There is not one grouping that is better suited than others. The arrangement in staggered rows brings benefits on large groupings (24 units and more) as well as on smaller ones (6,9,12,15). Nevertheless, groupings that are a multiple of 6 have been defined for conventional packs. «Unconventional» groupings of 15,28,35 are often better suited to nested packs and can allow to generate higher savings. Today’s standard container diameters also result from an optimization based on conventional packs ; this is why Femaag has developed Opti’Nest, a tool that can simulate the impact of a diameter change on the number of nested packs that can be loaded on a pallet.
Converting simultaneously several lines with different models of shrink-wrappers and palletizers can appear to be a complicated task. Femaag makes it quite simple by proposing you a staggering device that can be easily fitted on any existing equipment and providing full support in your project from the shrink-wrapper to the pallet (technical study, follow-up of palletizer’s modifications, modifications on the shrink-wrapper ...).
If you choose to maximize the benefits of nested packs by removing cardboard trays or plates, your changeover times will be much shorter. Otherwise, depending on your particular case,changeover times will be equal or at worse 5 minutes longer than for a conventional pack.
No, quite the opposite. Moving to nested packs allows to reduce the film thickness since an increased number of contact points between containers is much more effective than a cardboard support : at equal film thickness a nested pack without tray is stiffer than a conventional pack with a tray.
Printed films can be a good opportunity to improve the visual impact of your products. They are usually 8 to 10% more expensive than neutral ones. This extra cost can sound prohibitive if you keep using a conventional solution with cardboard trays. But if you remove trays, the total cost of secondary packaging materials is indeed much lower. In most cases, nested packs are wrapped in neutral film ; however, should you decide to use a printed film, the extra cost of printing will be entirely offset by the film weight reduction. No additional costs then, but a direct saving : the cost of your printed tray !
Yes. Femaag can adapt your shrink-wrapper so that it can produce packs without trays. Usually, the conveying systems (roller conveyors, tunnel plus belt conveyor, belt transfer system) can remain unchanged since the intrinsic resistance of nested packs allows them to be transported in harsh conditions. But if you really want to adapt your conveying system as well, Femaag can do it for you.
Most of the palletizers available on the market will be able to manage nested packs as a new format (new program and, in some cases, additional tool). In some specific cases, you might have to add a layer pad insertion system on your palletizer. Adding this feature will cost you around 50 k€. From our experience, this investment is usually paid off within 6 to 8 weeks.
Convincing them should be much easier now that nested packs, because of the benefits they offer for both consumers and distributors, have been widely adopted in the U.S and strongly develop in Europe. Indeed, as soon as they start with nested packs, distributors tend to ask for more. Most of our customers chose to start with a single format on a single line. 100% of them have extended nested packs to other formats and other lines. We can also support your approach by giving you access to our documentation (photos, videos, sales arguments) and supplying you with sample packs.