. Due to the arrangement of bottles diagonal achieves a more efficient layer scheme, and this represents again lower operating costs. The diagonal arrangement of bottles that make up the packaging allows to increase the utilization of the pallet up to 20%, depending on the diameter of the bottle: currently in Germany the bottle of 1.5 liters in a package of six units is piled on a Düsseldorf pallet with a schema layer consisting of 10 packs per pallet layer. The diagonal arrangement of bottles in the LitePac package allows to place twelve units of packaging for layer. With the system of packed in diagonal and a layer consisting of twelve packs, there are now 48 cartons on a pallet Düsseldorf that compared to a system of packaging linear conventional and a layer of 10 packs.

The result is less traffic for both pallets internally in the company and externally and capacity increased in the store. These factors also influence operating costs.

Adding everything, expected cost savings are very high due to lower costs in packaging material and energy consumption clearly minor by the removal of the tunnel of the applicator of handles and shrink. This is equivalent to a reduction in costs of more than 50 percent.

Fewer carriers, less surface installation, simplified layout of the line, less surface of support both in the store as well as in the supermarket, less traffic of pallets, all of this contributes to the packaging strapping technique to become a concept of packaging in the future.

The necessary technique to make these packages is provided by the new machine Packer EvoLite, composed by an input of packaging module and a module for strapping of packages. In the input module packaging fed continuously are separated on two tracks. Then four units of strapping on the module of strapping tailored packages LitePac.

The new machine EvoLite complies with the criteria enviro regarding energy efficiency and of means and as to impact environmental. The following features were decisive in the assessment for the award of the label enviro:

• efficient selection of the engine specially adapted to the movements and accelerations in the machine
• reduction of electricity consumption, perfect and precise sizing of the engines
• standby switches to reduce losses of heat in the tabs applied by welding
• decrease of the consumption of compressed air due to an optimal layout of duct and duct with transverse sections optimized employment
• waive possible maximum lubricants thanks to the use of continuous lubrication bearings and a special technique of brushes to lubricate conveyor belts
• ergonomic workplace with specially selected components to reduce noise and to strengthen the protection of staff.