UK Specialist Chemical Supplier Improves Product Protection with a Dual-Material Cirrus Setup

UK Specialist Chemical Supplier Improves Product Protection with a Dual-Material Cirrus Setup

A leading UK specialist chemical supplier serving research, pharmaceutical, biotechnology and materials-science customers installed two Cirrus Maxx systems from Severn Packaging, each configured to produce a different 400mm protective material.

One system runs SoftLayer for flexible product wrapping, while the second runs MultiPocket for wrapping, cushioning and void filling. Keeping both materials permanently available helps warehouse operators select the most appropriate protection for each product without repeatedly changing rolls or machine settings.

The Customer

The customer supplies an extensive range of specialist chemicals to research and industry customers across the UK, Europe and worldwide. Its warehouse packs products with different sizes, shapes and protection requirements, making it difficult for one protective material to provide the best solution for every application.

The company has not been named in this case study at its request.

The Challenge

The customer required a more flexible protective packaging process for a varied product range. Some products needed to be wrapped securely to protect surfaces, edges and corners, while other shipments required a combination of wrapping, cushioning and void filling within the carton.

Although one machine could run both film formats, regularly changing between materials would interrupt the packing process and make it less convenient for operators to select the best protection for each order.

The customer also wanted to improve equipment reliability. Its previous air-cushion machines contained several wearable components that required regular attention and replacement, affecting uptime and increasing maintenance requirements.

The project therefore focused on:

• Making two complementary protective materials immediately available.
• Matching the packaging material more closely to each product.
• Reducing material and machine-setting changeovers.
• Improving efficiency during busy packing periods.
• Reducing recurring wear-part maintenance.
• Increasing protective packaging uptime.

The Severn Packaging Solution

Severn Packaging installed two Cirrus Maxx inflatable protective packaging systems side by side, creating a dedicated dual-material packing station.

400mm SoftLayer for Product Wrapping

The first Cirrus Maxx produces 400mm SoftLayer. Its flexible connected-cell structure is designed to wrap around products, providing adaptable coverage across surfaces, edges and corners.

SoftLayer is selected when the principal requirement is to wrap and cushion an individual product before it is placed into the outer carton.

400mm MultiPocket for Wrapping and Void Filling

The second Cirrus Maxx produces 400mm MultiPocket. Its pocket configuration provides a hybrid protective solution that can be used for product wrapping, cushioning and filling empty space within a carton.

MultiPocket is selected when the application requires a more versatile combination of product protection and carton stabilisation.

Two Materials Permanently Ready

Assigning one system to each material means warehouse operators do not need to remove a roll, load the alternative format and change the machine setup. Both materials are available throughout the working day, making correct material selection quicker and easier.

A Simpler Machine Design

The Cirrus Maxx uses internal-sealing technology, removing the need for the conventional cutting blade and separate perforation-breaking mechanism found on many air-cushion machines. With fewer wearable items requiring routine attention, the new systems also address the uptime problems experienced with the customer’s previous equipment.

The Results

Protection Matched to the Product

The warehouse can now choose between a dedicated wrapping material and a hybrid wrapping and void-fill solution. This allows the protection method to be selected around the individual product and carton rather than applying the same material to every shipment.

No Routine Material Changeovers

SoftLayer and MultiPocket remain permanently loaded on separate systems. Removing routine roll and setting changes saves operator time and keeps both protective formats immediately available.

Improved Packing Efficiency

Operators can move directly to the appropriate system, produce the required quantity and continue packing. This creates a simpler workflow and is particularly valuable when order volumes increase.

Better Uptime

The Cirrus systems contain fewer of the wearable items that caused recurring problems on the previous machines. Reduced maintenance intervention gives the warehouse greater confidence that protective packaging will remain available when required.

Key Project Benefits

• Dedicated dual-material protective packaging station.
• 400mm SoftLayer permanently available for flexible product wrapping.
• 400mm MultiPocket permanently available for wrapping, cushioning and void filling.
• Protection selected according to the product and carton.
• No routine changeovers between the two materials.
• Reduced machine setup interruptions.
• Simpler material selection for warehouse operators.
• Improved efficiency during busy packing periods.
• Internal-sealing technology.
• Fewer wearable items requiring regular attention.
• Reduced maintenance interruptions and improved uptime.

Customer Comment

“Having SoftLayer and MultiPocket available on separate machines makes it much easier for the team to choose the right material for each product. We no longer need to change rolls between applications, and the Cirrus systems have fewer wearable items than our previous machines, which has helped improve uptime.”

Warehouse Manager
UK Specialist Chemical Supplier

Severn Packaging Comment

“The key benefit is the material configuration. SoftLayer is an excellent flexible wrapping material, while MultiPocket provides a useful combination of wrapping, cushioning and void filling. Giving each material its own Cirrus Maxx means both are always ready, so operators can select the best protection for the application without losing time to changeovers. The simpler internal-sealing design and improved uptime are valuable additional benefits.”

Lee Williams
Sales Director, Severn Packaging

More Than One Product Can Require More Than One Protective Material

Protective packaging works best when the material is selected around the product, carton and distribution risk. Severn Packaging assesses the complete packing process and can configure single or multiple Cirrus systems with complementary materials for wrapping, cushioning and void filling.