Case Study: How Del Monte Streamlined Distribution with Polypack’s PH-40DHL Shrink Wrap Machine

When it comes to high-volume packaging, consistency and reliability are everything. That’s why Del Monte turned to Polypack when they needed a solution to shrink wrap small boxes together for efficient distribution. The goal: create secure, transport-ready bundles without compromising speed or flexibility.

The Packaging Challenge

Del Monte was preparing to distribute a new line of small, shelf-stable boxed products. These boxes needed to be shrink wrapped into consistent, durable bundles for shipping to retailers and distribution centers. The packaging had to protect the product, look clean on the shelf, and keep up with the pace of production, all within a limited footprint.

PH-40 Shrink Wrap Machine

Solution: The PH Shrink Wrap Machine

We delivered a custom-engineered PH-40DHL shrink wrapping system, tailored to meet Del Monte’s production goals and product specifications.

The packaging process begins as individual boxes are fed from Del Monte’s upstream equipment onto the infeed conveyor of the PH-40DHL. From there, the boxes travel down the line until they reach a stacking product clamp, which temporarily holds them in place. Once the correct number of products has accumulated, the system releases the batch onto the stacker conveyor, where the stacking mechanism begins to build multi-level bundles.

Using a combination of cylinder-driven gates and support arms, the machine lifts the first layer of products and holds it in place while a second layer is formed below. Once the stack is complete, the bundle is transferred onto a staging conveyor, where it's held steady by another product clamp. This ensures proper spacing and orientation before the wrapping process begins.

The heart of the PH-40DHL is the dual-lane pusher assembly, which operates perpendicular to the infeed. This pusher drives the stacked product bundle through a film curtain, created by continuous feeds from upper and lower film rolls. As the bundle passes through the film, dancer bars monitor tension and signal the film drives to dispense just the right amount of material for a clean wrap.

Next, the bundle approaches the seal bar assembly, where it’s temporarily stabilized by an adjustable product hold-down mechanism. A photoelectric sensor detects the presence of the bundle and triggers the seal bars to close. The upper bar—heated and thermostatically controlled—presses against the lower silicone pad, sealing and cutting the film in one motion. This creates a secure sleeve around the bundle without disrupting product alignment.

Once sealed, the bundle is pushed onto a tunnel conveyor that carries it through the shrink tunnel. Inside the tunnel, a precisely regulated combination of heat and airflow causes the film to shrink tightly around the bundle, creating a tamper-evident, shelf-ready package. The tunnel features a slide-in heater bank and adjustable baffles to optimize energy use and airflow patterns, ensuring even shrinkage across the entire bundle.

Finally, the shrink-wrapped package exits onto the discharge conveyor, which reorients the product for smooth handoff to downstream equipment. Vendor-provided labelers may be positioned at this stage, applying necessary branding or tracking information before the bundles are palletized and shipped.

Results: High Performance Meets High Satisfaction

During the Factory Acceptance Test (FAT), Del Monte’s engineering team worked closely with Polypack technicians to fine-tune the system. Small adjustments were made to ensure optimal product handling and film tension based on real-time observations, an essential step in delivering a solution that not only met expectations but exceeded them.

“The Polypack team was responsive to our feedback and made key adjustments, delivering a high-quality machine at a competitive price. We are very pleased with the performance of our new Polypack machine!” -Orlando Carrillo, Engineering Manager, Del Monte

The PH-40DHL now plays a critical role in Del Monte’s packaging line, helping them improve efficiency, reduce manual labor, and deliver professional-grade bundles to distributors and retailers alike.

At Polypack, we don’t just build machines, we build partnerships. If you’re looking for a shrink wrapping solution that combines speed, accuracy, and flexibility, let’s talk about how we can support your packaging goals.

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