To boost pack-to-ship performance for irregularly shaped metal fabrications and powder-coated part production, Staber Industries has turned to new orbital stretch wrap technology. The Groveport, OH-based company purchased a Yellow Jacket 110®, a system engineered to secure oversized or odd-shaped palleted loads safely and cost-efficiently without bands. Staber Industries realized a speedy return on its investment through greater productivity, minimized labor, ease of operation, and importantly, the prevention of product damage during shipment.
More than 40% of Staber Industries' business focuses on contract fabrication work; key technologies include laser cutting, bending, and welding, as well as vapor degreasing and powder-coat painting of metal parts and assemblies. Its mission is consistent quality and cost-efficiency in each of its profit centers. But as its powder-coat paint line expanded to serve an increasing number of manufacturers, the company found a weak link in pack-to-ship productivity.
Staber needed to replace its labor-intensive and costly steel banding method. Since most of its loads are bulky and irregularly shaped, steel banding was not able to lock down each load, allowing shifting, sliding, and damage during shipment. Traditional stretch wrap methods could not safely secure their odd-shaped loads, so Staber turned to the new orbital stretch wrap technology offered by the Yellow Jacket 110.
Boost Productivity, Minimize Labor
"Steel banding was definitely a two-man operation," says Staber Industries president Bill Staber. "Now, with the Yellow Jacket 110, we have nearly tripled our pack-to-ship productivity and we need only one man to prepare the load for shipment. Our two-man operation used to take 15 minutes per pallet. Now our one-man operation takes under five minutes per load. The Yellow Jacket 110 is a big plus in getting more product out the door."
Unlike traditional stretch wrappers that wrap around a vertical axis, the Yellow Jacket 110 wraps around a horizontal axis. The wrapping cylinder carries a spool of stretch wrap on a moving dispenser. Mounted on a base, the cylinder easily moves parallel to the forks of a forklift. The stretch wrap is dispensed around and under the loaded pallet, while the cylinder is manually or automatically advanced forward across the pallet. This eliminates the need for bands or straps to attach irregularly shaped loads to pallets.
Secure Any Load Size/Shape, Without Scratching
"On the powder coat side of our business, there are no 12 in. sq products stacked 4-wide and 6-high on a skid," says Staber. "We handle all different shapes and sizes, things that are almost impossible to strap down, such as wrought iron railing, fencing, and gates; or the circular, wraparound valences for gas pumps. And, the other problem you run into is that once you paint something, it becomes slippery. You put these painted parts on top of one another and they slide all over the place, marring the paint job. Traditional methods simply tie the parts together, while this orbital technology locks the products down to the skid, which acts as the foundation," Staber explains.
With orbital technology, the pallet becomes the backbone of the load. This provides a superior package over traditional turntable wrapping methods that require more wraps and film, yet can still not fully secure the load. Wrap tension of the Yellow Jacket 110 adjusts easily to provide a range of 0-200% film stretch, which can secure cargo of any dimension, weight, or shape.
"As we expand our powder coat business, the Yellow Jacket helps us to cost-effectively pursue more of these job-shop, custom-type projects. It definitely relieves us of the problems involved in shipping these loads. It's peace of mind. We don't have to worry about damage to the powder coating. We just hit two red buttons and it's wrapped and secured through the entire shipping process," stresses Staber.
Pack-To-Ship Goals Easy To Attain
"When the Yellow Jacket 110 was delivered, it took all of 15 minutes to show everybody how to use it. It is extremely easy to operate," says Staber who particularly likes the system's operator convenience factors.
Although Staber Industries is currently dedicating the system to one shipping area, the Yellow Jacket 110 is designed for portability. It can be moved easily, on locking casters, throughout an operation and can be plugged into any 110 V outlet. The system works with all types of equipment -- rider forklifts and narrow aisle lifts -- and with a semiautomatic model, the rider can remain on the forklift for all operations.
Because orbital stretch wrap technology can lock down any load -- standard, irregular, or oversized -- the Yellow Jacket 110 is an easy, safe, secure, and cost-effective way to attain superior pack-to-ship performance.
