New technology preserves packaging & conserves materials at J. Lohr

Wines & Vines, Dec, 2004

J Lohr Winery in Paso Robles ships 800,000 cases of premium wine each year in attractively decorated cases, printed in color with a high-gloss varnish. Winery vice president David Mezynski insists that the quality of the graphics on J. Lohr's shipping cases reflect the quality of the contents.

Unfortunately, the combination of case weight and a varnished exterior surface can cause shipping problems. During the 10-mile transfer from the plant to Lohr's distribution warehouse, layers of cases would slide, creating irregular loads. Cases often protruded, causing interlocking pallets and making unloading difficult and prone to damage. This occurred despite multiple layers of stretch wrap.

Lock n'Pop, a Washington-based company known for low tack/high shear adhesives used in shipping, produces a product that solved J. Lohr's problem without damaging graphics or leaving unsightly residues. According to Joe Uzzardo, J. Lohr bottling supervisor, "We were quite skeptical (at first). Competitive products that claimed to be low tack and invisible stopped the sliding, but ripped cases on separation. Lock n'Pop solved both problems. With Lock n'Pop's formulations, our unloading and damage problems in both interplant and interstate shipping virtually disappeared. The equipment supplied for the 30-day test program never left the plant." Uzzardo adds that pallet stacks are now nice and tight, essentially eliminating case damage.

Uzzardo says that the application equipment is trouble-free and requires very limited maintenance. It runs off of plant air, and the adhesive is water soluble and easy to clean. The only programmed maintenance is to check the glue filter every two months and replace it every six.

Lock n'Pop is applied to cases leaving the case sealer at rates up to 18 cases per minute. Cases then proceed to the palletizer, which is typically programmed for four interlinked layers of 14 cases. On discharge, pallet loads receive the first of its two stages of wrapping, three layers at the top and two at the bottom.

The second stage of stretch wrapping occurs at the warehouse prior to shipment. Before Lock n'Pop, three additional stretch layers were added to the top and one to the bottom of the pallet. Now only two extra layers are added at the top of the pallet and none at the bottom, a 50% reduction in warehouse stretch wrap use.

Another direct benefit is that customer relations have also been improved. Customers, as well as Lohr's warehouse personnel, find that trucks are much easier to unload. Mezynski says he is pleased that the quality of J. Lohr's cases and shipments is now consistent with the company's image.

(For more information, visit locknpop.com.)