Client Background
Type: Manufacturer of aluminum battery trays for NEV brands
Product size: Up to 2 meters, irregular shape, 15–30kg each
Annual shipments: Over 100,000 units
Previous packaging: Manual strapping + cardboard edge protectors + corrugated paper
Challenge
Low efficiency: Each unit required 4 straps, 6 edge protectors, and 2 layers of paper – took 15–20 minutes per unit; labor-intensive.
Multiple materials: 5 different types (straps, protectors, paper, stretch film, tape) complicated procurement and inventory.
Moisture softening: Cardboard absorbed moisture during ocean transit, losing strength – transport damage rate ~1.2%.
High cost: Packaging materials and labor accounted for 6.5% of total product cost.
Solution
Automated stretch wrapping with pre-stretch algorithm: Machine-grade stretch film with automatic wrapper, using pre-stretch tracking to adjust wrapping path and tension based on shape – maximizing film utilization.
PE edge protectors replace cardboard – waterproof, crush-resistant, and recyclable (same material as film).
Colored stretch film: Outer layer in client’s brand color (blue) for both protection and branding.
Reduced to just 2 materials: Stretch film + PE protectors – eliminated straps, paper, and tape.
Results (Quantified)
Per-unit packaging time reduced from 15–20 to 3–5 minutes (70% efficiency gain)
Annual film material costs saved RMB 470,000 (~$65,000 USD)
Material types reduced from 5 to 2 – streamlined purchasing and warehousing
Transport damage rate fell from 1.2% to 0.08% (93% reduction)
Client rolled out this solution to their other three manufacturing sites
Client Testimonial
“This solution turned our packaging department from labor-intensive to an automation benchmark. The blue stretch film also makes our products instantly recognizable in the warehouse.” – Operations Director
