Industrial - Honours
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.
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.
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.
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.
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.
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.
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!
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.