Running cost is a line result, not a single machine number
The running cost of a sleeve sealer depends on film usage, shrink tunnel heat demand, rejected packs, labour involvement, changeover time, maintenance condition and whether the line can run without unnecessary stops.
A useful cost review starts with the real pack, the PE film specification, the agreed output window and the way products enter and leave the sleeve sealer. Quoting a headline machine price does not show how much film is wasted during setup, whether the tunnel is overloaded, or whether operators have to intervene to correct unstable bundles.
Main running-cost drivers
| Cost driver | What changes it | Evidence to collect |
|---|---|---|
| PE film consumption | Film width, overlap, gauge, rejected packs, setup length and poor roll control. | Film roll data, pack path, accepted/rejected count and setup waste. |
| Shrink tunnel energy | Warm-up, aperture, belt speed, dwell time, airflow, pack spacing and idle running. | Run pattern, shift timing, stable settings and actual loading. |
| Labour | Manual collation, format change, film loading, first-off checks and fault recovery. | Operator tasks, intervention frequency and changeover record. |
| Rejects and rework | Weak seals, holes, loose shrink, skew, contamination, product damage or blocked discharge. | Defect reason log and finished-bundle acceptance standard. |
| Maintenance | Condition of sealing components, belts, film path, tunnel cleanliness, sensors and guarding. | Inspection schedule, wear items and repeat fault history. |
Reduce cost without reducing pack quality
The safest reductions normally come from approving the correct film width, keeping the tunnel within a stable process window, reducing setup waste and removing avoidable stops. Reducing film thickness or heat too far can move cost into rejects, rework, complaints or transit damage, so changes should be tested against the finished-bundle acceptance criteria.
- Record the approved pack construction and film data.
- Measure accepted packs, rejects and setup waste separately.
- Check tunnel settings only after film and seal quality are controlled.
- Include changeover and restart waste in the operating picture.
- Review the full line, not only the wrapper.
Questions to answer before comparing running cost
Is tunnel energy always the largest running cost?
Not always. Tunnel energy can be significant, but film waste, rejected packs, manual intervention, changeover time and lost production can also dominate the real running cost.
Measure the process over a representative period rather than comparing only installed power or a catalogue value.
Does thinner PE film automatically save money?
Thinner film only saves money when the finished bundle still meets the agreed seal, shrink, handling and transit requirements with no rise in rejects.
Trial the film on the real product and downstream handling route before changing an approved specification.