Bizpack Packaging Blog

For businesses using shrink film every day, packaging material consumption can become a significant operating expense. When thousands or even millions of products are packed annually, a small amount of unnecessary film around each product can add up to a surprisingly large cost.

The solution, however, is not simply to use thinner or cheaper film.

The better strategy is to optimise film consumption while maintaining the required packaging performance.

Start With the Product

The first place to look is the product itself.

Products with different dimensions and shapes naturally require different amounts of film. If the film width or length is unnecessarily large, every package consumes additional material.

A packaging line should therefore be reviewed to determine whether film dimensions are properly matched to the product.

Check Product Positioning

Inconsistent product positioning can create inconsistent wrapping.

When products enter the machine differently, operators may compensate by increasing film usage or changing machine settings.

Standardising product placement can improve consistency and reduce unnecessary material consumption.

Review Machine Settings

Heat, conveyor speed, sealing conditions and other machine parameters influence the final package.

Incorrect settings can result in poor shrinking, film breakage and rejected packs.

When rejected products are repacked, the business effectively consumes film twice.

Therefore, reducing rejection can be just as important as reducing film thickness.

Measure Film Consumption Per Unit

One of the simplest ways to improve packaging efficiency is to measure actual film consumption.

Instead of asking only:

“How much does the film cost per kilogram?”

ask:

“How much film are we using per successfully packed product?”

This provides a much more useful measurement.

Businesses can compare film consumption before and after machine or material optimisation.

Don't Optimise Only for Material Price

A cheaper film can sometimes increase the overall packaging cost if it causes more breakage, poor seals or machine stoppages.

The real calculation should include:

Film cost + wastage + labour + downtime + rejected packs.

This gives a clearer picture of total packaging expenditure.

Optimisation Is Also About Sustainability

Reducing unnecessary film consumption can have an environmental benefit as well.

Using the right quantity of packaging material reduces material waste without requiring businesses to compromise product protection.

The goal should therefore be:

Minimum practical material consumption + reliable packaging performance.

At BIZPACK, packaging materials are best evaluated according to the application rather than simply the purchase price. A well-optimised shrink packaging process can help businesses improve productivity, control material consumption and maintain consistent product presentation.

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Internal Link: POF Shrink Film | Shrink Packaging Film