Monti
Stamper protects copper, aluminum parts with orbital wrapper
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The Challenge
At Monti Inc.’s Greenwood, South Carolina, facility, Plant Manager Nick LaVigne faced challenges with his vast material inventory. As a major supplier to Fortune 500 electrical distribution companies, Monti stamps 10,000 to 200,000 parts per part number annually across multiple materials. However, 30% of their production involves soft copper and aluminum, which require special handling.
The multi-plant manufacturer was struggling with the challenges of soft metal stampings:
- Rapid oxidation: Copper parts tarnished quickly when exposed to elements during storage and transport
- Product damage: Dense but soft copper and aluminum parts acquired dings, dents, and scratches from ordinary handling
- Cross-contamination risks: Frequent changeovers between steel, aluminum, and copper created contamination from feed rollers and debris
- WIP staging problems: Parts sitting in open bins for weeks between processes collected dust, humidity, and contaminants
- Transit damage: Heavy loads prone to shifting off pallets, causing reject orders and operational disruptions
Many of Monti’s parts are stamped from ¼-inch-thick copper and aluminum bar stock. LaVigne said that although the orbital wrapper is especially needed for copper and aluminum parts, the company uses it for ferrous materials as well.
The TAB Wrapper Tornado Solution
As part of its effort to prevent oxidation, block cross-contamination, and shield parts from damage, Monti purchased a TAB Wrapper Tornado orbital stretch wrapper to create protective packaging for their sensitive stampings.
The patented technology wraps stretch film 360 degrees around and under products and pallets, creating a protective layer that shields parts from contamination while providing superior load compression.
Key Benefits Include:
- Environmental protection: Stretch film secures and keeps parts clean to prevent oxidation
- Wireless forklift operation: Operators control the entire process via remote control without leaving their seat
- High compression wrapping: Firmly secures loads to pallets, preventing shifting during transport
- Versatile container handling: Secures Gaylords, drums, bins, and boxes as single unitized loads
- Under-one-minute operation: Automated wrapping process completes quickly with push-button simplicity
The system integrates seamlessly into Monti’s workflow. Forklift drivers simply position loads in the wrapping ring, press the start button, and the machine automatically wraps multiple layers before cutting the film.
“Almost every product that leaves our dock, whether we deliver it or whether we ship it on light freight, gets orbital-wrapped,” says LaVigne.
Implementation and Results
Monti now uses the orbital wrapper throughout their production process, from work-in-process staging to final shipment.
Key Results Included:
- Reduced reject rate: Cut the overall reject rate by up to 5% by eliminating transport damage
- Eliminated cross-contamination: WIP parts no longer collect dust, humidity, or contaminants during staging
- Protected soft metals: Copper and aluminum parts maintain quality throughout handling and transport
- Enhanced load stability: High compression wrapping prevents shifting and pallet failures during delivery
- Streamlined operations: Nearly every product leaving the dock gets orbital-wrapped for consistent protection
The machine proved so effective that Monti expanded its use beyond just copper and aluminum. The company now wraps steel parts and mixed materials with the same protective approach.
Read the full Monti case study in the Stamping Journal here.
Learn More About TAB Wrapper Solutions
TAB Wrapper offers proven orbital stretch wrapper technology, available in multiple configurations with wireless remote and automation options, for manufacturing operations handling sensitive materials.