Dutch door distributor Skantrae’s new RoRo StretchPack® door packaging line has now been in operation for seven months. Its implementation increases output by as much as 50-60%, according to operations manager Ruud Willemsen, with the increase in productivity paired with a better work environment for employees.

The door moves from the left to right through
the RoRo StretchPack ® machine while it is being packed into a tubular stretch film. Packaging and sealing are done in one operation only.

Skantrae developed the new line when its annual growth in custom door fabrication led to a capacity problem on the heat shrink packaging line. At that time, Willemsen and production manager Peter Klomp began looking for a way to optimize packaging.

“At that time we could only pack 400 to 500 doors each day using the heat shrink tunnel, and that was not sufficient,” Klomp says. “We needed to pack about 800-900 doors each day, so capacity was the main reason why we were searching for a new packaging solution.”

These doors are packed in a tubular stretch film with the new cardboard corner protection.

In fact, the two originally sought to purchase a new heat shrink oven. They then found the RoRo StretchPack from Tentoma, which was suitable for door packaging.

“We liked the idea of stretching the film to fit the door instead of applying too much film which we afterwards need to put through a heat shrink tunnel,” Willemsen says.

The company also made additional improvements alongside the new packaging line . Klomp says that in the past, each door was lifted by hand before packaging when mounting cardboard corner protection on the door.

“That was about 800 lifts each day,” Klomp says. “On the new packaging line from Tentoma we have a lifting table integrated into the infeed conveyor. When the door is placed on the conveyor, we just push a button to lift the door for mounting corner protection. The cardboard for corner protection was redesigned to fit the new packaging line.”

That redesign allows the company to reduce its number of cardboard sizes from a dozen to a single size.

The film is sealed at the ends, which protects the
doors against dirt and moisture. The film surface has low friction, so they are not sticking together.

“I would estimate that the packaging output has increased with at least 50 to 60% even with less labor,” Willemsen says. “The old line did 60 doors per hour, and the new line packs for now 90 doors per hour, and we are still increasing that number. Now we do not have to work overtime in the evening and at the weekend anymore when we need to pack more than 500 doors per day.”

Klomp adds that packaging quality wasn’t an issue with the old packaging line. However, when comparing the old line to the new, he says the company is proud of the result as he estimates a film savings of 30% compared to the heat shrink solution. The change reduces Skantrae’s carbon footprint as well.

With a stock of 120,000 doors and an annual sale of more than 600,000 doors, Skantrae is one of the main distributors of doors in in the
Netherlands.

Bas Bosch works closely on daily operations on the line. He says that his colleagues in the packaging department believe the new line has “significantly” improved the working environment, with those employees giving honorable mention to the new lifting function.

Skantrae has a stock of 120,000 doors with annual sales totaling more than 600,000 doors.

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