Posted by Alpha Packaging on | Comments Off on When to Choose Corrugated Boxes Over Corrugated Plastic
When choosing the ideal packaging solutions for your products, you may opt for either traditional paper corrugated or plastic corrugated packaging materials. Each material offers unique benefits for specific applications, depending on the end use, your goals around sustainability, and your available packaging budget.
In this guide, you’ll learn more about the differences between corrugated boxes and corrugated plastic and when to select either material for your products.
Corrugated Boxes vs. Corrugated Plastic
Both corrugated boxes and plastic corrugated packaging work to protect many types of products, but the material you choose will depend on certain factors.
Plastic Corrugated
This material consists of durable die-cut plastic featuring multiple cross-corrugated layers. Its sturdiness makes plastic corrugated packaging reusable up to 100 times, which is why it’s one of the more cost-effective and sustainable materials available.
Lightweight design that’s only 1/3 to 1/5 the weight of ATA-type packaging cases
Shock-resistant nature via shock-absorbing liners
Weather-proof materials that are also easy to clean, enabling them to hold up in harsh conditions and after heavy use
Resistance to tampering using reliable security sealing solutions
These aspects make plastic corrugated packaging a popular option for a wide range of applications requiring superior durability and longevity, such as medical devices, electronics, musical instruments, aerospace components, rare artifacts, and trade show materials.
Corrugated Boxes
Another common material is corrugated boxes, which comprises flat linerboard layers with adhered wavy medium, fluted paper. Depending on requirements, you can implement single-wall, double-wall, or triple-wall corrugated boxes, with triple-wall cardboard offering the highest level of strength.
Some other benefits of paper corrugated boxes include the following:
High biodegradability and recyclability for single-use and environmentally sustainable applications
Cost-effectiveness with one-way shipping orders
Many size options to enable fast fulfillment
Customized printing of labels and graphics for marketing and brand awareness
Many applications can make use of corrugated boxes packaging when plastic corrugated packaging isn’t suitable, including e-commerce products, retail displays and fulfillment, point-of-sale packaging, and general distribution.
Are Corregated Boxes or Plastic Corregated Materials Right for You?
While both corrugated boxes and plastic corrugated materials offer their unique advantages, it’s important to make the right choice for your specific application.
Ultimately, you should choose plastic corrugated materials if you intend to reuse your packaging materials several times, your products are of high sensitivity or value and need extra protection, you need reliable tamper resistance, or if the packaging will be in wet or harsh environments.
Meanwhile, corrugated paper or cardboard materials are suitable for applications in need of single-use and cost-effective solutions. You may also benefit more from this option if you wish to prioritize recyclability or sustainability and if standard packaging sizes are sufficient to meet your needs.
Another factor to consider is the total cost of ownership for packaging. Plastic corrugated packaging comes with higher initial costs but, through reuse up to 100 times, can save significantly on cost-per-use. Conversely, paper corrugated materials might cost less upfront, but this low initial price comes at the cost of single-use applications that could lead to higher costs in the long run.
Let Alpha Packaging Help You Decide
If you’re not sure which type of packaging material to choose, the decision will depend largely on the intended application, your packaging budget, and the number of times you wish to use your packaging. At Alpha Packaging, you’ll be able to implement both options, with custom packaging available to meet your specific project specifications.
Whether you want to use corrugated plastic or paper materials, we can optimize packaging with custom foam inserts, white label printing for branding and marketing, and design and prototyping services with unparalleled expertise, all of which can contribute to the perfect solution for your business.
Our team is ready to evaluate your precise packaging needs and make a personalized recommendation to maximize both protection and cost-effectiveness for your products.
Posted by Alpha Packaging on | Comments Off on Understanding the Total Cost of Ownership in Packaging
What is Total Cost of Ownership (TCO) and Why Does It Matter?
When a business is considering investing in new equipment, one of the most important questions to ask is whether the purchase will deliver a strong return on investment (ROI). The most accurate way to answer that question is to calculate the equipment’s total cost of ownership (TCO). Total cost of ownership is a term used to describe the full long-term expenses associated with acquiring, operating, and maintaining a piece of equipment throughout its lifetime.
With packaging machinery, this means considering ongoing maintenance and repair costs, energy consumption, operator training, and the cost of packaging materials. Understanding the direct and indirect costs associated with new equipment is the best way to predict your ROI and make informed investment decisions.
Why Does TCO Matter in Packaging?
For many businesses, packaging is an unavoidable expense that plays a large role in operational efficiency and revenue generation. Packaging methods directly influence whether or not products ship safely and on time, and also impact labor requirements, operation costs, and much more. Taking the time to calculate the total cost of operating packaging equipment allows businesses to determine which option will be the most economical to run and maintain, helping to maximize profitability and improve competitiveness.
Key Elements of TCO in Packaging
For packaging equipment, finding total cost of ownership involves evaluating three main expense areas: acquisition costs, operational costs, and disposal costs.
Acquisition Costs
Acquisition costs are the most straightforward aspect of calculating TCO. They include the costs associated with purchasing the packaging equipment itself and any related items required for operation. While many businesses assume a machine’s purchase price reflects the total cost of their packaging investment, it’s actually only one part of the true cost of ownership.
Operational Costs
Once acquisition costs are determined, the next step is to evaluate your equipment’s operating costs. These ongoing expenses make up a significant portion of the total cost of ownership and are required to keep your equipment running efficiently. For example, common operational costs include:
Energy costs. The price of electricity used to run your equipment.
Maintenance and repairs. All machinery requires ongoing preventative maintenance to keep it running at its best. Certain components may also need to be replaced or repaired throughout the equipment’s lifetime. Systems like Lantech packaging machinery are designed for long-term reliability to minimize these specific costs.
Training and payroll expenses. Consider whether you’ll need to hire additional staff to run your new equipment and factor in the time and resources you’ll need for training.
In addition to the expenses previously mentioned, you should also consider the efficiency of your packaging processes. Inefficient packaging methods slow down your output, increasing payroll expenses. Taking the time to consider indirect costs like these will help you find ways to improve the efficiency and profitability of your operations. Since operational costs vary widely depending on the equipment involved, your production volume, and other factors, the calculation requires careful consideration.
Disposal Costs
One often overlooked aspect of TCO is disposal costs. Over time, all machinery loses value and functionality. When your equipment reaches the end of its lifespan, you will be responsible for its disposal and any associated expenses. You’ll need to review the regulations in place for your industry to determine how your equipment can be safely disposed of or properly recycled. You can also consider whether or not resale is an option. No matter what disposal method you choose, the unavoidable associated expenses should be factored into your TCO analysis.
Calculating TCO for Packaging
The formula for calculating packaging TCO can be complex because certain parts of the packaging process are consumable. However, you can get a good start by considering basic factors like initial costs, maintenance costs over five years, and the remaining value of the equipment after five years. Begin with the initial cost and then add the expected maintenance costs. From this, subtract the remaining value after deprecation to obtain the total cost of ownership.
Partner with Alpha Packaging
The right packaging equipment can dramatically improve your operation’s efficiency and profitability, but making a smart investment requires a good understanding of the total cost of ownership. As a leader in corrugated box manufacturing solutions, Alpha Packaging delivers custom packaging systems that help companies improve their operations. With over 200 years of combined experience, our experts are here to help you select the right machinery for overcoming industry-specific challenges. Contact us with any questions or request a quote to get started.
Posted by Alpha Packaging on | Comments Off on Packaging Automation Systems & Equipment Explained
Manual packaging systems can create a bottleneck and contribute to high labor costs in your operations. Automated packaging machines are designed to remedy these issues while enhancing packaging consistency. Packaging automation handles case erecting, packing, taping, and labeling more efficiently than manual labor.
At Alpha Packaging, we’ve developed standard and customizable automated packaging solutions that cut down the time and cost of multi-stage packaging processes. Our robust packaging equipment includes 3M case sealing systems, Lantech packaging machinery, crush-resistant Emba by Ultima box folders, and more.
Read on to learn more about these examples of packaging automation systems and the benefits of choosing packaging equipment from Alpha Packaging.
What Are Packaging Automation Systems?
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Packaging automation systems use robotic machinery to complete packaging tasks with minimal human intervention. Automated packaging machines can package individual products in boxes as well as large pallets of goods at a lower cost, with less material waste, and with no risk of human error.
The following automated case erectors, case sealers, stretch film machines, and box-making systems from Alpha Packaging are ideal for retail, food and beverage, and e-commerce industries.
Case Erectors
Automated case erectors can quickly fold and assemble flat cases into boxes. Our semi-automatic and fully automatic case erectors work fast to assemble up to 30 cases per minute without errors.
Case Sealers
Once each box is filled with the necessary goods, our case sealers seal them with the appropriate amount of tape. These machines pair well with case erectors to create a convenient, streamlined process. Our case sealers are easy to operate and require little maintenance.
Stretch Film Machines
Wrapping pallets of sealed cases prepares them for shipping and secure handling. Our stretch film machines quickly wind plastic films around regular and irregularly shaped loads to prevent slippage. We recommend using stretch film machines with pallet grip machines for a fully controlled process.
Automated Box-Making Equipment
Alpha Packaging partners with Emba by Ultima to provide automated box-making equipment. These machines can quickly produce corrugated cardboard boxes from flat cutouts, using a highly replicable process that preserves the geometry and strength of the box. Emba by Ultima machines also reduce material costs by not crushing the corrugated flute during box production.
The Advantages of Crush-Resistant Boxes
Crush-resistant boxes are vital to operations that rely on high stacking during transport or in warehouses. However, many machines on the market crush the corrugated flute during the box-making process, defeating the purpose of the corrugated box. Our Emba by Ultima machines create stronger, crush-resistant boxes without compromising the corrugated flute. As a result, our solution offers packaging lines and box users the following benefits:
Sustainability and Long-Term Impact of Automated Packaging Solutions
Automated machinery helps businesses with long-term sustainability goals. Our box-making and packaging automation systems reduce material waste and last longer. We test all of our boxes through Dynamic Stiffness Testing (DST) and Box Crush Testing (BCT) protocols to guarantee durability and strength. To learn more about the sustainability and cost-saving benefits of automated packaging solutions, including our crush-resistant box-making machines, you can read our guide on how stronger boxes save costs.
Why Alpha’s Packaging Automation Stands Out
Alpha Packaging partners with industry leaders to offer reliable equipment solutions, including innovative box-making machines like our Emba 245 QS Ultima. Our equipment is also cost-effective—your business can quickly recoup the cost of the initial investment by saving on manual labor and material waste. We can also customize automated packaging solutions for your specific needs, whether you are a major manufacturer or a small business. To better understand the financial benefits, read our analysis on understanding the total cost of ownership in packaging.
Cost-Saving Automated Packaging Solutions for Businesses
Automated packaging equipment is a substantial investment, so Alpha Packaging offers a deferred payment plan for businesses to reap the benefits of automation as soon as possible. Rather than paying upfront for the equipment, our clients can pay incrementally by purchasing packaging materials like stretch film and boxes at a slight markup. This allows even small or growing businesses to benefit from the enhanced efficiency and productivity of automation with far less financial strain.
Ready to Automate Your Packaging With Alpha Packaging?
Upgrade your packaging processes today with automated packaging equipment from Alpha Packaging. Choose solutions like Emba by Ultima crush-resistant box-makers, Lantech case erectors, 3M case sealers, and more. Our team will work with you to create custom solutions powered by ArtiosCAD and provide deferred payment options so your organization can reap the benefits of automation without a large upfront payment. Request a quote today to get started.
Posted by Alpha Packaging on | Comments Off on Difference Between Shrink Film and Stretch Film
Difference Between Shrink Film and Stretch Film
Many types of goods are packaged or bundled with thin polymer films for protection during shipping and storage. Shrink film and stretch film are common examples, but they are made from different materials and serve different purposes.
Here, we’ll look at how they differ, some available options, and how they are typically used in different industries.
Shrink Film
Shrink film, or shrink wrap, is a versatile packaging material that shrinks to mold to the shape of its contents when heat is applied. It is generally used to wrap single product items for individual sale or use. Shrink wrap plastic is available in center-fold or tubular forms on rolls, or as pre-measured bags in different sizes. Shrink wrapping produces a durable and clear barrier to protect the product inside while letting consumers see the contents.
In general, the plastic must be heated to around 300°F to begin the shrinking process. Heat catalyzes the molecules in the film, causing them to align and shrink around the object. While it can be applied with hand-held heat guns, shrink wrap machines that cut and heat seal in one operation are more efficient. These use a conveyor or heat tunnel for quick and even heat distribution.
Materials
Shrink films are made from the following materials:
Polyethylene: A type of polyolefin often used with heavy products and for bundling; lower shrink rate than other options
Polyolefin: Safe for food and non-food products; strong and low-odor film; cross-linked polyolefin is highly clear and sterile
Polyvinyl Chloride (PVC): Only for non-edible products; must be used with proper ventilation due to hydrogen chloride release; cost-effective
In addition to the film material, there are several important considerations when selecting the most suitable shrink film for an application. These include film gauge (i.e., thickness), moisture vapor transmission rate (MVTR), shrink temperature, shrink rate of the material, how much pressure the shrunken plastic applies to the product inside, and tear or puncture resistance.
Applications
Shrink film is used in many industries for a range of products such as:
Electronics
Food
Games & Sporting Goods
Hardware & Housewares
Printing & Paper Products
Benefits
Shrink film offers various advantages for packaging, including:
Cost reduction over boxes, cartons, and other options
Presentation of products in a tidy and secure package that can be seen through
Protection against component loss, breakage, or spoilage
Sustainability of recyclable plastic
Stretch Film
Stretch film, or stretch wrap, is a flexible and stretchable plastic film that can be wrapped around products to bundle and protect them during shipping and storage. It is often used to secure groups of boxes, bags, or single large objects on pallets. It can be applied by hand or with automated or semi-automated packaging equipment.
Plastic stretch film is available in several gauges and widths and can be purchased pre-stretched for ease of application. Specialized types of stretch film are available for UV protection, ventilation, anti-static buildup, and color preference or opacity.
Materials
Stretch films can be made of several types of polyethylene, the most common being linear low-density polyethylene (LLDPE). Depending on the application, low-density polyethylene (LDPE) or high-density polyethylene (HDPE) may deliver improved performance.
Applications
Stretch film is used in many industries for these and other purposes:
Pallet wrapping
Protecting items from dirt, dust, or moisture
Securing rolling or mobile items during storage and transportation
Color coding pallets or bundles, blocking UV exposure, or obscuring contents from view
Bundling small or like items for more efficient storage and shipping
Benefits
Stretch film offers several benefits, such as:
Cost-effectiveness
Durable product protection from tampering, loss, or damage
Efficient transportation and storage of goods
Recyclable plastic is sustainable
Reduces injury risk from falling products
Why Choose Alpha Packaging, Inc.
Shrink film and stretch film are two effective ways to package and protect items. Manufacturers and producers rely on them to minimize damage and loss and to keep products organized.
Alpha Packaging, Inc. provides a full range of packaging supplies, products, and materials including shrink film and stretch film. We also manufacture corrugated board and cardboard boxes, mailers, shipping boxes, and pizza boxes. Additional services include custom packaging, printing, and foam inserts.
Contact us to learn more about our catalog and manufacturing capabilities, or request a quote to get started today.
