Penn Sheet Metal
Penn Sheet Metal Speeds Packaging, Stops Injuries with TAB Wrapper Tornado
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The Challenge
Business was booming at Penn Sheet Metal in Allentown, Pennsylvania. Since President Mike Roeder purchased the metal fabrication company in 2002, revenues have increased to more than $5 million annually. Product line expansions in architectural components, roofing systems, and custom decorative building products, plus new roll forming and laser cutting services, drove their sales growth.
But with growth comes new techniques and issues. With 10-15 pallet loads requiring daily wrapping and shipment, their packaging process was hindering growth and hurting their on-time delivery record.
Penn Sheet Metal’s product range made packaging particularly challenging:
- Unusual pallet dimensions: Downspouts and gutters required 10’ x 4’; wall panel systems needed 16’ x 5’ pallets
- Manual process: Each pallet took 15 minutes to wrap by hand, sometimes up to 30 minutes, and longer for irregular loads
- Worker injuries: Frequent scratches, cuts, splinters, bashed knuckles, and sore backs from manual wrapping
- Inconsistent wrapping: Workers could only wrap the pallet ends by hand, requiring metal banding to compensate
- Production disruption: 20 machinists had to stop manufacturing to handle their own packaging
“I always felt there had to be a better way, but manual stretch wrapping and banding were standard procedure forever, not just for us, but for almost everyone in the industry,” says Roeder. “We were wasting so much time wrapping pallets by hand until I’d finally had enough and looked for a solution.”
The TAB Wrapper Tornado Solution
Roeder learned about the TAB Wrapper Tornado orbital wrapper online and recognized its potential for handling Penn Sheet Metal’s challenging long pallet loads. The automated wrapping system automatically wraps stretch film 360 degrees around and under pallets, creating weather-resistant, secure loads that resist shifting during transit.
Roeder invested in the largest standard model featuring a 100-inch wrapping ring that accommodates pallet widths up to five feet, along with the wireless automation package.
Key Benefits Include:
- Wrapping capability: Stationary wrapping ring design handles awkward pallet sizes
- Complete load security: Wraps entire pallet loads front to back, top to bottom, eliminating the need for metal banding in their operation
- Single-operator efficiency: Forklift drivers manage the process via wireless remote without leaving their seat
- Weather protection: Creates a protective layer for outdoor storage and jobsite delivery
- Plug-and-play installation: Connects to standard 240-volt power and compressed air lines
To operate the TAB Wrapper, forklift drivers center pallet loads in the wrapping ring, press start on the remote, and slowly move forward or back as the machine wraps the entire pallet from end to end. The automated cut-and-wrap system completes the process.
Implementation and Results
The TAB Wrapper installation at Penn Sheet Metal resulted in immediate improvements across the company’s operations.
Key Results Included:
- Time savings: Cut wrapping time from 15 minutes to 60 seconds or less per pallet
- Labor efficiency: Only one employee is now needed in the pallet wrapping process
- Annual savings: More than 78 full eight-hour workdays saved per year (2.5 hours saved daily)
- Eliminated injuries: No more cuts, scratches, splinters, or back injuries from manual wrapping
- Perfect transit record: Zero orders rejected for product damage since installation
- Enhanced load security: Increased wrap quality for their long and awkward pallet loads
The transformation was immediate. The automated wrapper arrived by flatbed truck and was fully operational within 20 minutes of delivery. Training took just 5-10 minutes per worker. “Everyone loves using it and there’s no going back to wrapping by hand,” says Roeder.
The timing proved critical. After several experienced workers retired, the automated wrapper turned potential productivity losses into gains. All 20 employees now use the TAB Wrapper Tornado for everything that leaves the building. Customers immediately noticed the professional improvement. Roofers, builders, and contractors can now transport pallets easily, quickly identify parts through clear plastic wrap, and keep materials protected from the weather.
“We’re getting a much better, more secure wrap every time, even on our longest skids, and it wouldn’t even be possible to wrap them by hand,” says Roeder. “The TAB Wrapper Tornado is a solid, well-built machine that has saved us huge amounts of time. Anyone wrapping long pallets needs to get it.”
Read the full case study in FAB Shop Magazine Direct.
Learn More About TAB Wrapper Solutions
Available in multiple configurations with wireless remote and automation options, the TAB Wrapper offers proven orbital stretch wrapper technology for manufacturers handling heavy or irregularly shaped products.
