How material consumption and film performance can be significantly improved for beverage load units.
Modern securing methods for the transport of load units in the beverage industry repeatedly reach their limits. Inefficient combinations of film solutions and wrapping technology often lead to inadequate transport security. The negative effects on product quality and brand perception can be significant — and most importantly: they are avoidable.
Two real use cases show how conventional beverage load units can be significantly improved in material consumption and film performance
Two anonymized use cases illustrate — based on real data — what material savings are realistic and how the stability of beverage load units can be noticeably increased.
What products were on the pallets?
Use Case 1 – Tested pallet with:
- beverage packs, 1-liter mineral water PET bottles, six-packs
- carbonated
- 4-layer load unit with cardboard interlayers
Use Case 2 – Tested pallet with:
- beverage packs, 1-liter iced tea / soft drink PET bottles, six-packs
- non-carbonated
- 4-layer load unit with cardboard interlayers
Which films were used?
Use Case 1 – Comparison shrink vs. stretch:
- status quo: shrink hood, approx. 817 g per pallet
- optimized: DUO PLAST stretch film, 560 g (–31% material)
- effect: significantly improved pallet stability and a more stable connection to the pallet base
- reduction of plastic movement: 20 cm → 3 cm
- reduction of elastic movement: 26 cm → 18 cm
Use Case 2 – Comparison standard film vs. DUO DOUBLE EDGE (DDK)
- status quo: 23 μm stretch film, 750 mm width, consumption 752 g
- optimized: 23 μm DUO PLAST stretch film with double edge, 500 mm width
- consumption halved: 752 g → 375 g (–50%)
- plastic horizontal movement: 9 cm → 0.5 cm
- elastic movement: over 30 cm → 13 cm
Which tests were carried out?
Both presentations document the same standardized load unit test using a horizontal impact test:
- G-forces: 0.5 g
- tested in: longitudinal and transverse direction
- measured variables: plastic & elastic displacement
- standard reference: corresponds to the EUMOS 40509 standard
Conclusion:
The use cases clearly show that modern stretch films — such as DUO RUNTEC or DUO DOPPELKANTE — can secure load units in a way that is both more stable and more material-efficient.
With correct parameterization, 30–50% less film material is possible — while simultaneously achieving significantly higher transport stability. Small adjustments in pre-stretching / application tension on the machine or in the wrapping pattern often lead to major improvements.
DUO PLAST relies on state-of-the-art blown film technology, extensive expertise in machine engineering, and validated testing procedures to design each load unit efficiently, safely, and with process stability.
