Why Are Re-Wraps Common in Shrink Wrapping, and How Can You Prevent Them?

97 Views Business
Chrystal Bell-Smyth

Shrink wrapping is essential in modern packaging operations. It enhances product presentation, extends shelf life, and ensures tamper resistance. However, one recurring issue faced by manufacturers and contract packagers is the need for re-wraps—redoing the shrink wrap process due to imperfections or errors. This can cost time, materials, and ultimately, money.

Re-wraps aren’t just a minor inconvenience—they disrupt workflow efficiency, reduce productivity, and can even damage product integrity. This blog explores why re-wraps happen, what they signal about your packaging line, and how advanced technology, like a shrink wrap sealer, can help prevent them.

What Are the Most Common Reasons for Re-Wraps?

Re-wraps typically result from inconsistencies in shrink film application or machine malfunctions. Some of the most common causes include:

Incorrect Bag Sizing: Using shrink film that is either too large or too tight for the product leads to loose or uneven seals.
Inconsistent Film Feeding: Irregular film tension or slippage can result in wrinkled or improperly sealed packages.
Misaligned Products: If products are not consistently aligned on the conveyor, the seal may miss or form improperly.
Inaccurate Temperature Control: If the shrink tunnel is too hot or too cold, it affects the quality and finish of the final wrap.
Outdated or Worn Equipment: Older machines without modern servo control systems or motion technology often lack the precision needed for consistent sealing.

Why Does Machine Technology Play a Key Role?

The technology behind your shrink wrap sealer makes all the difference in achieving reliable and repeatable results. A modern Side Seal Shrink Wrap Machine with continuous motion capabilities ensures that each package is sealed with precision, regardless of size or spacing.

Servo motion control eliminates the guesswork and mechanical inconsistency of traditional systems. Instead of relying on belts, brakes, or mechanical cams, servo systems offer digital precision, adapting to product variations in real-time. This results in fewer re-wraps, lower material waste, and faster packaging lines.

How Does Continuous Motion Reduce Re-Wrap Frequency?

A continuous motion packaging machine allows products to move through the sealing and shrinking process without stopping. This eliminates “stop-and-go” mechanics that often cause misfeeds or improper sealing. Unlike intermittent-motion machines, continuous motion systems can handle chaotic supply lines—meaning products with variable dimensions and inconsistent spacing can still be sealed correctly.

The result? A smooth, uninterrupted flow that significantly reduces the chances of operator error or packaging defects.

What Role Does Film Play in Preventing Re-Wraps?

Film type and quality have a direct impact on shrink packaging performance. Improperly selected film can stretch, bunch, or shrink unevenly, requiring rework.

To prevent these issues:

Choose Multi-Purpose Film: Films that work across different SKUs and shapes reduce setup time and errors.
Use Correct Gauge: Heavier products require thicker film to hold their shape during shrinking.
Monitor Film Tension: Automatic side sealing machines with tension control features help maintain consistency.

Why Are Servo-Controlled Side Sealer Machines More Reliable?

Servo-controlled systems like those found in Kallfass’s side sealer machines offer unmatched sealing precision. They eliminate wear-and-tear issues related to clutches, motor brakes, and contactors found in traditional machines.

Key benefits of servo control:

Consistent sealing at high speeds
No need for compressed air or pneumatic parts
Faster changeovers with software-based control
Energy-efficient operation with minimal heat loss

How Does Bag Size Impact Shrink Wrap Performance?

Getting the bag size right is critical. An oversized bag wastes film and produces loose wraps. A tight bag causes tearing, uneven shrinking, or misalignment during sealing.

Advanced automatic shrink wrap sealers measure product dimensions and adjust bag length accordingly. This reduces operator dependence and speeds up changeovers. The right bag size also ensures product presentation is clean and professional.

What Maintenance Practices Help Avoid Re-Wraps?

Preventative maintenance is essential in any high-speed packaging line. Here’s how to stay ahead of problems:

Clean Sealing Elements Regularly: Residue buildup causes inconsistent sealing.
Check Rollers and Guides: Worn rollers can result in film feeding issues.
Inspect Film Sensors and Cutters: Replace parts that show signs of fatigue or inaccuracy.

With automatic side sealing machines like those offered by Kallfass USA, maintenance requirements are minimal. No sealing wires, pneumatics, or temperature controllers are used, reducing downtime by nearly 70%.

What Makes Kallfass Systems a Smart Investment?

At Kallfass USA, our systems are purpose-built to minimize re-wraps at every stage of production. Whether you’re packaging chocolates, pharmaceuticals, or printed materials, our machines deliver maximum uptime and unmatched versatility.

Here’s why many manufacturers trust our technology:

Film Savings of 10–15%: Thanks to servo motion and energy regeneration features
No Compressed Air Required: Lower energy bills and fewer components to maintain
Integrated Emergency Heating: Continue operations even if a thermocouple breaks
Software-Based Operation: No PLCs or hard-coded programs required
Run All Film Types: No film switching delays or limitations

These machines are designed for manufacturers who value speed, precision, and durability—not just price.

Which Industries Are Most Affected by Re-Wraps?

Re-wraps impact a variety of sectors, especially those with strict quality control standards. Industries that see the most benefit from shrink wrap automation include:

Pharmaceuticals and Nutraceuticals
Food and Bakery
Cosmetics and Personal Care
Home Goods and Retail Packaging
Printing and Publishing

Using the wrong machine or outdated technology in these industries can lead to damaged packaging, increased material waste, and production delays—all of which affect your bottom line.

How Can You Evaluate the Right Shrink Wrap Sealer for Your Line?

When selecting a new shrink wrap solution, consider:

Packaging Speed Requirements: Does your current setup meet peak demand?
Product Variation: Do your SKUs vary in shape and size?
Line Integration: Can the new machine integrate with conveyors and other systems?
Downtime History: Are you losing hours to maintenance and rework?

An automatic side sealing machine with continuous motion offers long-term performance and reliability. Kallfass machines are engineered with these needs in mind, helping you maintain consistency while scaling up.

What’s the Best Way to Start Preventing Re-Wraps?

If you’re dealing with frequent re-wraps, it’s time to reassess your packaging technology. Upgrading to a modern shrink wrap sealer can streamline your operation, reduce errors, and lower long-term costs. Pair this with better film selection and regular maintenance, and you’ll significantly improve your packaging line performance.

Ready to Improve Your Shrink Wrapping Efficiency?

At Complete Packaging Solutions & Systems Inc. / Kallfass USA, we help manufacturers and contract packagers achieve high-speed, low-waste shrink wrapping with precision-engineered automation systems. Whether you need a Side Seal Shrink Wrap Machine, a custom automatic side sealing machine, or a fully integrated continuous motion packaging machine, our team is here to help you eliminate re-wraps and maximize output.

Contact Complete Packaging Solutions & Systems Inc. / Kallfass USA today to schedule a demo or request a custom quote.

Share on social media: