🐾 Case Study: Nova Products – From Shrink Wrapping at 10 ppm to Flow Wrapping at 60 ppm

Nova Products improved output and packaging consistency by switching to a GSP 50s flow wrapper — shown here during manual feeding trials.

A True Production Turnaround with the GSP 50s Flow Wrapper

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🏭 Background

Nova Products, an Australian pet-treat manufacturer, was packaging treats on a small shrink-wrapper line that managed only around 10 packs per minute.Each pack still required a manually applied label, which slowed production and added recurring labour costs.

To modernise the process, PacMatix proposed a GSP 50s horizontal flow wrapper fitted with print-registration film control, enabling the use of pre-printed film for fully finished retail packaging in one automated step.

⚙️ Engineering & Trial Phase

Before installation, PacMatix engineers ran multiple material trials in our Carrum Downs workshop using a showroom GSP 50s flow wrapping machine. We tested films from several suppliers to find the best combination of sealability, tack, and appearance.

Ultimately, we partnered with Filton Packaging, whose high-tack, high-seal film produced the cleanest results. Filton also provided graphic design and print artwork support, helping Nova transition smoothly to pre-printed rollstock.

Ryno from PacMatix conducting setup and operator training on the GSP 50s flow wrapper at Nova Products during installation and commissioning.

🖨️ Automation Add-ons

To further streamline the line, we integrated a thermal ink-jet printer for on-film date coding — eliminating the final manual step of applying stickers.

🎥 Watch the GSP 50s in Action

A quick demo of the Nova Products line during early production runs — showing stable film tracking, consistent sealing, and efficient manual loading

📈 Results & Performance

Mark Murphy from LM Engineering,  modelled the project in detail, assuming a nominal 70 ppm speed with a 70 % efficiency factor — equivalent to around 60 packs per minute in real-world conditions.

Metric	Before (Shrink Wrapper)	After (GSP 50s Flow Wrapper)
Production Speed	10 ppm	≈ 60 ppm
Labour Per Shift	2 operators + labelling	1 operator
Cost per Pack	$ 0.09	$ 0.05
Cost per Carton	$ 2.48	$ 1.45
ROI Payback	—	< 12 months (verified model)

💰 The ROI in Action

Annualised saving:

At 35 000 packs per day and 240 operating days, Nova saves roughly $336000 per year.

That’s a six-figure saving achieved through labour reduction, film efficiency, and throughput increase — delivering payback within 12 months with money in the bank!

🧰 Installation & Training

Once the GSP 50s was delivered and commissioned, Ryno from PacMatix worked directly with Nova Products’ production team to ensure a smooth start-up and full operator confidence.

During on-site training, Ryno covered:

• Film threading and print-registration setup

• Change-over procedures between product runs

• Preventative maintenance checks and cleaning points

• On-film coding verification using the integrated inkjet printer

By the end of the first production day, Nova’s operators were comfortably running at over 50 packs per minute with consistent sealing quality.

PacMatix’s involvement doesn’t end at installation — our Aftersales Support program provides ongoing assistance, spare parts supply, and technical advice to keep production running efficiently long after commissioning..

Hands-on training session — Ryno guiding Nova Products’ operator during first production runs with the new GSP 50s.

"Installation of our new flow wrap machine went in without a hitch. Ryno spent 3 days with our operators to ensure they are in a good position to run product. I have been so impressed by how quickly we became operational. Thank you" - Melanie Parker (Production Manager)

"We bought a flow wrapper from Ettiene at Pacmatix and upon testing multiple products and run rates, this is by far the best one not only quality of machine but also the level of support. I have called the team for support on random times and they have always delivered. The team at Pacmatix really understands the business goals and provides necessary support and the equipment for the job. If you want peace of mind and deliver your business target reach out to Pacmatix" . Mark Murphy (Project Consultant)

🎨 Visual Summary

Switching from manual shrink wrapping to a GSP 50s flow wrapper cut Nova Products’ packaging cost per pack by around 44%, while increasing output sixfold.

Automating with the GSP 50s flow wrapper boosted production speed from 10 to 60 packs per minute — a sixfold increase in throughput.

The GSP 50s flow wrapper reduced manual labour from two operators with manual labelling to one operator per shift — cutting labour requirements by around 50%.

Typical payback achieved in under 12 months through combined labour savings and film efficiency improvements after installing a GSP 50s flow wrapper.

🧩 Collaborative Success

This project succeeded thanks to teamwork between:

• PacMatix — system design, testing, installation, and operator training

• Filton Packaging — film selection, design, and printing

• LM Engineering — project management and ROI analysis

  
  

Together, the group delivered a fully automated, efficient, and attractive packaging line that strengthens Nova’s market competitiveness.

Explore more:

• 🔗 GSP 50s Flow wrapper

• 🔗 GSP Flow Wrapper Range

• 🔗 More Case Studies

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• 🔗 Kwik Tech Gems

Frequently Asked Questions:

1: How long does a typical GSP 50s installation and training take?

 Most installations are completed within 2–3 days, including operator training and initial production runs. PacMatix ensures your team is fully confident before handover, with follow-up support available anytime through our Aftersales Support program.

2: Can the GSP 50s flow wrapper run different product sizes or pack styles?

Yes. The GSP 50s features servo-driven changeovers that allow fast adjustments between product formats. With recipe storage and adjustable formers, operators can switch runs in minutes without tools.

3: What type of films does the GSP 50s support?

The GSP 50s is compatible with a wide range of materials — from standard OPP and laminated films to sustainable paper-based substrates. PacMatix can help test and validate new materials before production.

4: How does PacMatix support customers after commissioning?

 Our Aftersales Support team provides ongoing maintenance, spare parts, and remote technical assistance to ensure long-term uptime and performance reliability.

5: What kind of ROI can be expected when upgrading from manual wrapping?

While results vary by application, customers typically see payback in under 12 months through reduced labour, higher throughput, and improved film efficiency — as demonstrated in this Nova Products case.