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PAC: Raw Material Product (sold in Canada) - Silver

Lock n'Pop Palletizing Adhesive

Overview

Lock ‘n Pop is a spray-on water based adhesive which eliminates or minimizes extra materials that would normally be disposed of, such as stretch wrap, tier sheets, corner boards etc. Their goals: reduction of ancillary packaging, increased throughput and productivity at the manufacturing site and increased unit stability.

Motivation for Change

A 19 year history with 100% recycled corrugated packaging taught me the legitimate importance of sustainability long before it was popular.

Cost Effectiveness

The economic benefits of Lock n'Pop® are threefold: Reduction of ancillary packaging, increased throughput and productivity at the manufacturing site, and increased unit stability.

Lock n'Pop® is a spray-on water based adhesive which eliminates or minimizes extra materials that would normally be disposed of, such as stretch wrap, tier sheets, corner boards, and other dunnage. Not only is there are positive economic advantage in not needing these solids, the units are lighter weight with a higher ratio of product/pallet leading directly to freight savings.

Increased productivity and throughput at the manufacturing site are where many large cost benefits are realized. Replacing solids (such as corner boards, tier sheets, dunnage) lead to sizable productivity gains in warehouse efficiency and fewer raw materials deliveries. Lock n'Pop® is applied in-line and offers throughput advantages also. Looking past the reduction in materials, wrapping times can be reduced (normally by 65% - 85%) along with the time consuming, and often labour intensive, addition of tier sheets, corner boards, and dunnage.

Often overlooked in production cost analysis is the measurement of shrinkage and loss due to damage within the supply chain. Penalties for shifted loads, the return of loads, and reshipment of goods are a large cost area that is directly mitigated by the use of Lock n'Pop®.

Performance

Lock n'Pop® possesses infinite shear strength (which eliminates lateral shifting) and a very low tensile strength (which enables depalletizing). For many packages and units, standard wraps, corners, etc will not prevent a load from shifting. Performance testing has shown that the unit stability when using Lock n'Pop® along with a top tier wrap only can double load stability, and the use of a single wrap of stretch film can triple load stability. In most cases, this represents a reduction in wrap of 50% - 85%.

In the majority of applications, Lock n'Pop® can have a net positive impact on cost reduction, environmental impact, and attain positive impact on unit stability and performance.

Effective Recovery

Lock n'Pop® products interface with the primary shipping packages, add extremely small volumes of solids, are biodegradable, and 100% recyclable/repulpable resulting in an exemplary example of effective recovery of materials.

Community Benefit

We have seen an increase in the acceptance of packages being ‘Locked’ with our product as they go to retail and ‘Popped’ by the end consumer. This at one time was considered taboo.

We think that the consumer will continue to become more savvy with regard to “packaging & shipping assists” and that there is an opportunity for Marketing to jump on and communicate these positive sustainable efforts to the consumer, directly on the package!

Material Health

Lock n'Pop® is derived from renewable plant resources and is water-based, Non-toxic, and has no VOCs. Lock n'Pop® does not meet the definition of “Hazardous” as specified in 29 CFR 1910.1200 (Hazard Communication).

Resource & Energy Optimization

Here is a “real-world” summary of a recent project with a prospective client:

•Client wrapping units for the shipment from their production facility to their large distribution warehouse
•Pallet wrap then removed for product chilling and a subsequent Pick-and-Pack distribution procedure

Through trials and viability testing, the benefits of incorporating Lock n'Pop® were observed as being:

•Increase in throughput at the production plant versus wrapping (Lock n'Pop® is applied in-line)
•Elimination of scrap/baling of pallet wrap at the warehouse facility. Decreased waste bin fee, tipping fee and overall disposal frequency
•Labour efficiency increase. At 3-5 minutes per unit for cutting and removal of the wrap, rolling it up, and delivering it to the disposal area (using $15/hour labour rate) equals $0.75 - $1.25 savings per skid

The applied cost of Lock n'Pop® for this application @ $0.70. The outgoing mixed product loads continue to make excellent use of the well suited stretch film and equipment.


The positive impact to energy & resource optimization is so often found in the willingness to make a process change as opposed to marginal adjustments to existing materials and the status quo.

Categories: Transport PAC Award Winner Additive

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