Adhesive preserves palletized wine cases: a wine producer uses Lock n' Pop to keep pallets unitized during the long trip to the warehouse

Food & Drug Packaging, Feb, 2005

As with a book, a shipping case can t always be judged by its cover. But looks definitely count in the case of J. Lohr Winery in northern California, a premium producer that ships 800,000 attractively decorated cartons to discerning wine customers each year. Lohr insists on quality packaging graphics, which the company counts on to support sales, image and profits. Lohr's shipping cases are printed in color with a high-gloss varnish.

Until recently the problem was that, despite multiple layers of stretch wrap, sliding layers of palletized cases stubbornly protruded and scarred Lohr's cartons. During a problem-solving test program, however, use of Lock n' Pop invisible adhesive minimized the shipping damage. The winery has since stuck with a good thing. Now, not only have consumers kept popping the corks of Lohr's securely-packaged products, but use of Lock n' Pop also has cut stretch wrap use and reduced time-costing unloading labor.

Lohr's difficulties had stemmed from its cases' combination of high weight and varnished exterior surface. Before using Lock n' Pop, routine 10-mile transfers to the distribution warehouse caused shifting cases, and irregular loads led to interlocking pallets that made unloading unwieldy and damage-prone.

Lohr bottling supervisor Joe Uzzardo initially was skeptical the answer would be Lock n' Pop--a water-based, high-shear adhesive designed for palletizing boxes, bags and frozen or chilled packages. But Lock n' Pop got a grip on the trouble while protecting graphics without unsightly residues. Uzzardo says, With Lock n' Pop's formulations, our unloading and damage problems in both interplant and interstate shipping virtually disappeared."

Lock n' Pop forms a chemical bond with package surfaces, a grip that holds firm until pallets are unstacked. Cases easily "pop" apart by lifting because of low tensile strength. Unlike other adhesives, it leaves no stickiness or marring. Application equipment proved trouble-free and safe. Application involves no heat and runs off plant air.

At Lohr's plant, when cases leave the case sealer, Lock n' Pop is applied at up to 18 cases per minute. Cases proceed to a palletizer typically programmed for four interlinked layers of 14 cases. Pallet loads receive the first of two stages of stretch wrapping--three layers at the top and two at the bottom. The second stage of wrapping occurs at the warehouse before shipping. Previously, three additional layers were applied to the top of the pallet, with one added to the bottom. With Lock n' Pop, only two further layers are added at the top and none below: a 50% reduction in warehouse stretch wrap use.

Lohr Vice President David Mezynski is pleased with a bonus benefit: improved customer relations. Customers and Lohr's own warehouse workers find trucks easier to unload. Using Lock n' Pop, Mezynski is satisfied the quality of wine cases and shipments are consistent with the company's image-an outcome worth toasting.

For more information

Lock n' Pop 800-225-3009; www.locknpop.com

IN A NUTSHELL

Problem: Stretch wrapping of pallets was wasteful and provided insufficient protection,

Solution: Sprayed adhesive for unitizing corrugated cases.

Results: Economical protection for decorated cartons.