Containment ROI for the CPG Industry: How Optimized Stretch Wrapping Prevents Product Damage and Reduces Film Costs

Consumer Packaged Goods (CPG) manufacturing environments operate at the intersection of high-speed production, fragile packaging, and strict quality requirements. From food and beverage to personal care, household goods, and cosmetics, CPG pallets must move quickly and safely through production, warehousing, and distribution — often under tight retailer compliance standards.

Yet many CPG facilities continue to struggle with pallet instability, damaged product, excessive film usage, and inconsistent wrapping performance. Lightweight packaging, mixed materials, and rapidly changing SKUs make these loads particularly sensitive to poor containment.

This is where proper containment force becomes critical. By measuring and controlling the force applied during stretch wrapping, CPG manufacturers can protect products, reduce film consumption, and achieve measurable ROI — without slowing production. This article explores how certified containment force, supported by Lantech LeanWrap® technologies such as Metered Film Delivery®, Load Guardian®, and Pallet Grip®, delivers predictable stability and financial returns across CPG packaging operations.

Table of Contents

1. Why CPG Loads Are Hard to Stabilize
2. Financial and Operational Impact of Poor Containment in CPG
3. The Importance of Certified Containment Force in the CPG Industry
4. Key Lantech Technologies That Improve ROI
5. ROI Comparison Table
6. Common CPG Load Scenarios and Solutions
7. How to Implement Certified Containment in a CPG Facility
8. Conclusion
9. FAQs

Why CPG Loads Are Hard to Stabilize

CPG pallet loads present several structural challenges that increase instability risk:

• Lightweight packaging: Bottles, pouches, cartons, and thin corrugated cases deform easily when subjected to uneven force.
• Shifting center of gravity: Tall pallets with lightweight upper layers are prone to tipping if containment force is inconsistent.
• Multi-material pallets: Mixed combinations of corrugated, plastic, shrink film, and flexible packaging create uneven friction between layers.
• SKU variability: Frequent changeovers between products alter load dimensions and weight profiles throughout the day.
• Seasonal volume spikes: Peak production periods increase throughput demands, magnifying the impact of wrapping inconsistencies.

These factors make pallet stability in consumer goods more complex than in single-product manufacturing environments.

Financial and Operational Impact of Poor Containment in CPG

When containment force is not properly controlled, CPG manufacturers experience both visible and hidden costs:

• Crushed cartons and deformed packaging, leading to retailer rejections
• Leaking bottles and damaged closures, especially in liquid products
• Increased chargebacks and compliance penalties
• Rework labor and line interruptions caused by unstable pallets
• Customer dissatisfaction and brand damage

To compensate, many plants apply extra wraps or tighter settings. This increases film usage but does not guarantee stability — especially for fragile packaging. The result is higher cost-per-pallet with inconsistent protection.

The Importance of Certified Containment Force in the CPG Industry

Certified containment force provides a structured approach to stabilizing CPG loads by:

• Applying the right amount of force, not excessive film
• Preventing product deformation caused by over-wrapping
• Ensuring repeatable results across shifts and SKUs
• Supporting compliance with retailer handling requirements

Lantech’s containment force recommendations emphasizes that safe-to-ship pallets are achieved by measuring and controlling force, rather than relying on visual inspection or operator judgment. This is especially important in CPG plants where packaging damage may not be immediately visible but can lead to downstream failures.

Key Lantech Technologies That Improve ROI

Metered Film Delivery

Metered Film Delivery is central to achieving optimal containment force. The system measures the perimeter of each pallet and delivers a precise length of film per revolution, ensuring consistent containment force regardless of pallet size or geometry.

In the Metered Film Delivery in the Food & Beverage Industry case study, this approach enabled a CPG operation to:

• Reduce film usage by 25%
• Improve load consistency across varying pallet sizes
• Maintain stable, safe-to-ship loads without over-wrapping

This film reduction resulted in a savings of $54,750 annually.

Load Guardian

Load Guardian standardizes wrap profiles by guiding operators through a structured setup process based on load characteristics. The system then applies consistent and appropriate wrap settings to achieve the target containment force.

For CPG plants, this means:

• Reduced reliance on operator experience
• Ensures safe-to-ship loads every time
• Consistent wrapping performance during high-throughput production and throughout shifts

Pallet Grip

Pallet Grip forms a reinforced film cable at the base of the pallet by rolling the bottom six inches of film, locking the load to the pallet. This is especially valuable for lightweight consumer goods that are prone to sliding.

Benefits include:

• Reduced pallet shift during forklift handling
• Improved stability for all loads, especially tall, lightweight loads
• Fewer load failures during transport and warehousing

ROI Comparison Table

Common CPG Load Scenarios and Solutions

Bottled and Shrink-Wrapped Beverages

Lightweight bottles and shrink film reduce interlayer friction. Metered Film Delivery ensures consistent force without crushing bottles, while Pallet Grip anchors the load.

Household and Cleaning Products

Tall cartons with uneven weights benefit from balanced containment force on all pallet sides, preventing lean and collapse.

Flexible Pouches and Cartons

Soft packaging deforms easily under excessive tension. Optimal load containment prevents over-wrapping while maintaining stability.

Mixed Case Pallets

SKU variability requires automated adjustment. Load Guardian ensures correct containment settings without manual trial-and-error.

How to Implement Optimal Load Containment in a CPG Facility

1. Analyze load failures and damage reports
2. Measure existing containment force
3. Identify over-wrapping and under-wrapping patterns
4. Standardize wrap profiles using automation
5. Implement advanced stretch wrapping technology such as Metered Film Delivery, Load Guardian, and Pallet Grip
6. Train operators on containment principles
7. Document film savings, damage reduction, and ROI

This approach ensures improvements are repeatable and scalable across production lines.

Conclusion

For CPG manufacturers, certified containment force delivers one of the highest-impact, fastest-payback improvements available in packaging operations. By combining containment measurement with automated stretch wrapping technologies, plants can:

• Reduce film usage
• Protect fragile packaging
• Minimize damage and chargebacks
• Improve consistency during high-speed production

Certified containment transforms stretch wrapping into a controlled, engineering-driven process — delivering measurable ROI while supporting quality, safety, and brand integrity across the supply chain.