EVi® Tape Audit Program & Case Story
Following up on recent operational consultancy, EVi® offers interested companies the Tape Audit Program, a collaboration program with customers where EVi’s® experience is made available to verify whether the procedures in use can or should be improved to support and guarantee maximum yield during end-of-line packaging operations.
With the Tape Audit Program, the efficiency and productivity of sealing is improved through the identification and standardization of packaging practices, with the aim of ensuring packaging closure safety, eco-compatibility, operational and material savings.
For example, we report one of our latest experiences with a production company that had an interest in improving the historical procedures present in its end-of-line and, in particular, wanted to solve the problems it was encountering on the closure of the packaging. The company was concerned because, among other things, the packaging required multiple applications of plastic tape strips to ensure a potential correct closure (considering that the package would then have to withstand several temperature changes during transport) and was concerned about the amount of tape it was using which, in addition to not being an environmentally friendly choice, was in clear conflict with the aim of reducing costs.
After meeting with the Company for an evaluation of the procedures in place and presenting the Tape Audit Program, the consulting process examined the end-of-line packaging process, the materials used, the workstations and the logistics spaces involved to identify areas for improvement.
Evaluating the findings and collaborating directly with the customer’s R&D department, two possible solutions emerged which, after a “live operational test”, determined the strategic transition to the use of WAT tape.
In short, a production company was worried about using too much packaging tape to seal its packaging and saw the possibility of making its packaging “green” increasingly distant. With the idea of ensuring better closure, each carton packed used two lengths of tape at both the top and bottom, for a total of four lengths.
The extra lengths of tape were necessary to create a strong seal on the cartons (which were high in recycled material) because they could encounter climatic situations with high temperatures during transport.
In addition, the additional lengths of tape increased the time it took to seal a carton, and the application process required at least 6 employees in the sealing area to keep up with production levels.
Following up on a couple of possible solutions presented that involved the use of materials with characteristics similar to those normally used and carefully evaluating the results that emerged from the Tape Audit Program, it was decided to use a type of tape different from the traditional plastic tape and proceed with WAT tape for a live test in production.
WAT tape uses a water-activated starch-based adhesive to create a deep, penetrating bond with the surface of the box. Used with an automatic dispenser, the WAT belt offers operators an efficient, healthy and reliable solution for sealing the packaging even with boxes with a high recycled content (please note that the volume of recycled material content in corrugated cardboard packaging has a direct effect on the ability of the belts to bond with the surface to be sealed). Kraft cardboard fibers are larger in size and quickly “bond” to adhesives. Recycled content fibers are much shorter due to the recycling process, and this limits the ability of common adhesive tape to create an effective closing bond. The WAT tape adheres very effectively regardless of the composition of the box material.
WAT generates an immediate and strong bond that translates into a superior seal of closure of the packaging. In this specific case, considering the weight of the product, it was decided to use a tape with medium reinforcement which, with a single strip, guaranteed the seal of the package. Composed of a strong, fast-priming plant-based adhesive and supported by layers of kraft paper, WAT quickly develops a strong, penetrating hold when applied. This seal penetrates the cardboard material and “welds” the WAT tape to the packaging fibers. This type of seal, in addition to guaranteeing the safety of the closure regardless of the temperature variations that the packaging will have to withstand, is defined as “destructive sealing” because any attempt to open implies the destruction of the packaging and therefore WAT also becomes an effective anti-shoplifting.
Once the production tests have been verified, the new packaging procedure has been definitively introduced.
The solution used, based on the best interpretation of the feedback received “in the field” combined with the use of appropriate materials and related application tools, has contributed to significantly reducing packaging costs. The strength of the WAT belt has reduced waste and the labor required in end-of-line operations, while increasing productivity and packaging safety.
In the positive feedback of the new solution, it should not be forgotten that the high adhesive strength of WAT tape allows end-of-line operators to reduce the number of tape lengths per box: workers now apply only a single strip of tape per side, effectively halving the consumption and waste of material used.
The reduction in the belt used has increased the productivity of carton sealing. With a reduction in the belt lengths required to seal each package, tape consumption and waste has been effectively halved and the time required to seal the individual package has been reduced. The use of tape dispensers has further reduced sealing time as the strip of tape is dispensed and automatically dispensed when the operator requires it.
With the increased packaging speed achieved with automatic dispensers, the company has been able to significantly reduce labor costs. Originally, to maintain production levels, six operators were engaged in packaging practices; The new procedure has made it possible to reduce the number of packaging workers to three units, allowing the other three to be assigned to new operational tasks.
Finally, with the use of reinforced WAT tape, a further reduction in costs has been achieved; in fact, by replacing the packaging (the box was printed and sealed according to the weight of the contents) with a simple box and customized WAT tape, an interesting saving on the supply of materials was obtained.
The operational feedback after the first six months of use of the new procedure has in fact recorded a cost saving on the end of the line of 32% and eliminated the disputes relating to the receipt of the open packaging.
To conclude, EVi®, through the Tape Audit Program, is developing interesting convenient and tailor-made solutions that can give added value to the operating profitability of the customers who choose them, where in addition to protecting the environment, the safety of the closure is guaranteed and the disposal of the entire packaging is allowed in a single solution, saving time and money.
To find out more , contact info@evi-italia.com