Industrial - Honours

Roller Wrap – Reusable Logistics Packaging

The Roller Wrap is a type of reusable logistics or tertiary packaging designed to replace three different types of single use tertiary packaging to improve the environmental sustainability of logistics packaging by reducing logistics packaging waste.

David Quick

Logistics Packaging Waste – Improving the Environmental Sustainability of Tertiary Packaging

Packaging accounts for the most significant waste stream produced by the retail sector. It is a significant generator of large and diverse amounts of waste through the use of single-use and disposable packaging. While many retail chains are actively working to reduce the environmental footprint of the packaging used, their logistics or tertiary packaging still relies heavily on the use of single-use and disposable packaging. The aim of this project was to identify the problematic tertiary packaging currently in use by retail chains and develop a more environmentally sustainable product and or system to replace them. The product that was developed was the Roller Wrap, a type of reusable tertiary packaging that replaces three of the most problematic tertiary packaging materials identified and still in use.
The Roller Wrap, a type of tertiary packaging designed to replace the single-use and disposable packaging currently used by retail chains to transport their goods.

The Roller Wrap

The Roller Wrap is a reusable retractable wrap designed to replace problematic single-use and disposable tertiary packaging. The design integrates with existing reusable pallets, as well as other forms of packaging, systems and processes, vehicles, equipment, and infrastructure. The retractable wrap is designed to be simple, safe and quick to apply and remove from palletised stock, as well as to store and transport when not in use. It has also been designed for disassembly using screws, joints and connectors instead of adhesives. This makes it quick and easy to remove and replace broken and damaged parts. The design is also modular, combining with other wraps, to keep the products compact in size and lightweight, increasing accessibility for the intended users. To connect the wraps, connecting straps will not only allow the wraps to connect, but allow for the wraps to conform to the top of the often irregular shape of palletised stock.
The Roller Wrap is comprised of four main parts, the torsion assembly housed within the case, the case, the wrap, and the handle.

Components

The Roller Wrap is comprised of four main parts, the torsion assembly housed within the case, the case, the wrap, and the handle.
The case is comprised of several parts: • The case houses the mechanisms of the wrap, the wrap itself, and provides a frame for attaching the other case components. • Strap attachment points provide a sturdy location for attaching the connecting straps. • End caps close the case as well as provide attachment points for the wrap and mechanisms. • End protectors provide protection for both the wrap and the mechanisms. • Connecting straps provide handles for moving the wrap and a way to secure the wraps together on top of a pallet.

Components – Case

The case is comprised of several parts:
• The case houses the mechanisms of the wrap, the wrap itself, and provides a frame for attaching the other case components.
• Strap attachment points provide a sturdy location for attaching the connecting straps.
• End caps close the case as well as provide attachment points for the wrap and the mechanisms.
• End protectors provide protection for both the wrap and the mechanisms.
• Connecting straps provide handles for moving the wrap and a way to secure the wraps together on top of a pallet.
The wrap itself is comprised of several parts: • The flap and tubing attach the wrap to the torsion assembly. • The wrap is used to contain the stock. It also has a pattern of slits that allow for horizontal expansion which allows the wrap to stretch horizontally and secure the gap between adjacent wraps. • Three straps secure the wrap vertically, allowing the wrap to be tensioned when in use. The outside straps also have slits that allow for hooks to be attached and connect to adjacent wraps.

Components – Wrap

The wrap itself is comprised of several parts:
• The flap and tubing attach the wrap to the torsion assembly.
• The wrap is used to contain the stock. It also has a pattern of slits that allow for horizontal expansion which allows the wrap to stretch horizontally and secure the gap between adjacent wraps.
• Three straps secure the wrap vertically, allowing the wrap to be tensioned when in use. The outside straps also have slits that allow for hooks to be attached and connect to adjacent wraps.
The handle is comprised of several parts: • The handle provides a point for the wrap and straps to attach to. Its slim profile avoids increasing the area taken up by each pallet when wraps are attached. • The handle contains a metal frame that provides additional strength and a strong point to attach the connecting straps to. • Wrap strap attachment points provide points for the wrap to attach to. These points also allow for the wrap to be tightened to secure the wrap. • Connecting straps allow each end of the handle to attach to the pallet as well as each adjacent wrap.

Components – Handle

The handle is comprised of several parts:
• The handle provides a point for the wrap and straps to attach to. Its slim profile avoids increasing the area taken up by each pallet when wraps are attached.
• The handle contains a metal frame that provides additional strength and a strong point to attach the connecting straps to.
• Wrap strap attachment points provide points for the wrap to attach to. These points also allow for the wrap to be tightened to secure the wrap.
• Connecting straps allow each end of the handle to attach to the pallet as well as each adjacent wrap.
The Roller Wrap in use, combining with other Roller Wraps, to secured the palletised stock sitting on a reusable pallet, another type of tertiary packaging.

How it Works

The Roller Wrap in use, combining with other Roller Wraps, to secure the palletised stock sitting on a reusable pallet, another type of tertiary packaging. Four wraps are placed on top of the palletised stock, and connected to each of the other wraps by the connecting straps attached to the case. This secures the wraps together and the space between them as well. Each wrap is then extended down to the pallet. Each handle then attaches to the pallet at each end, and to each adjacent handle, using the connecting straps. Lastly, while not shown in the images provided each wrap can attach to each adjacent wrap through the use of hooks attached to the slits in the outside straps of each wrap.

TECHNOLOGY

There are three important pieces of technology within the Roller Wrap which enable it to work, the torsion assembly, the tensioning mechanism, and the wrap locking mechanism.

The torsion assembly, the long cylindrical component in the centre which the wrap attaches to, provides the mechanical power through a torsion spring that powers the retraction of the wrap.

Torsion Assembly

The torsion assembly, the long cylindrical component in the centre which the wrap attaches to, provides the mechanical power through a torsion spring that powers the retraction of the wrap.
The tensioning mechanism allows for the torsion assembly to be tensioned and de-tensioned quickly and easily while the torsion assembly remains inside the case.

Tensioning Mechanism

The tensioning mechanism allows for the torsion assembly to be tensioned and de-tensioned quickly and easily while the torsion assembly remains inside the case.
The wrap locking mechanism locks the wrap in place, stopping the wrap from extending or retracting unintentionally.

Wrap Locking Mechanism

The wrap locking mechanism locks the wrap in place, stopping the wrap from extending or retracting unintentionally.

Systems

For the Roller Wrap to function it will rely on several existing and proposed systems. • The Roller Wrap makes use of the existing logistics and reverse logistics systems to move up and down the supply chain as needed. • A system for delivering replacement parts to repair the wraps will be established, and will work as part of the existing logistics system. • A system will be established to collect broken and damaged parts for repair or recycling, and will work as part of the existing reverse logistics system.

For the Roller Wrap to function it will rely on several existing and proposed systems.
• The Roller Wrap makes use of the existing logistics and reverse logistics systems to move up and down the supply chain as needed.
• A system for delivering replacement parts to repair the wraps will be established, and will work as part of the existing logistics system.
• A system will be established to collect broken and damaged parts for repair or recycling, and will work as part of the existing reverse logistics system.

MATERIALS

The roller wrap is comprised of the following materials:
• The case and end caps are made of high-density polyethylene (HDPE).
• The end protectors and handle are made of thermoplastic elastomer (TPE).
• The case, wrap and handle straps are made from load bearing polyester webbing.
• The wrap is made from polycotton canvas with a tear stop weave.
• The metal frame, the mechanisms, and off-the-shelf components will be made from stainless steel.

These materials have been selected for their strength, resistance to breakage and or damaged, weather resistances properties, and recyclability.

MANUFACTURING

The design makes use of several different manufacturing techniques:
• The case is extruded.
• The end caps and end protectors are injection moulded.
• The wrap is produced using laser die cutting and sewing.
• The straps are produced use sewing.
• The metal frame is produced using metal bending
• The handle is created using insert moulding.
• Custom stainless steel parts are created using casting.

All other parts are off-the-shelf components and as such can be purchased.

Final Model

SUMMARY

The Roller Wrap will help the retail industry meet the APCO Australia’s 2025 National Packaging Targets of which many are signatories, by being reusable and removing the need for the identified problematic single-use and disposable plastic packaging currently in use. The Roller Wrap also meets the identified key criteria as it is also integrates with existing systems, processes, vehicles, equipment, infrastructure, and other packaging, prioritises safety, is quick and easy to use, while also fulfilling the role of the single-use and disposable tertiary packaging it has been designed to replace.

That’s a wrap!

The proposed design, the Roller Wrap.

David Quick

David has found his passion in industrial design, with its blend of technical skills and creativity. He is passionate about using creative problem solving to provide innovative solutions to produce meaningful and positive change.