Shrink packaging rolls are available in many forms and made from various materials. Below, we discuss shrink packaging rolls and tips for determining the correct machines for each roll. Adjusting from shrink bags to rolls can help increase efficiency and machine capabilities. So whether you are searching for your first shrink packaging roll or information for re-ordering, view the tips below to help find the suitable materials and machines for your application.
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Shrink Roll Material
The correct material is essential if you need to rebuy a shrink roll or purchase it for the first time. Packaging a product with improper shrink materials can cause numerous issues. Below is a brief description of common materials used for shrink packaging rolls.
PVC – Shrinks at lower temperatures than other films but does contain chloride that can emit an odor when heat is applied. This material is not for direct food contact. After heat is used, it becomes more stiff and brittle. Many products are wrapped with PVC, though not as popular now with other options on the market. PVC is still often used for shrink banding over lids and caps. It is also typical for wrapping tools, art, and dog bones.
Polyolefin – Centerfold polyolefin rolls have become known for full enclosure shrink packaging. Many variations of polyolefin shrink film depend on the application and machine used. The centerfold means the roll is folded in half lengthways and placed on the roll. Products are inserted into the fold in the roll and sealed to enclose the product entirely.
Polyethylene – Popular rolls for shrink packaging bottles, cans, and other items. Most polyethylene shrink rolls come single-wound, meaning they come off the roll flat. The material is folded over the case and then sealed. After heat is applied and the film shrinks, the package, known as bullseyes, will have holes on each end. Most polyethylene shrink rolls are at least a two-mil thickness, and some are thicker depending on the packaging application.
Shrink Packaging Roll Tip #1: Know the size and weight of the largest wrapped product.
Shrink Packaging Roll Tip #2: Determine what will happen to the item after it is wrapped. Will the item go into a larger box, ship via common carrier with the wrap exposed, or will the product go into frozen storage?
Shrink Packaging Roll Tip #3: With the information gathered from the first two tips, determine if a thicker material will be needed or if a thin shrink packaging roll can be used for the product application.
Shrink Packaging Roll Tip #4: Determine if the wrapped items should be fully sealed or enclosed or if open ends are acceptable.
Shrink Packaging Roll Tip #5: Determine the proper equipment with the correct shrink packaging roll. Below is a brief look at equipment to consider based on the type of roll you choose.
Shrink Packaging Equipment
Suitable shrink packaging equipment will require a heat source and a sealer depending on the application. For fully enclosed wrapping, a sealer will be needed. There are many options available for both sealers and heating sources.
Sealers – Heat sealers mend materials together to form a seal. The style of shrink roll used will determine the ideal sealer.
I Bar Sealers – Used for thinner materials, the single sealing bar heats when closed and seals one side of the film. After the first seal is made, the product must be rotated and sealed again for full enclosure.
L Bar Sealers – Made for centerfold shrink rolls to seal open ends for a full enclosure. L bar sealers have multiple sealing options available. The amount of desired production can better determine the sealing element. A hot knife L bar sealer is the best option for the most output.
Shrink Bundlers – Made for packaging cases of drinks or cans, often using a cardboard tray on the bottom. The sealer for bundling is usually a hot knife due to the packaging roll thickness. Like an I bar sealer, the bundler sealer will only seal one side, leaving two open ends.
Heat Sources – It is possible that, depending on the shrink roll being used, a sealer is not needed. Rolls of tubing and other applications may not require a sealer. They will need a heat source to shrink the material around the product.
Heat Guns – Heat guns are for low-output shrink packaging. They can be waved around shrink products to heat materials. Thinner materials can quickly establish burn holes with a heat gun, and thicker materials can take longer to reach a total shrink with a heat gun. We recommend a heat gun for anyone beginning shrink packaging and wrapping under one hundred products daily.
Shrink Tunnels – Though they cost substantially more than a heat gun, they are more consistent and efficient. Shrink tunnel temperatures can be set with a conveyor belt running through the tunnel. Users can adjust the belt speed and temp to accommodate the shrink packaging roll used. Shrink tunnels can pay for themselves through increased packaging rates and reducing the number of redo’s. Determining the correct shrink material before buying a shrink tunnel is critical. Three common types of tunnels are convection, infrared, and steam tunnels. Some tunnels will not work with specific shrink materials.
Conclusion
Shink packaging rolls are not one size fits all. There are several factors to determine the proper thickness, size, material, and style. In addition to determining the correct roll, the right equipment should be considered. Aside from the roll material, size, and thickness, efficiency should also be considered when choosing a machine.
For companies packaging products under 15 lbs. that will go into a box for shipping, a 75 gauge shrink film is the standard thickness. Light products can be used with a 60 gauge polyolefin roll for easy opening. Heavier items will need thicker shrink film. Strong 100 gauge shrink film will handle many applications, but beyond that, a polyethylene roll should be considered. For more shrink roll tips and information, call 1-800-441-5090 or shop online.
It's important to identify some specifics about your product to be packaged before diving into the details of the films available to you. Without question, a packaging supplier is key to selecting the appropriate film for your needs. Their industry experience and ability to understand your needs gives them the expertise to ascertain which types of films will and won’t work for your product.
Some of the packaging considerations you’ll need to be aware of include:
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What type of product you are packaging
The product’s weight, shape, and dimensions
Your objectives for color and labeling
Whether the film can be printed to meet your needs
How the product will be packaged into the flexible film (manually or via machine, and what type of machine
The product’s journey from creation to shipment to the shelf and beyond
Whether it will be handled often and/or subject to rough handling
The types of climates/environments it will experience
Whether it requires specific film additives to keep it fresh (e.g., oxygen or moisture barrier)
Requirements for anti-tampering and security of the finished good
With so many types of flexible packaging film available, you are sure to find the right packaging for your product. Whether you need an option with a high melting point, one that emphasizes durability, or one that prioritizes recyclability and sustainability, there is a shrink film product available to suit your needs. With all of the opportunities for a custom finish to any product, it’s always important to do your research and consider your specific needs to determine the best options.
Also, you’ll need to do some homework regarding equipment. If you have an automatic shrink wrapper or are planning to purchase one in the future, it’s important to keep an eye on your bag length and running speeds. Sometimes operators adjust the bag length from the original specs to make running the line easier. This is particularly more noticeable on older pneumatic shrink wrap equipment. Running your film at just 1" larger than necessary can equate to 2,000 extra feet of film used per day. That’s approximately 118 wasted rolls of film.
Be sure to think about how capable your internal maintenance technicians are. Adding a shrink film wrapper to your packaging line will require technical support on a regular and as-needed basis. Assess your internal maintenance team’s comfort level with working on the new machine(s), and make sure you have a backup technician for when service is needed and your internal team can’t handle the repair.
Before purchasing and storing shrink film, make sure you know its storage requirements. You don’t want to try to work with climate-compromised packaging. Your supplier should have this information available if you’re unsure what your material requires. Overall, shrink packaging is best stored in temperatures between 30 and 77 degrees Fahrenheit. Naturally, summer and winter are the seasons that require you to be most attentive to your storage environment.
Your facility will likely be subject to high heat in the summer, if not during springtime. If shrink sleeves are kept in temperatures exceeding 100 degrees, they may prematurely shrink and compromise their ability to protect your goods. During these hot months, keep your shrink materials stored in the coolest areas of your facility without subjecting them to refrigeration.
They should be kept cool, but not too cold. The coolest spots in your warehouse are typically close to the floors – on the lowest part of your pallet racks – and away from windows or places that are subject to a lot of sunlight. You’ll also want to keep your shrink films away from high-traffic doors because the temperatures in these areas tend to fluctuate greatly.
Additionally, try to schedule your shrink film deliveries early in the day. That way, the materials won’t sit in the back of a hot trailer when traveling from warehouse to warehouse. Not only will you avoid the harshest hours of the sun, but you’ll also give yourself more time to store them before the temperature reaches its peak.
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As mentioned, packaging films tend to become especially brittle in cold temperatures, which greatly reduces their stretching and shrinking properties. While the PVC may crack, it can even shatter like glass if left in extremely cold conditions for too long.
As in the summer, store your rolls away from doors to avoid temperature fluctuations. You also want to ensure rain or snow won’t create unwanted moisture in the rolls. If you’ve been using PVC shrink film to package frozen foods or other products that spend time in a freezer truck or refrigerator, consider switching to a polyolefin film. This is a more durable, food-safe, and recyclable material that will keep your package intact during transit and packaging.
When you take shrink film out of storage, you may not know how to tell if it’s been compromised. One key sign is sticky rolls. If PVC rolls stick together, they were likely exposed to too much heat. Don't risk downtime on the packaging line by trying to use them anyway. Skip over the rolls that are stuck together. Bagging and sagging are also signs of overheated film. The rolls may begin to sag on the edges or show bagging within their layers. Using these rolls can interfere with the tracking on your machines, so avoid using these compromised rolls as well.
Remember, even the highest-quality shrink film and packaging materials are apt to deteriorate when subject to these environmental factors. No matter what quality film rolls you’re purchasing, take the time to assess how you’ll store them to ensure they protect and present your product exactly as you’ve planned.
Finally, keep your target audience at the forefront of your packaging design. The type of material you choose is a part of your brand, so any disconnect between that and your brand’s message will confuse consumers and make them lose trust. To appeal to your customers, you have to research and understand them enough before you make these key marketing and branding decisions. Market research is a great way to learn what your target audience values and decide how to pair those details with your budget, transportation, and sustainability needs and goals. Always listen to your key demographic and cater to their needs specifically.
For a quick look at some additional considerations regarding your use of shrink wrap film, check out this free shrink film cheat sheet.
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