Our Company

What is now Kalamazoo Packaging Systems began in 1970 as Kalamazoo Engineering. In 1978, we were introduced to a stretch film hand dispenser that turned our attention to the packaging industry. We put one full time employee on developing our interest in the stretch film applicator business and prototyping our current handwrapper. In 1980 we started Kalamazoo Packaging Systems. Our first exposure to window and panel wrapping was in late 1980, when we produced machines to package office panels. At this same time, we produced our first window wrapper. Through the 1980’s we produced a number of pallet wrappers that were converted to wrap or package windows.

By 1990, it was generally accepted that wrapping windows in plastic film was an efficient way to package them for shipment to their destination. However, window wrapping machines were expected to accomplish much different tasks than pallet wrappers, so we developed a specialized unit: our model 939 high speed window wrapper. Since 1990 we have produced about 150 of these systems, and they are all operating at this time. Serial #1 is wrapping windows every day in November of 2003.

In 1992 we built our first wringer type window wrapper. Since then we have produced about 50 of these units in sizes varying from a 40" wringer opening to a 90" opening. These wringers are supported by various types of loaders and unloaders and recieve widespread use. Our most popular wringer is the 850PMVW, but we also build wringers to package lineals that are supplied with window and door systems.

Our newest creation is what we call a 939M9 Jumbo. This system can handle windows up to 120" tall and 144" wide. In the last year we have produced 5 of these units, which are packaging the popular large window, sliding door, and bay window products.

Over the years we have packaged millions of windows. We have built enough of this equipment to have the best ideas on how to package a window. With this in mind, call us any time at 800-253-4625. We will answer the phone Monday through Friday between 7:30 a.m. and 4:00 p.m. Eastern Time. We look forward to talking to you!

Packaging Windows

Using plastic stretch wrap for window packaging began in the late 1970's. Over the years, this method has become the way nearly all new and replacement windows are packaged for shipment. The manner in which the windows are handled, the film product that is used, and the application methods have evolved over the years to become a very reliable, cost effective system.

The film product is the key to a quality package. If you do not use a good quality film, you are not going to have the best results. The average window needs about 5 ounces of film for proper protection. If you are paying approximately 90 cents per pound for film, an ounce of film is costing you 5.6 cents. So, the film for this part of the package will only cost you about 28 cents per window. The difference between the good film and the bargain film just isn’t worth it.

Today you can purchase high quality, multi-layer film products with high slip exterior layers that have extreme strength and puncture resistance in a 50 gauge thickness. This film stretched at about 20% will give you maximum protection with puncture resistance and high slip. The film is the package; therefore you do not want to jeopardize the integrity of your product by packaging it in a lower quality film.

One of our best films has the following characteristics:

 

These features give you:

When to Package the Product

As time passes, the trend is to have the assembly group package the windows right after production in the same department that they were made in. Then, when the window is placed in a cart the first time it is already packaged and protected from damage. The tendency is to use multiple wrapping systems on the manufacturing floor. Only packaged windows are transported in a cart to the shipping dock.

How Do I Apply the Film to Create the Package?

There are two ways: Vertically using the 939-M9 or horizontally using the model 850PMVW. Both systems perform equally well. We have multiple installations of both systems. The user must decide which method they prefer.

Vertical Wrapper- Model 939-M9

We have been building the model 939 since 1990. This is the ninth version of the system we have produced. All nine versions are similar, but for part support, technical advice, and system setup we like to know what version of the 939 it is.

One person running the 939 will wrap between 250 and 325 during an 8-hour shift. It handles random windows extremely well and can, by changing the program selector switch, wrap dimensions from 24"x36" to 96"x96" on the same machine. The 939-M9 Jumbo can wrap windows up to to 144"x120" in size. With this machine, the product is wrapped vertically in the same manner that it is installed. The film applied is 30" wide and the multi-layer 50 gauge high slip film product does an outstanding job. The method in which the film is applied may be selected from three stored programs in the 939-M9 process control computer. These three programs as well as the ability to change window size on the operatior console allow optimum wrap for the window being packaged.

 

Horizontal Wrapper – Model 850PMVW

Our family of horizontal window wrappers ranges from the model 840 with a 40" wide opening in the wrapper up to the 890 with a 90" opening in the wrapper. The height of the window (or length in this case) is not really a problem as long as the operator(s) can handle it. Our most popular model is the 850. It uses the 12" by 50 gauge multi-layer high slip film products – the same as our vertical wrapper but smaller. Two people running an 850PMVW can wrap 700 to 800 windows in an 8-hour shift. We have developed and sold loading and unloading assistance modules that go with the entire 800 series. These aid in the lifting and moving processes, allowing for more productivity.

One person can operate the 800 series, but the production rate drops to about 350 windows a shift. Also, the 800 series does not have the random capability of the 939. Which system works best for your situation is totally dependant on your needs and preferences.

Packaging Lineals

In the last few years, our window customers have requested equiptment with the ability to package lineals. If done by hand this is a very labor-intensive task, and unless the individual doing the packaging is very conscientious, the hand wrapped package doesn’t stand up very well.

We make two systems for packaging lineals. The 830PMV (right) with V type input and output conveyors is great for larger bundles. With either 10" or 12" V roller conveyors you can unitize a rather large bundle of material without compromising package quality. We have done some as large as 12"x12" by 22 feet long with excellent package integrity. For best results, you should use a film product like that used in the carpet industry. We reccomend very tough film with a very slippery exterior so that bundles are easy to slide in and out of a truck.

For smaller bundles we built the 816PMV (left) with belted input and output conveyors. It will also handle up to a 12"x12" bundle without a limit on length. The 816PMV works best on smaller bundles with a high finish integrity. This system will give best results with the tough high slip film just like the 830PMV.

Support

After building systems to apply stretch film for 25 years, we have come to the conclusion that the system must be simple enough that in most cases the user can repair it when something fails. All systems come with parts explosions, which are part lists with a Kalamazoo part number and a Grainger part number (when available). Wiring diagrams and a computer logic diagram are also supplied. If the user wants a copy of the computer program on a disk we can supply that also. The cable to connect a laptop to the process control computer for program modification is not supplied with the system, but we do supply the part number for it.

For best service results get a volt meter and a cell phone and call us at our 800 number between 7:30 a.m. and 4:00 p.m. Eastern time. We would like to know the serial number of the machine to tells us what wiring diagram the machine has. In most cases there is a wiring diagram parts list someplace on the machine. Generally we can tell you what your problem is in about 3 or 4 minutes. Most parts are available locally, but if not we are one half mile from the Grand Rapids United Parcel Service terminal, so you can have the part the next day. We realize that when the system is down you cannot do your job, so we make it our priority to get your machine running quickly. The number one system failure is poor or low voltage electrical power. All of our systems built since 2002 have AC drives to control the motors, helping the system handle low voltage. We have had good results with these systems. The ones built prior to 2002 will have problems if you have low voltage and the machine has not had maintenance after 165,000 cycles. Read your manual for help on this, as it will tell you what you should look for in your maintenance cycle.

 

Unlike in 1980 it is now generally accepted that the packaging of a window involves film of some type. Stretch film seems to be more cost effective than shrink film, but still has not won out 100%.

The new thinner and tougher stretch film stretched about 20% seems to do the best job. These films are extra slippery on the outside and their multi layer construction makes them very tough. Remember that inside a truck on the road during the summer, the temperature can reach 160 to180 degrees. This will cause the film to further shrink. Always be aware of this; do not put the film on too tight and don't ever prestretch it.

There seems to be more demand for very large systems similar to our 939M9 Jumbo. We can only wrap 120" tall because the equiptment must fit inside the truck to be transported. The largest swing that we have done is 144". I would think we could go larger than this if needed, however this would be an enormous package to wrap.

Flexibility on the manufacturing floor is the name of the game. Most of our model 800 series wrappers are on casters, which makes it easier to reconfigure the manufacturing process. In the 21st century, what you will be producing in 20015 is not what you made in 2008. The process and layout will be in a constant state of change. This should be taken into consideration when you are buying your equipment.

Conclusion

Kalamazoo Packaging has been building equipment to apply stretch film since 1978. In that time there have been may changes in film and the industries we support.

From atomic waste to airport baggage to windows and doors, we have tried them all. In most cases we came up with a saleable solution. Since the birth of our first handwrapper in 1978, we have been continiously searching for new product designs to help you out.

If you have something new and you would like us to look at it, we will gladly do that for you. If we can help you we will, but if we cannot we will honestly tell you so. We will be here to help you with your product needs, and we will always have a real person answer the phone when you call.