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The Birth of Stretch Films: Revolutionising Load Stabilisation

As the global economy soared in the 1960s, products began crossing continents, especially in the FMCG industry.

A pressing need emerged: stabilising pallets to ensure the safe and efficient movement of goods.

However, suppliers faced three cumbersome options: loading hundreds of individual boxes onto a truck, using metal straps, or employing shrink bags to unitise loads.

Load unitisation became paramount.

All were time-consuming, labour-intensive, and costly.

In 1972, a breakthrough occurred when it was discovered that stretch film could secure loads effectively.

This innovation quickly gained popularity, and various types of stretch wraps became essential across industries such as manufacturing, e-commerce, agriculture, food and beverage, and more.

Stretch film offers numerous benefits:

Cost-effective option for load unitisation.
Minimises shipping damage.
Keeps products free from dust and moisture.
Enhances load handling, streamlining operations for loading and unloading pallets.
Versatile and adaptable, usable on any surface, whether flat or pointed.
UVI stretch films protect products from UV rays when stored outdoors.

Opaque films conceal products, reducing theft and protecting valuable items.

The Evolution of Stretch Films

Stretch film has transformed the packaging industry with its cost-effective and efficient protection and securing of goods.

Over the years, it has evolved significantly to meet changing market demands.

The Early Days of Stretch Film

The Genesis

In the early days of packaging, the industry faced a significant challenge: how to efficiently and securely transport goods.

Traditional methods for stabilising loads, which were mentioned previously, were laborious, time-consuming, and not cost-effective.

These included:

Loading individual boxes onto trucks: This method was highly inefficient and prone to errors and damage.
Using metal straps: While metal straps provided some stability, they were difficult to apply, could damage the goods, and posed safety risks.
Employing shrink bags: Though better than the previous two methods, shrink bags required heat to apply, which was another added complexity and cost.

The quest for a better solution led to the invention of stretch film in the early 1970s.

Manual Stretch Film

The first generation of stretch film was quite basic.

Made from simple plastic materials, these early films had to be manually applied to pallets and products.

Workers would stretch the film by hand, wrapping it around the items to secure them.

Labour-Intensive: The manual application was highly labour-intensive and physically demanding. Workers had to exert significant effort to stretch and wrap the film tightly enough to secure the load.
Time-Consuming: The process took a considerable amount of time, slowing down operations and increasing labour costs.
Limited Protection: While early stretch films provided some degree of protection, they were still inferior for utmost load unitisation and good protection.

Early Benefits

Despite its drawbacks, early stretch film brought about several key benefits that made it a preferable alternative to the existing methods:

Improved Load Stability: Even in its basic form, the stretch film significantly improved the stability of palletised goods, reducing the risk of products shifting during transit.
Cost Savings: Over time, the stretch film proved to be more cost-effective than metal straps or shrink bags, as it reduced the amount of labour and materials needed.
Versatility: Stretch film can be used on a variety of products and surfaces, making it a versatile solution for different industries.

Evolution and Innovation

The limitations of early stretch film prompted continuous innovation.

As the demand for more efficient and protective packaging solutions grew, the industry saw several key developments:

Introduction of Machine Stretch Film: Machine stretch film was developed to address labour and time challenges. This type of film is used with automated stretch-wrapping machines, which, with the advancement of wrapping machines in the US then, drastically improves the speed and efficiency of the wrapping process.
Material Improvements: Advances in plastic materials, particularly the development of LLDPE (Linear Low-Density Polyethylene), provided better elasticity and durability compared to the original LDPE (Low-Density Polyethylene). This can be attributed to technological advancements and chemical companies’ innovations in resin development.
Enhanced Protection: Newer films have better properties, offering better protection and load unitisation, ensuring that products remain stabilised and protected.

The Impact

The advent of stretch film marked a significant turning point in the packaging industry. It not only streamlined operations but also enhanced the safety and security of goods during transit.

As a result, stretch film quickly became a standard in various industries, from manufacturing and e-commerce to agriculture and food and beverage.

Today, the legacy of early stretch film continues to influence modern packaging solutions.

The innovations born out of the challenges of the 1960s and 1970s have paved the way for advanced materials, automated systems, and environmentally friendly options that we see today.

Published by Thong Guan, 31 July 2024