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Interview Warehouse Totaal

Standard machines suitable for

  • Pallets measuring 600x800, 800x1200 and 1000x1200
  • Pallet height: 2400mm
  • Capacity: up to 50 pallets per hour
  • Low lanes, thus suitable for all pallet trucks

Various options

  • Top sheet
  • Scanning
  • Labeling
  • Weighing
  • Data communication
  • Wrapping programs for randomly stacked pallets
  • Extra pallet formats

Modular taller wrappers increasingly popular
You can always add options

The Tallwrapper 2202 is Tallpack's next generation modular wrapping line. Providers of logistical services can opt for lines featuring input and output positions as well as tall wrappers. But they can also opt for complete peace of mind by establishing communication with WMS systems.

The Warehousing & Distribution sector continues to grow in the Benelux. Volumes are increasing considerably and qualified employees are becoming more difficult to find. And this is further boosting mechanization and automation within warehouses. But the same also applies when it comes to wrapping pallets. There is ever increasing demand for the Tallpack's modular tall wrapper. The company recently launched the Tallwrapper 2202, which is the third generation of pallet wrappers released by the Dutch manufacturer.

“All our systems are Dutch-made”, says sales director Michiel Brink. “This instills confidence in customers. They can even look around the production facilities if they want.” 

The newly developed tall wrapper, which bears the same name, is faster than the previous version – the 2201 - and especially the filmholder with which you can wrap the film is narrower; it thus requires less space. In addition, we have modified the film measurement system so film can be wrapped with almost zero tension or angular tension (i.e. for tissues/toilet paper, etc.). “ 

The film head is now narrower, which means less floor space is needed”, adds Brink.

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DSV and Remeha
Brink says Tallpack currently has over 200 automatic tall wrappers in the Benelux, in numerous versions. This includes systems at logistical service provider DSV and boiler constructor Remeha. In both these cases, modular tall wrappers have been realized with fixed elements as well as expansions.

The choices start as soon as pallets are placed inside the wrapper. Is this done using a manual pallet truck, an EPT or a fork-lift truck? These choices can have consequences for the height of conveyor belts. And on what type of pallets the products are eventually transported to and from customers. Dozens of different pallet formats are available. Take the paper industry, for example, where pallets are modified to suit the width of the paper format, which can differ per product. How many pallet positions does a logistical service provider need? They always require at least three: one to insert the pallet; one for removing the pallet and one for the wrapper. You need at least five or six if an automatic tall wrapper is going to be worthwhile. The number of positions you eventually need will be determined by the required capacity and how much of a buffer you want to create.”

Modular structure
You can select several options in modular tall wrappers, each of which comes in different versions. It all starts with the most simple option; insert, wrap and remove. But logistical service providers can also decide to wrap different types of pallets on the same line; use different wrapping programs and a different number of wraps; use top sheets and get Tallpack to manage data about the various types of packaging in a WMS system. In this case, all you have to do is scan a pallet code at the start, and the pallet wrapping process will be executed automatically, which includes placing a pallet label at the end of the line. The advantage of a modular tall wrapper is that users can always upscale to an advanced approach towards pallet packaging and pallet data processing.

Look at ROI
“Modular lines have become very popular in recent years”, confirms Brink. Besides the quality materials that Tallpack uses without exceptions for all its components, customers have also informed him of another common theme in the company's solutions. “We are successful because we are very quick in responding to specific customer requests. Our aim is not to just sell wrappers, but to actually offer logistical solutions. Because we work with a modular line with fixed components, we can quickly calculate how much each of the options cost. This allows customers to then calculate their return on investment. We can calculate the cost per packaged pallet in advance, depending on the quality and quantity of the film used by the wrapper.” Besides a machine constructor, Tallpack is also an innovative supplier of film. We are thus able to offer total solutions that meet the specific needs of customers. “If you look over a period of ten years, costs are primarily associated with film consumption rather than the line itself, which is a one-off investment that can be written off over a long period of time”

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From zero
The exact design of automatic tall wrappers is determined by what users intend to do with them. “The first step always involves customers wanting to switch to automatic wrapping. They must then decide if they also want a top sheet. Tallpack's range features a top sheet dispenser, which was recently made even more Lean and Mean together with a group of university students.

The capacity of the TW 2202 tall wrapper is 50 pallets per hour, but this can be increased to seventy or eighty per hour. Everything is determined by the number of wraps and the height of the pallet. Whether this is worthwhile, will be determined by how supply and transport have been arranged. Similarly, you must also consider how many buffer positions there are before and after the wrapper and top sheet dispenser. “You can actually fill the whole line with pallets, but this only makes sense if you can cope with the output. As a result, we always look at pallet flows in the warehouse before we start construction”.

In this sense, the line is also modular because you can add new elements or remove them at a later time. “For example, it does not make sense to install a label applicator if this is not compatible with the company's logistical process. However, this step can be taken in the future. Alternatively, some customers may not initially need a top sheet, but will do so in the future. Or they may decide to use a weighing unit to check the pallet load at a later stage.”

Scanning en Labeling
Scanning and labeling are two parts of the wrapping line that definitely contribute to the popularity of Tall wrappers, says Brink. This includes data management, which means Tallpack can offer customers complete peace of mind. “This allows us to create a sort of black box, whereby end users need not worry about any part of the pallet wrapping process. Data management is arranged by Tallpack and immediately shows where unresolved errors are located if malfunctions in the wrapping process are encountered. Customers want everything at their fingertips. And by using HMI, we can quickly identify what has gone wrong. In this case, it is not about finding who is responsible, but about how we can resolve the issue as quickly as possible.”

Pallet code
The process is as follows. The inserted pallet is issued with a code, which it has been assigned by the WMS system of the logistical service provider. This code is scanned and transferred to the customer's ERP system in real-time”. First and foremost, this tells the end user that the pallet is actually being handled. The system uses the code to see exactly what kind of pallet it is and how it must be wrapped - light or heavy duty; the number of wraps and whether a top sheet is needed. Brink: “If pallets are transported within the Netherlands, wraps tend to be less heavy duty than those used for overseas transport. And, for example, some pallets also need a top sheet because they must remain free of dust even after spending a long time in the warehouse. Pallets can also be wrapped to make them resistant to splashing, in case pallets are stored outside or in moist areas. And customer must also decide whether a pallet label must be placed at the end of the line, before the pallet is transported or taken to the warehouse.” Everything is aimed at optimizing (read: minimizing) the cost per pallet.

“If a dispatch label must be placed on wrapped pallets, the same code (at the start of the line) will provide a signal with appropriate information for the pallet label.” This nformation is also passed on to the WMS system, thus completing the whole the circuit. This means logistical service providers know exactly where their pallets are located and when.

[kader]Serial construction
Tallpack can construct modular tall wrappers for its customers at attractive prices. This involves making sure wrapping lines offer an appealing price/quality ratio. “We have been constructing modular lines for a few years now. We build wrappers, top sheet dispensers and pallet lanes serially wherever possible. 
Installed lanes all feature double gears and reinforced chains and our rollers are made from 3-millimeter-thick rolled steel. Tallpack prefers to work with renowned A brands like Festo, Sick and SEW. During the design phase, we try to implement the DIN norm for components wherever possible. 
We want to keep our production activities in the Netherlands because this offers many advantages to our customers.

In short, Tallpack International uses its Dutch-made modular wrapping lines to offer tailor-made total solutions that meet ever increasing needs within the market.

End of interview

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