Printed and Custom Poly Bags

Minimum Quantities and Custom Poly Bags
When ordering custom size and/or printed poly bags, the minimum order is probably the most significant consideration (other than price).  How this minimum quantity is determined is unique compared to other products your business may purchase and is helpful to understand.  Where most minimums are determined by a number of cases or individual units, poly bag minimums can vary and are determined by the weight of the source material (poly resins - Step 1 in the image below).  This results in two fairly simple rules:

• Larger and/or thicker bags will result in a smaller minimum quantity
• Smaller and/or thinner bags will result in a larger minimum quantity

The smallest minimum with most domestic manufacturers is usually 1000 lbs, though some go as low as 500 lbs.  The number of bags you can make from 1000 pounds of resin will vary from very high with a 4" x 6" 2mil bag (over 90,000 bags) to much less with a 51" x 49" x 73" 6mil bag (under 1000 bags). Additionally, as your minimum increases, your costs will typically decrease - this follows the same general "bulk order" rule of any transaction.

The diagram below is an illustration of how the manufacturing process works, which may help you better understand how custom bags are made and minimums determined.  The rolls of poly, Step 10, are then taken to other machines for cutting and sealing into the appropriate bag sizes.

More technical information on this manufacturing process as well as this source image can be found here.

Colored Bags
Most stock bags are clear, so if you need a custom color, you will be bound to the same rules as if it was a custom sized bag, even if it is a common stock size, because the bags have to be manufactured just for this purpose.  Colored bag minimums may be even higher because it requires more work and the colored resin material is simply not as common as the clear.  For example, the manufacturing line (see image above) must be purged of the colored material following production, which adds labor and time and subsequently can increase the cost.  As a result, custom colored bags may require a higher minimum quantity than a comparable clear bag of the same size.

Custom Printing Options
Most custom printing is done in-line (between steps 9 and 10, or after step 10 in the image above), meaning that the poly material is printed before it is made in to a bag.  Rarely, if ever, are bags printed post-production.  This means that you'll be held to the same rules as a standard custom bag, noted above, even though the bag you want printed may be a very common stock size.

Printed bags also have the additional charge of having the artwork done and the printing plates made.  This can range anywhere from around $200 and up, depending upon the complexity of the artwork and the numbers of colors involved.

There are two general types of printing options:

• Registered Print
  This is the most common, where you choose how many images will be on the bag and you specify the location (typically centered on the face of the bag).
• Random Repeat
  This is not as common for logos and graphics, but is most seen with generic warnings or ingredients.  Random repeat simply means that the bag will be printed at random locations on the bag and with somewhat random spacing.  An example would be a suffocation warning.  As a result, some of the print may be partial as it happens to fall on the poly sheeting in a place where it is cut to make the sheeting in to a bag.

The only way to know for certain what your minimums will be is to request a quote.  This will allow all of the variables to be factored in.  Contact us today and let us know what you need and we will help you determine what will work best for your needs and your budget.

Printed Stretch Film and Alternatives

Generally, there are four reasons why a company may be interested in printed stretch film (or stretch wrap):

• To minimize the possibility of pallets being broken in transit
• Security/Theft deterrence
• Warehouse/Internal identification
• Brand exposure

Essentially, printed stretch film is the same as regular stretch film, but with your logo or the text of your choice printed on the roll.  In light of the reasons noted above, it can be a very useful option.  It can also present its own potential negatives:

• Neck-down - distortion of the logo/text caused when the film is stretched
• Overlap rendering the logo/text illegible or unidentifiable
• Direction - with a logo, or more particularly with text, the wrap must be applied in a certain direction or it goes on backwards, rendering it illegible
• Cost - printed stretch wrap can be 2-3 times more expensive than standard stretch wrap
• Waste - once stretch wrap is used, it cannot be reused
• Redundancy of effort - often, the printed stretch wrap is not the primary wrap and is applied in only one or two layers after the primary wrap has been applied.

Additionally, if printed stretch wrap is not applied correctly, it may actually do your company more harm than good.

There are, however, alternatives to printed stretch wrap that can still meet all or most of the above specified advantages to printed stretch wrap:

Colored Stretch Wrap

This is one of the most cost-effective alternatives.  Any printed material will require a custom-run of that product and will also entail artwork and plate charges.  Many stretch wrap distributors stock colored stretch wrap, whether it be in the form of bundling film (2" - 6"), hand wrap (10" - 30") or machine wrap (20"+).  Colored stretch wrap can offer security by obscuring the view of the contents of the pallet; can provide internal identification so that personnel know, for example, which skids are returns and which are new; and can minimize the possibility of pallets being broken down because most freight carriers do not use colored film.  If you ship with orange film and your customer receives the pallet wrapped in something other than orange, you will know that the load has been tampered with and you can deal with that accordingly with your customer and freight carrier.  Like any stretch wrap, colored stretch wrap cannot be reused.  While more expensive than standard stretch wrap, colored stretch wrap is still less expensive than printed stretch wrap and is typically available in smaller minimum quantities and can be used as a simple over-wrap rather than as a primary wrap, or can be used as the primary wrap as well.

Colored stretch wrap can also be combined with custom printed labels in order to get your brand name on the pallet and generate awareness of your company.  This combination can achieve all of the goals related to using printed stretch wrap and is much more flexible and cost-effective.

Printed Pallet Covers
This is one of the more cost-effective options that will accomplish brand exposure along with security and identification.  One advantage printed pallet covers offer that is unique is that there is the possibility they may be re-used, particularly if utilized internally.  They may be used under clear stretch wrap or over any wrapped load.  The print will not be susceptible to distortion (or neck-down) or overlap as would printed stretch wrap.  Printed pallet covers are available in a variety of sizes, colors and in different mil thicknesses, depending upon your needs.  A guide to know how to measure for a pallet cover can be found here.

Colored pallet covers, printed or unprinted, may also help you accomplish your goals.  As opposed to colored stretch wrap, which is very thin and requires several overlapping wraps to achieve any significant degree of opacity (solid color, lacking transparency), colored pallet covers are already thick enough to provide the level of opacity needed for security and/or identification purposes. Samples of stock pallet covers are available at no charge to help you most accurately determine what size and thickness work best for your needs before you make any special printed and/or colored order.

Printed Tape
Printed tape is another cost-effective alternative to printed stretch wrap.  An advantage to this option is that there are stock prints available for security purposes or to discourage the load from being broken down in transit.  Custom printing is available as well.  Printed tape can also be used for other applications - such as on boxes, drums, or any other container or packaging option.  Printed tape can provide brand exposure, internal identification, and can discourage your pallets from being broken.

Given the relatively high cost and other limitations of printed stretch wrap, it is not a viable option for most users, though it may look attractive in concept.