In brief
There is no universal pallets-per-day threshold. A machine becomes worth evaluating when measurable process cost, inconsistency, safety exposure or capacity constraints justify the change.
Use observed site data and representative trials; do not rely on generic savings percentages or payback promises.
Measure the current process
Record pallets by load family and shift, active wrapping time, waiting, roll changes, film applied, breaks, rewraps and damage. Separate normal days from peaks and exceptions.
Define what the machine must solve
Possible objectives include repeatability, throughput, reduced manual handling, controlled programmes or better usage data. Rank them so equipment is not selected from headline speed alone.
Check load and site fit
Assess pallet dimensions, weights, stability, floor space, access, guarding, power, material flow and integration. A rotating turntable, rotary arm and mobile wrapper do not suit every load or layout.
Build total cost of ownership
Include purchase or lease, installation, guarding, training, film, labour, servicing, wear parts, downtime and financing. Compare the same period and state every assumption.
Trial and govern the process
Test representative loads and document film, carriage, programme and acceptance measures. Plan maintenance, authorised settings, operator training and a fallback for downtime before approval.
| Area | Baseline | Future-state evidence |
|---|---|---|
| Throughput | Pallets and time by shift | Observed cycle and queue impact |
| Material | Applied film and exceptions | Trialled applied film |
| People | Task time and handling | Revised workflow and training |
| Ownership | Current complete process cost | Equipment, service and downtime cost |
Practical checklist
- Observe the current process
- Define ranked objectives
- Check representative load and site fit
- Model total ownership cost
- Trial film and programmes
- Plan maintenance and downtime