The success of metal fabricators is based upon versatility, productivity, and safety when it comes to both their products and their people. These considerations leave companies constantly searching for innovative ways to boost pack-to-ship performance.

One such metal fabricator, Tri-State Fabricators, realized a total productivity package with the installation of an orbital stretch wrap system, designed to cost-effectively and reliably secure irregular or odd-shaped loads without bands.

The Cincinnati, Ohio-based company has found increased shipping capacities as well as minimized labor requirements and damage. Maintenance and materials costs have also declined. In addition, there has been a significant drop in injuries and worker compensation claims.

With job shop and long-term contract work, the company services small businesses to large corporations in a variety of market segments. Its versatility results in load sizes of all shapes, dimensions and weights.

"We ship parts that are the size of a quarter all the way up to lengths of 18 feet," says Jack Deimling, shipping manager for Tri-State Fabricators. "No matter what size or shape of load, I have to make sure that the product remains safely on the skid throughout shipment."

Nearly two years ago, the department was using a three-person packing crew —one person on the forklift and two people to wrap the load. "The forklift operator would have to stop everything, find two people; pull them off their jobs, so they could take up to 20 minutes to wrap one load. This was costly, time consuming and inefficient. With the new stretch wrap system, one person can do the job of three, more safely, more economically and with less wear and tear on the forklift," stresses Deimling.

"The unit has allowed us to nearly triple our shipping capacity, while significantly cutting our costs. Before the [stretch wrap system], we were doing only about 30 pallets a day," he adds. "Now, we're doing 80 to 90 pallets each day, and I can turn a truck in about 15 minutes."