Case Summary At A Glance：
| Item | Details |
| Destination Country | Costa Rica |
| Client Type | Agricultural Export Packaging Facility |
| Equipment Model | YG1650SP Semi-Automatic Skid Wrapping Machine |
| Quantity | 2 Units |
| Delivery Time | Q2 2026 |
| Core Working Condition | High-humidity tropical warehouse environment, 24/5 continuous operation, wrapping palletized fertilizer and chemical products for export |
| Project Core Challenge | Manual stretch film wrapping was inconsistent, labor-intensive, and caused frequent load instability during ocean transit, leading to product damage claims |
| Key Performance Outcome | Wrapping cycle time reduced from 4 minutes to 1.5 minutes per pallet; film usage reduced by 28%; zero transit load failures in the first 3 months |
| Benchmark Applicability | Export-oriented agricultural, chemical, and food processing facilities require stable, weather-resistant pallet wrapping for ocean freight |
This case is directly applicable to Central and South American export packaging operations, particularly for bagged products, boxed cargo, and drummed chemicals requiring consistent film tension and coverage.
Project Background & Site Conditions
The client is a major agricultural input supplier based in Costa Rica, operating a large packaging and distribution center near the Port of Caldera. The facility handles over 500 pallets daily, primarily containing bagged fertilizers, granular pesticides, and packaged seeds destined for export markets across Central America and the Caribbean.
Project Type: Export pallet wrapping and load stabilization
Site Conditions: The packaging warehouse is located in a tropical coastal region with ambient temperatures averaging 28–32°C and relative humidity consistently above 80% throughout the year. The facility operates on a single shift basis with occasional overtime during peak export seasons. Floor space is partially constrained, requiring compact equipment that can be positioned near the conveyor line without occupying excessive aisle space.
Client’s Previous Pain Points:
- Inconsistent wrapping quality: Manual wrapping with handheld film rolls resulted in uneven tension, loose film at the base, and inadequate top coverage – causing load shift and bag tearing during container stuffing and ocean transit
- High film waste: Operators overlapped excessively to compensate for poor technique, using 30–40% more film than technically required
- Labor inefficiency: Each pallet required 3–4 minutes of manual wrapping, and dedicated wrapping staff could only process 12–15 pallets per hour
- Physical strain: Workers reported fatigue and repetitive motion injuries from continuous bending and reaching during wrapping
- Transit damage claims: Approximately 3% of exported pallets suffered damage-related claims, primarily due to load destabilization during rough sea conditions
- No traceability: Manual wrapping lacked consistency metrics, making it impossible to standardize or audit wrapping quality
Client Procurement Requirements:
- Semi-automatic operation compatible with existing forklift-based pallet handling system
- Adjustable wrap settings for varying load heights and product types
- Pre-stretch film capability to reduce film consumption without compromising load integrity
- Reliable performance in high-temperature, high-humidity environments
- Simple operator interface with minimal training requirement
- Compact footprint to fit within existing packaging line layout
- Robust electrical components suitable for a 220V/50Hz supply with voltage fluctuations
Equipment Selection & Configuration
After evaluating the client’s pallet dimensions, throughput targets, and operational constraints, the YG1650SP skid wrapping machine was selected as the optimal solution. The selection process involved analyzing pallet flow, available floor space, and film consumption targets.
Primary Equipment Model: YG1650SP Semi-Automatic Skid Wrapping Machine
| Specification | YG1650SP Value |
| Turntable Diameter | 1650 mm |
| Suitable Pallet Size | 500–1200 × 500–1200 mm |
| Packaging Height | 500–2000 mm |
| Turntable Load Capacity | 2000 kg |
| Machine Weight | 500 kg |
| Machine Power | 1.5 kW |
| Power Supply | 220V/50Hz |
| Turntable Speed | 0–12 rpm (adjustable) |
| Applicable Film | 15–35 μ pre-stretch stretch film (25μ recommended) |
| Packaging Specifications | 1200 × 800 mm, Height 600 mm, Weight under 2000 kg |
Why YG1650SP Was Selected:
- Pallet size flexibility: The 1650mm turntable accommodates the client’s mixed pallet sizes (1100×1100 and 1200×800) without requiring manual repositioning
- Height coverage: 2000mm maximum wrapping height covers all current load configurations, with room for taller palletized drums
- Load capacity: 2000kg capacity comfortably handles the heaviest fertilizer pallets
- Pre-stretch capability: 250% pre-stretch mechanism significantly reduces film usage – a key cost driver for high-volume export operations
- Speed adjustability: 0–12 rpm turntable speed allows operators to match wrapping speed to product stability (slower for unstable bagged loads, faster for rigid boxed loads)
- PLC programmability: Allows precise control of top/bottom wrap counts and film overlap, ensuring consistency across operators
Customization for Costa Rican Conditions:
- Corrosion-resistant electrical enclosure: IP65-rated control box to protect PLC and drive components from high-humidity and salt-laden coastal air
- Heat-dissipation fan: Additional cooling fan installed in the electrical cabinet to maintain component temperatures within safe limits during prolonged operation
- Heavy-duty casters: Upgraded locking casters for easy repositioning within the crowded warehouse while maintaining stability during operation
- Bilingual interface: Control panel labels and operating instructions in Spanish (with English backup) for local operator ease
- Voltage stabilizer: Built-in surge protection to accommodate the facility’s ±10% voltage fluctuations common in the region
Selection Rationale:
The YG1650SP-X variant (including ramp, 2400mm height capacity) was considered but deemed unnecessary as the client uses forklift-based pallet placement and no pallets exceed 2000mm height. The additional ramp feature would have occupied valuable floor space. The base YG1650SP provided all required functionality at a more space-efficient configuration.
Project Outcomes
- Wrapping throughput increased from 12–15 pallets/hour (manual) to 40–45 pallets/hour – a 200% improvement
- Film consumption reduced by 28% across all load types, saving approximately 1.5 tons of stretch film annually
- Transit damage claims dropped from 3% to under 0.2% – a 93% reduction in product loss
- Labor cost reduced by eliminating 2 dedicated wrapping positions (operators reassigned to palletizing and inspection)
- Operator fatigue eliminated – no more bending, stretching, or repetitive arm motions; operators simply place the film and press start
- Training time reduced from days to under 20 minutes for new operators
Complete Export & Delivery Process
The export of these fully automatic pallet wrapping machine units to Costa Rica followed a structured process designed to ensure smooth customs clearance, safe transport, and successful on-site commissioning.
Application Analysis: The client’s pallet dimensions, load weights, product types, and throughput requirements were analyzed using facility layout drawings, product photos, and detailed questionnaires. A customized wrapping schedule was developed.
Free Selection Consultation: Based on the analysis, the YG1650SP was recommended over the YG1650SP-X variant. The client received detailed comparison data to validate the selection.
Parameter Fine-Tuning: The PLC parameters were pre-programmed with the client’s preferred wrap patterns (bottom wraps, top wraps, overlap percentage) before shipment, reducing on-site setup time.
Manufacturing: Both units were manufactured to order with the Costa Rica-specific customizations (IP65 enclosure, cooling fan, surge protection, Spanish labels).
Packaging:
- Anti-rust treatment applied to all exposed steel surfaces
- Heavy-duty shrink-wrap film is applied over the entire machine to protect against moisture
- Reinforced wooden crating with internal bracing
- Desiccant packs and VCI paper were installed to prevent corrosion during ocean transit
- The control panel and electrical components are separately cushioned with foam
Installation Guidance: Remote video installation support was provided to the client’s maintenance team. Both units were placed on the production floor within 2 hours of arrival and connected to the 220V/50Hz supply.
Operator Training: A comprehensive training session was conducted via video conference, covering:
- Safe operating procedures for the pallet packing machine
- Programming wrap parameters for different load types
- Film roll loading and splicing techniques
- Daily maintenance checklist (cleaning turntable, checking film path, inspecting electrical connections)
- Troubleshooting common issues (film breakage, turntable stall, PLC error codes)
Client Feedback & Real Evaluation
Three months after commissioning, the client’s Warehouse Manager provided the following evaluation:
“Our export packaging operation has been transformed. Before, we had two workers dedicated to hand-wrapping pallets, and we still had damage claims every shipment. Now one operator runs both skid wrapping machines while supervising the palletizing line. The film savings alone justify the investment – we use 28% less film and the wrap quality is visibly superior. The pre-stretch function is remarkable – the film holds the load so tightly that we no longer need edge protectors on many loads. The only issue we had was a minor misalignment on the film carriage guide roller after the first week – we fixed it ourselves with a screwdriver, and it has been running perfectly since. We have already recommended this equipment to our sister facility in Guatemala.”
— Warehouse Manager, Agricultural Export Facility, Costa Rica
Manufacturer Response: The mounting bolt specification has been upgraded to a larger diameter for all future shipments to high-use facilities. Updated training videos with clearer Spanish voiceover have been provided.
After-Sales Support & Long-Term Service
Understanding the challenges of equipment maintenance in Central America, a comprehensive support framework has been established:
- 12-month standard warranty on the complete unit
- Emergency parts dispatch within 72 hours for critical components
- Recommended spare parts kit provided with each unit
- 24/7 remote technical support via video call and messaging platforms (WhatsApp supported)
- On-site technician dispatch available for major service requirements (typically within 5–7 days)
- Comprehensive digital maintenance library including video tutorials with Spanish subtitles
Preventive Maintenance Guidance:
- Daily: Turntable surface cleaning, film path inspection, emergency stop check
- Weekly: Chain drive lubrication, pre-stretch belt tension check, electrical connection tightening
- Monthly: Full system inspection, bearing lubrication, PLC parameter backup
- Quarterly: Professional service recommended (gear drive inspection, motor brush check)
Ongoing Optimization:
- Continuous performance monitoring via client-provided production logs
- Recommendations for wrap pattern adjustments based on seasonal humidity changes (affecting film properties)
- Free consultation for additional equipment needs as the client’s operation expands
Case Summary & Applicability Guide
Core Value Delivered
This Costa Rican case demonstrates that the YG1650SP skid wrapping machine delivers:
- Measurable throughput gains – 200% increase in wrapping speed compared to manual methods
- Substantial film savings – 28% reduction in stretch film consumption with equivalent or better load holding force
- Reliability in harsh environments – stable operation in tropical high-humidity conditions with zero electrical failures
- Operational simplicity – PLC programmability and intuitive interface enable rapid changeover and minimal training
- Documented damage reduction – 93% reduction in transit load failures, directly improving customer satisfaction and reducing claims
- Complete export capability – seamless delivery and commissioning in Costa Rica with full documentation and Spanish support
Comparable Projects
This case is directly applicable to:
- Export-oriented agricultural processing plants in Central and South America
- Chemical and fertilizer packaging facilities requiring high-volume pallet wrapping
- Food and beverage manufacturers seeking consistent load stability for ocean freight
- Distribution centers in tropical climates need robust, low-maintenance wrapping equipment
- Facilities transitioning from manual to automated pallet wrapping with limited floor space
For more information about this pallet packing machine or to discuss your specific pallet dimensions and throughput requirements, please contact our sales team with your load specifications.
Phone / WhatsApp / WeChat: +86 159 3715 3321
