A Midwest condiment producer needed to integrate a high-speed shrink wrapper with a trayless conveyor for oval ketchup bottles. This case study demonstrates how the FHOPEPACK automatic bundler (model FH‑S120) handled the irregular 1.25:1 ovality ratio, delivered 120 bundles per minute on a 2×6 pack pattern, cut film waste by 34% relative, and achieved a 14‑month payback on a $148,000 investment.
🛠️ Client Background
The client, a Midwestern condiment manufacturer, produces 1.5 million bottles of ketchup per week on a single high‑speed line. Their bottles are slightly oval (major axis 65 mm, minor axis 52 mm, height 220 mm, ovality ratio 1.25:1) and historically required cardboard trays for stability during packaging. The company aimed to eliminate tray costs and switch to a trayless conveyor system while boosting line speed from 80 to 120 bundles per minute. Their existing downstream equipment could not handle the oval geometry without tray support, creating a clear gap between cost‑reduction goals and technical feasibility.
The production team had already invested in a new trayless conveyor but found that oval bottles toppled during accumulation and film wrapping. They needed a shrink bundler that could gently orient and stabilize the bottles without trays, while maintaining the high output required for their 24/5 operation. Three suppliers were evaluated; FHOPEPACK was the only one that provided a documented case of handling similar non‑round containers at the required speed and pack pattern.
🏗️ Challenge
The primary challenge was achieving stable, high‑speed bundling of 12‑bottle packs (2×6 layout) where the oval shape caused uneven film tension and package shifting. Without trays, the bottle necks had to be aligned precisely within ±2 mm of the pack centerline to prevent film tears. The trayless conveyor introduced lateral forces of up to 15 N during merges, which could misalign oval bottles if not counteracted by the wrapper’s infeed system.
Additional constraints included:
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Bottle ovality ratio: 1.25:1 (major/minor axis), which exceeds the typical <1.1:1 that standard wrappers handle without active orientation.
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Film type: 25‑µm PE shrink film, minimum acceptable seal strength 12 N/15 mm.
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Changeover: Required in under 15 minutes between bottle sizes (planned future SKUs).
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Space limit: Only 4.2 m of linear infeed available between the trayless conveyor and the wrapper.
Historical data from the client’s earlier tray‑dependent lines showed a 7% rejection rate on oval bottles; any solution had to reduce that to below 1%.
📈 Solution Design
The FHOPEPACK automatic bundler (model FH‑S120) was selected after a pilot test using the client’s actual bottles. The machine features a servo‑driven rotary infeed with optical sensors that detect the bottle’s major axis orientation and rotate each bottle into the correct pack position. The trayless conveyor merges two lanes into a 2×6 pattern using a synchronized timing belt, with lateral guides adjusted to ±0.5 mm tolerance.
The FH‑S120 applies pre‑stretched film at 250% elongation, with a dual‑roll film carriage that reduces film waste by up to 18% compared to single‑roll systems (this contributes to the overall 34% reduction documented in Results). The solution integrated four subsystems:
| Subsystem | Component / Spec | Purpose |
|---|---|---|
| Infeed orientation | Rotary ring with 4 servo‑motor fingers, cycle time 0.3 s | Rotate oval bottles to align major axis |
| Accumulation | Timed belt with adjustable side rails, 2.5 m length | Create stable 2×6 packs without trays |
| Shrink tunnel | Hot air (185 °C setpoint, ±2 °C control), 3.2 m length | Uniform film shrinkage at 120 packs/min |
| Film system | Dual‑roll carriage, 500 mm roll width, PLC‑controlled tension | Minimize film scrap during start/stop |
A quick‑change module for the orientation fingers was included, cutting changeover time to 11 minutes for bottle dimension changes.
🛡️ Implementation
Installation was completed over a 7‑day shutdown, with FHOPEPACK field engineers on site for commissioning and training. The first three days focused on mechanical integration of the rotary infeed with the existing trayless conveyor, including real‑time alignment of the side rails to match bottle ovality. Days 4‑5 covered electrical wiring and PLC communication (EtherNet/IP to the client’s Rockwell system). Days 6‑7 were used for dry runs and tuning the film sealing temperature.
Initial tuning revealed that the optical sensors needed a 10‑ms exposure adjustment because the dark red ketchup reduced contrast. After a firmware update, orientation accuracy reached 99.7% on first pass. Operators received 8 hours of hands‑on training (4 hours on normal operation and start‑up, 2 hours on changeover, 2 hours on fault recovery). The FHOPEPACK remote support system (via Modbus TCP) was activated for the first two months of production.
A pre‑production run of 50,000 packs was completed with zero major defects. The only adjustment needed was increasing tunnel air velocity from 2.5 m/s to 3.0 m/s to prevent film sag on the flat sides of the oval bottles.
⚙️ Results Data
After six months of production, the FH‑S120 delivered a consistent throughput of 120 bundles per minute with a defect rate of 0.4%. Film waste fell from 6.2% to 4.1% (a 34% relative reduction). Line availability reached 98.2%, with unplanned downtime limited to film roll changes and one sensor recalibration.
Key metrics measured on the line:
| Metric | Before Retrofit | After Retrofit | Improvement |
|---|---|---|---|
| Line speed (packs/min) | 80 | 120 | +50% |
| Bottle rejection rate | 7.0% | 0.4% | –94% |
| Film waste per shift (kg) | 12.4 | 8.2 | –34% |
| Changeover time (min) | 22 | 11 | –50% |
| Energy consumption (kWh/1,000 packs) | 4.8 | 4.2 | –12.5% |
Note on daily throughput: At 120 packs/min over two 8‑hour shifts (960 min/day), the line processes 115,200 packs per day. This is the basis for all annual calculations below. The earlier reference to 216,000 packs/day in the original summary was a typographical error; the correct value is 115,200 packs/day.
The FH‑S120 required only two scheduled preventive maintenance stops in six months: one for bearing lubrication at 1,000 hours and one for seal bar replacement at 500,000 cycles.
🛠️ ROI Analysis
The total project investment was $148,000, including the FH‑S120 wrapper, installation, training, and one year of remote support. The elimination of cardboard trays saved $0.0042 per 12‑bottle pack (based on the client’s actual tray cost). At 115,200 packs per day and 250 operating days per year, that yields $120,960 in annual tray savings. Combined with film waste savings ($8,640/year) and lower energy costs ($1,728/year at $0.10/kWh), total annual savings reach $131,328. The payback period is approximately 14 months ($148,000 ÷ $131,328 = 1.13 years).
Tray elimination accounts for 92% of the savings. Energy savings are calculated as the 0.6 kWh/1,000 packs reduction × 28.8 million packs per year (115,200 packs/day × 250 days) × $0.10/kWh = $1,728.
Additional non‑quantified benefits include:
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Freed 40 m² of storage space previously used for trays.
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Eliminated one operator per shift for tray handling.
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Improved sustainability score (trayless = less cardboard waste).
The internal rate of return (IRR) over 5 years, assuming 3% annual volume growth, is estimated at 32%. This is an illustrative calculation only; actual IRR depends on regional tray costs, electricity rates, and volume growth. Verify with your own cost data before committing.
Actionable insight: If your line runs at 100+ packs/min and uses trays primarily for bottle stability, eliminating trays with a shrink wrapper designed for non‑round containers can yield payback in under 18 months. The key is verifying the wrapper’s orientation mechanism with your actual bottle geometry – don’t rely on generic “oval‑capable” claims.
🏗️ Purchase‑Decision Checklist
Before ordering a high‑speed shrink wrapper for trayless conveyance of oval bottles, verify these five items:
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Bottle geometry data – Provide major/minor axis, height, weight, and surface texture to the supplier. Request a trial using your bottles.
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Infeed orientation accuracy – Confirm the wrapper can detect and rotate oval bottles at full line speed (e.g., 120 packs/min). Sensors must work with your bottle color.
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Film type and tension specs – Specify minimum seal strength and pre‑stretch ratio. Dual‑roll carriages reduce waste; confirm compatibility.
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Changeover time guarantee – Ask for documented <15‑minute changeover for different bottle sizes (including oval variants).
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Integration interfaces – Validate conveyor height, PLC protocol (e.g., EtherNet/IP), and available infeed length. FHOPEPACK’s FH‑S120 performs optimally with a 2.5 m minimum infeed.
🛡️ Compliance Note: This equipment is designed to meet ISO and ASTM requirements. Verify with the manufacturer.
📈 FAQ
Q: Can the FH‑S120 handle bottles with a 1.3:1 ovality ratio?
A: The machine was verified for 1.25:1. For higher ratios, request a custom orientation module. Typical upper limit is 1.35:1 without major modification – confirm with FHOPEPACK.
Q: How much floor space does the shrink tunnel require?
A: The FH‑S120 with hot‑air tunnel occupies approximately 6.5 m × 1.8 m including infeed and discharge. The tunnel length is 3.2 m. Allow a 1 m clearance on each side for maintenance.
Q: Is the film roll width fixed at 500 mm?
A: The standard dual‑roll carriage accepts 500 mm rolls. Roll width is adjustable from 400 mm to 550 mm with an optional kit – specify when ordering.
Q: What is the typical payback if bottles are not oval?
A: For round bottles on trayless conveyors, payback is often shorter (8–12 months) because orientation is simpler. Film and tray savings remain similar. Use the calculation template from the ROI section with your own numbers.
