Pitt Meadows Plumbing
Contractor Eliminates Manual Pallet Wrapping to Secure Metal Parts, Protect Workers
As Featured In
A pallet load of carbon steel, Schedule 40 pipe is raised on a forklift and ready for wrapping.
The Challenge
At FABTECH 2023, Steve Robinson, President of Pitt Meadows Plumbing and Mechanical Systems Ltd., watched an orbital wrapper quickly secure a pallet of metal parts. He immediately saw it as the solution to a problem that had been slowing his company down.
Although the family-owned contractor in Maple Ridge, British Columbia, had already invested in advanced technology throughout their operations, from automated measurement tools to 3D pipe drawing software, their packaging process was still old-fashioned. Every year, they were manually wrapping more than 1,500 pallet loads.
The outdated approach created expensive challenges:
- Labor-intensive process: Wrapping their pallets required three people, including a forklift operator and two workers passing stretch wrap rolls back and forth
- Inconsistent results: Pallets often needed banding, strapping, or protective dunnage to keep their products in place
- Last-minute fixes: Loads were sometimes flagged for rewrapping before shipment
- Damaged deliveries: Rejections from shifting loads during transit cost up to $2,000 each and could delay construction projects
- Safety issues: Workers reported back discomfort from bending underneath the raised pallet loads
With pallets valued at up to $2,000 and looming deadlines, Pitt Meadows needed a reliable way to secure shipments.
“Nobody was thrilled to stretch wrap the pallet loads for delivery,” recalls Andrea Wilson, Inventory Control Manager.
The TAB Wrapper Tornado Solution
To bring packaging up to the same standard as the rest of their operations, Robinson purchased two 80-inch Smart Controls TAB Wrapper Tornado orbital stretch wrappers. One was used for stainless steel and copper, while the other was dedicated to carbon steel, cast iron, and other materials.
The TAB Wrapper Tornado applies stretch film around and underneath pallets while they are raised on forklifts. The process takes less than 30 seconds and creates stable loads that hold firm during transport. It also removes the need for boxes, crates, strapping, and banding.
Key benefits included:
- Operation by a single forklift driver using a wireless remote
- Ability to wrap products of any length
- Weather-resistant wrapping to protect against rust and moisture
Drivers simply position the pallet in the wrapping ring, press start, and move forward as the machine applies multiple layers of film. When complete, the driver presses “stop” on the remote control, the built-in automated cut and wrap device automatically cuts the end of the plastic, and the driver moves the wrapped pallet to its next destination.
“We liked how the driver could operate the machine without getting on and off the forklift,” says Wilson. “This is a much faster, more efficient way to wrap our pallets.”
At Pitt Meadows Plumbing and Mechanical Systems Ltd., Simon Robinson wraps a pallet load of Schedule 40 pipe using the TAB Wrapper Tornado.
Pipe products are tightly wrapped and ready for shipment.
Implementation and Results
The results at Pitt Meadows Plumbing were better than expected across the board.
- Zero delivery rejections: Every shipment has arrived safely since installation
- Improved safety: Workers no longer deal with cuts or back pain from manual wrapping
- Increased capacity: The company can handle growing demand without more staff
- Weather-resistance: Weather-resistant wrapping keeps materials protected outdoors
- Easier visibility: Clear film makes it easy to see pallet contents without unwrapping
- Happier workforce: A job that nobody wanted to do is now one that everyone is eager to take on
Training took only 30 minutes, and the improvement in worker morale was immediate.
“Everybody loves the TAB Wrapper Tornado. We took a dirty job that nobody wanted to do and turned it into one everyone wants,” says Wilson.
The system also proved valuable on construction sites. Since pallets are often stored outside, the tight film keeps materials dry and protected while allowing crews to see and access what they need quickly — no more wasted time or risk from cutting off boxes, bands, and straps.
“We are sending out secure loads every time,” says Wilson. “Now we stay on schedule, meet deadlines without scrambling, and can handle growth without extra hiring.”
Read the full case study in the FF Journal.
TAB Wrapper Orbital Stretch Wrapper Solutions
TAB Wrapper offers proven orbital stretch wrapper technology, available in multiple configurations with wireless remote and automation options, for operations handling challenging products.