What our clients are saying

What our clients are saying

'To me it's been a huge success.'

Sanitarium - Auckland

Some things in life just go together perfectly. At Sanitarium that’s obviously Weetbix and fruit, Light n’ Tasty and UP & GO. Now, with an upgrade at their Auckland distribution centre, it’s also true for their Spinny S500 and Nanowrap.

For over a century the Sanitarium brand has delivered on their core philosophy of ‘a better life through better nutrition’. Sanitarium is one of those brands that are seen as part of the fabric of being a Kiwi.

We all grew up eating Weetbix and Honey Puffs, spreading Marmite and Peanut Butter on our toast after school. In more recent times we’ve enjoyed newer brands like UP&GO and SoGood, along with delicious new muesli and cereal products. The company has grown up with us too, developing the product range and expanding the scale of the operation.

During this time it’s only natural that certain growing pains occur. After closing the southern branch and moving everything to Auckland the busy FMCG brand was pushed for space and reaching capacity limits at their distribution centre here.

They needed their packaging processes to be as healthy as their products. This meant not just upgrading their wrapping equipment but also assessing if the pallet wrap in use was delivering the goods (in every sense of the phrase).

The perfect pairing result wasn’t therefore an ‘off the shelf’ solution. Instead a careful scoping process was undertaken, a range of measurements collected over time to ensure any change would deliver quantifiable ongoing improvement.

When the data came back it was obvious that a switch to Nanowrap would provide the best result. While the new wrap was more expensive per roll the actual film used per pallet had been reduced considerably, making the move a cost-effective one.

While the company had two wrapping machines these units were old and passed their ‘best before’ date. The decision was made to upgrade one machine to a high-specification fully automatic machine, the Spinny S500, with plans to update the other at a later date.

There was only a small space available for this change so a custom-fit layout was required for the Spinny installation. With this new equipment a new full safety system was installed, making certain of the continued good health of everyone working in the busy DC.

The results of the move have delighted the team there. Pallets are being wrapped faster and more efficiently. The roping function of the S500 is particularly helpful, as is the ability to have several programmes built in to the ongoing operation of the unit.

Peter Levett is the Distribution Manager at the distribution centre. Working closely with Universal Packaging in the auditing and scoping process he was confident of the change. Now, after a good amount of time has passed, he’s very happy the commitment was made.

Such results can be measured simply in the number of orders for new pallet wrap. “We used to buy a pallet of wrap every six weeks or so. Now we’re buying one every six months,” says Peter. “It’s everything I thought it would be – and more.”

“We’ve also noticed a massive increase in productivity,” he says, a combination of the new pallet wrapper and a decrease in wrap breakage packaging pauses.

Sanitarium Pallet Problems Solved

  • Shifting from an old, over used machine to the Spinny S500 allowed for faster and higher production rates. The fully automatic system means that operators don't even have to leave their forklifts any any stage of the wrapping process.
  • Nanowrap combines 33 separate layers into an ultra-thin polymer of high-performance pallet wrap. This uniquely formulated film has a core formation that delivers an incredible 300% stretch capacity.

    With less wrap and less waste, maximum load stability and minimal weight, Nanowrap provides the most effective and efficient pallet wrap in New Zealand.
  • Combined, Nanowrap and the Spinny S500 deliveres incredible film savings for Sanitarium. Peter has reduced his orders significantly. Previously, it was typical to order a new pallet of wrap every 6 weeks. Now, only 1 pallet is needed every 6 months

'Our in transit damages disappeared altogether'

'Our in transit damages disappeared altogether'

Universal packaging have been working with Foodstuffs for over 8 years, so when the Roberts Line Distribution Centre were re laying their racking system, we stepped in with a machine and wrap solution that would take their productivity to new heights.

“We’re finding it’s brilliant. There are no breaks, it can be wrapped consistently and it’s easy to use – we’ve got no issues whatsoever.”

Feed For Thought

Mainfeeds are making light work of heavy pallets thanks to a change in pallet packaging product.

With three mills in Otago, Auckland and the Manawatu, Mainfeeds has its hands full providing quality feed for hens, chickens, pigs, rabbits and dogs around New Zealand.

Between their three facilities the company produces over 140,000 tonnes of feed annually, a lot of which is packaged and shipped around the country.

“We’ve been supplying Mainfeeds with pallet wrap since around 2014,” says Universal Packaging Technical Consultant Jed Goudie. “Since then we’ve seen them grow and grow, and we’ve worked with them to improve their shipping efficiency.”

Murray Collie is the Plant Manager in charge of the Mainfeeds Waikouaiti operation in Otago. In his time there and, previously, in the meat processing industry, Murray has seen the results of improved packaging on the floor and at the bottom line.

“We’ve been wrapping pallets for 20 years now,” says Murray. “These pallets go all around the South Island, and we need them to be secure.”

While today things are running smoothly Mainfeeds distribution hasn’t always been easy with “breaks and shifting loads and the product damage that comes with it,” says Murray.

“Try as we did, it was always difficult to get the wrap we were using to provide adequate tension around the pallet,” says Murray. “We’re wrapping both smaller pallets and those going up to the one tonne mark. Getting the balance of secure containment without tearing the wrap was always a balancing act.”

In 2018 the company moved its nationwide operation to Nanowrap and, according to Murray, “we’ve never looked back.”

“We’re finding it’s brilliant. There are no breaks, it can be wrapped consistently and it’s easy to use – we’ve got no issues whatsoever.”

For Jed it was crucial to get the wrap strong enough to safely wrap pallets weighing up to one tonne while doing so in the most cost-effective manner possible.

“We scoped a few options and Nanowrap was the clear winner,” says Jed. “It wrapped tight consistently for Mainfeeds. And, forgive the pun, but when you take into account product damage, replacement costs and the various other costs that come with wrap breakage, well, the savings aren’t exactly chicken feed.”

With around 100 tonnes of bagged products going out the door weekly, having confidence that the wrap can carry the weight is crucial to the growing operation. So too is knowing there’s additional support from Universal if it’s ever needed.

“It’s not just the wrap, it’s the service too,” says Murray. “Jed’s always popping in when he’s down hereto check everything is working as it should, when we make an order the team are always easy to deal with, and the wraps always promptly delivered.”

After a massive fire gutted a significant part of the Seales Winslow plant the company rose from the ashes with a clear vision for the future and a renewed commitment to evolve and improve its packaging capability.

The adjustable tension during the cycle is a massive help compared to what we had (pre-fire). There’s no breakage and no time wasting anymore.”

  • A fire broke out in wooden boxes outside the shed. By the time the fire service arrived over half the 5000-square-metre building was alight. The resulting blaze injured three firefighters and reduced the entire packing line and storage shed to charred ashes.
  • The company went to Aurora Process Solutions and Universal Packaging with a brief for a coordinated focus across filling, conveying, conditioning, labelling, palletising and wrapping. Universal Packaging worked with Aurora Process to assess the previous set-up and made suggestions for a Spinny unit that could offer greater flexibility for what was required.
  • Throughput is up and inefficiency is down in Ashburton. For a self-proclaimed ‘OCD Operations Manager’, Tyler is also happy with the neatness of the each wrapped pallet, stating, “I certainly like how the wrap’s ‘tail’ is neatly cut and packed away.”
  • The Seales Winslow team also appreciates all controls are intuitive and easy to use, which makes a significant difference in the speed of day-to-day operation. The busy Ashburton plant is so pleased with the system they’re now recommending it to others.

“Truthfully, we’re over the moon with the result.”

“Truthfully, we’re over the moon with the result.”

Pallets of full individual drink bottles are some of the most challenging to transport while avoiding load movement and subsequent product damage. For a company with a major focus on sustainable practise ‘more wrap’ was not the answer. Instead NZ Drinks and Universal Packaging have banded together for the best result…

NZ Drinks takes pride in being ‘the largest, fastest and most efficient automated water bottling facility in New Zealand’. Their investment in state of the art technology and innovative production automation allows the company to produce, pack and send over 200 million bottles of water per year.

Since 2010 the Pokeno site has been supplying customers throughout New Zealand and internationally. During this time Factory Manager Raa Turua has overseen improvements to the packaging and dispatch processes. Yet one major packaging problem was still causing headaches.

“We still had the travelling issue with the six pack, which is a tall product that doesn’t sit well in the back of a truck,” Raa says. “We were originally doing a column stack, which didn’t help things. Changing to an interlocking load definitely helped. But it definitely didn’t solve everything.”

It was a significant challenge for the busy operation, particularly given the consequences for the reputation of the brand and the resources needed to fix each problem pallet.

“Close to half the product was being returned from one of our major customers,” says Raa. “Their quality control processes were really stringent – if anything was out of place the load would come right back.”

“All up it takes hours to fix the issue when a pallet comes back,” says Raa. “We simply couldn’t go on with this occurring.”

For NZ Drinks a temporary ‘band-aid’ solution could not be an answer – they needed something that would last. Universal Packaging came back with the perfect answer… a band aid.

Universal installed a roping unit on the automatic stretch wrapper. This banding attachment folds the edge of film forming a tough rope enabling the film to be applied at an increased tension. This makes strong reinforced wrap, eliminating load movement. After installing and running trials the new system came through with flying colours.

“We won’t install something unless we can measure the results,” says Universal Sales Manager Matt Goddin. “So the roping unit was tested not just as part of the NZ Drinks packaging operation but also at the end point of the pallet’s journey.”

The results have been perfect – the 50% return rate dropping to 0% with the operation of the new equipment.

“Full credit for the band project – it’s added the tightness needed around the whole pallet without having to add a huge amount more wrap,” says Raa. “Truthfully, we’re over the moon with the result.”

Preventing product damage, time wastage and unnecessary transport emissions has been a significant help for the company as it continues to make gains in overall sustainability processes.

“Universal Packaging play a really big role in ensuring our deliveries are dispatched on time, on spec and in a condition we know will be delivered safely to our customers,”

Yes, we can - Jamestrong Christchurch packs tight and right

Jamestrong knows the importance of a good reputation and their customer’s peace of mind – and how both can only be achieved with an unerring focus on the highest of standards.

That’s why the busy can manufacturer needs to make sure their operation is 100% perfect. From the raw materials, through production, into shipping and on to final use, everything is carefully measured, assessed and maintained.

Using Clearwrap, the newest Jamestrong facility in Christchurch is making sure this perfection in packaging occurs.

With six plants throughout Australia and New Zealand supplying a considerable range of international brands the company has a lot of experience to call on both from within their team and those of their trusted suppliers.

“We’d been supplying their (Jamestrong’s) Hastings site for a while, so it was a natural progression to working with their new Christchurch operation when they opened a year and a half ago,” says Universal Packaging’s Technical Consultant Garth Hill.

“Of course, you can’t rest on your laurels, so we needed to make sure everything was right on site – and that it stayed that way.”

Jamestrong takes pride in being ‘experts at every level’ in their operation, ensuring that their products, everything from food and nutrition steel cans to aerosol cans, are made precisely, reliably and sustainably to the highest benchmarks. This diligent precision has far-reaching effects.

“Synlait Milk is their biggest customer and they are very stringent when it comes to well-wrapped pallets. There can’t be any gaps. In this way they make certain cans are not compromised, damaged or contaminated,” says Garth. “So Jamestrong needed quality packaging backed by reliable service.”

Ali Yaqubi, Operations Support at the Christchurch facility, certainly appreciates the service put in by the team.

“Universal Packaging play a really big role in ensuring our deliveries are dispatched on time, on spec and in a condition we know will be delivered safely to our customers,” he says.

For over three decades we’ve been making sure everything’s tight and right for Kiwi businesses.
Correct stretch wrapping not only ensures goods arrive in the best condition, it minimises damage costs and maximises process efficiency. That’s why we take a broad view of your operation – to see where we can save time and money within every aspect of your pallet wrapping process.

Since we first opened our doors in 1985 our team has worked with New Zealand companies from Kaitaia to the Bluff. Be it light or heavy, from tissue paper to concrete blocks, if it’s dispatched on a daily basis the chances are that we’ve helped to wrap it.

This experience is vital. Pallet wrap, shrink wrap or stretch film, you can call it what you want. But when you need to get the most from product and processes, from how and where it’s wrapped to key matters of security, efficiency and cost effectiveness, call us first.

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