Cut Costs, Reduce Waste, Boost Safety: The Case for Automated Stretch Wrappers

What looks like a cost-saving step often turns into a profit drain.

Manual pallet wrapping can lead to wasted film, operator injuries and unstable loads. Automated stretch wrappers, like MHS Lift’s Robopac equipment, eliminate these risks by cutting film usage, improving safety and ensuring consistent, secure pallets.

Why does manual pallet wrapping seem cheaper than it really is?

At first glance, having warehouse staff wrap pallets by hand seems inexpensive. There’s no upfront investment in equipment, and labor is already on the floor. But the reality is that manual wrapping quietly drains money and efficiency in three critical ways.

How much shrink wrap is wasted with manual wrapping?

Hand-wrapping is inconsistent. Employees often over-stretch or under-stretch film, leading to:

• Excess material waste – Employees may use 2–3 times more film than necessary.
• Higher supply costs – Film usage can add up to thousands of dollars per year in wasted plastic.

Automated stretch wrappers precisely control film tension, applying just the right amount every time – often reducing film consumption by 30–50%.

What safety risks come with manual pallet wrapping?

Repetitive bending, twisting and walking in circles around pallets leads to:

• Injuries, slips, trips and falls – Employees strain their back, shoulders and wrists, and risk slipping and falling from moving quickly around pallets on busy floors.
• Lost productivity – Injuries increase absenteeism and workers’ comp costs.

Robopac automated stretch wrappers eliminate these risks by taking the physical strain off employees.

How does manual wrapping affect load stability?

Inconsistent tension and overlapping patterns mean pallets wrapped by hand are often:

• Too loose – Loads shift in transit, causing damage or safety hazards.
• Too tight – Product packaging gets crushed.
• Non-uniform – Each employee wraps differently, creating unpredictable results.

Automated wrapping ensures every pallet is tightly secured to the same standard, reducing product damage and rejected shipments.

How can automation fix these problems?

MHS Lift offers Robopac semi-automatic and fully automatic stretch wrapping systems. These machines:

• Cut film usage by up to half.
• Eliminate manual wrapping injuries.
• Standardize pallet load security.
• Boost throughput by wrapping more pallets per hour.

For many operations, the return on investment comes in under 12–18 months thanks to lower film spend and fewer product losses.

FAQ

Q1: How quickly can a stretch wrapper pay for itself?
Most companies see ROI in 12–18 months through reduced film and labor costs.

Q2: Can small warehouses benefit from automation?
Yes – semi-automatic models like the Robopac Robot S7 are compact, flexible and ideal for lower volumes.

Q3: What industries benefit most from automated wrapping?
E-commerce, food & beverage, manufacturing and 3PLs all gain from reduced film costs, fewer injuries and more consistent pallets.

Q4: Do stretch wrappers work with different pallet sizes?
Yes – Robopac models handle a wide range of load sizes and film types, making them versatile for mixed operations.

Ready to eliminate hidden costs in your warehouse?

Request a warehouse workflow assessment from MHS Lift to see how Robopac stretch wrappers can cut costs and improve safety in your operation. Give us a call today: (877) 647-9320.