Form a repeatable group
Define product count, pattern, diameter or width, height, filled weight and the least stable container. Upstream guides and collation should form the same group without scuffing, tipping or excessive line pressure.
Multipack design guide
Tray, pad or trayless shrink wrapping: which multipack format is suitable?
A tray adds side and base support, a pad supports the base with less containment, and a trayless pack relies more heavily on product geometry, collation and film. Test the complete handling route after cooling.
Direct answer
Pack support and film work together after the tunnel
Choose a tray when the group needs strong base and side support, a pad when base support is useful but a full tray is unnecessary, or trayless wrapping when the containers can remain collated through wrapping, shrinking, cooling and distribution. The decision depends on product stability, bundle weight, film construction, opening sides, lifting, accumulation, pallet pattern and transport testing—not on film reduction alone.
| Pack route | What provides support | Key questions |
|---|---|---|
| Tray and shrink film | Tray base and sides plus the contracted film | Tray strength, product fit, film coverage, open sides, stacking and pallet handling |
| Pad and shrink film | Flat base support plus product geometry and film | Pad stiffness, product containment, transfer, film pull, lifting and edge exposure |
| Trayless shrink bundle | Product-to-product contact, collation geometry and film | Container stability, pack weight, film duty, guide pressure, cooling and handling route |
Engineering sequence
Design the bundle around the full movement path
Confirm the sleeve-film duty
Use the production PE or other approved sleeve film and record supplier, construction, gauge, width, print and perforation. Film must create the accepted open sides and bundle stability without damaging labels, closures or products.
Prove tunnel loading and cooling
Closely spaced heavy packs can change thermal loading. Run representative pitch, gaps and restart, then support the warm bundle until the film and pack reach the accepted handling condition.
Test the next operation
Lift, turn, accumulate, case-pack or palletise the bundle as production will. A pack that survives a short hand carry is not automatically suitable for conveyor transfers or distribution.
Multipack evidence to provide
- Container dimensions, filled weight, material, closure and surface condition.
- Pack count, row pattern and acceptable product orientation.
- Tray or pad drawing and material where used.
- Production film code, gauge, width, print and perforation.
- Required side opening, carrying method and pallet pattern.
- Upstream collation, target accepted output, discharge support and cooling.
- Handling and transport acceptance checks after full cooling.
Buyer questions
Questions about tray, pad and trayless shrink bundles
Can bottles and cans be shrink wrapped without a tray?
Some bottle and can groups can be trayless when the container geometry, collation, total weight, film and handling route create a stable bundle. The least stable pack should be tested through transfers, cooling, accumulation and pallet handling. Do not assume a trayless result from a short manual sample alone.
When is a pad useful instead of a full tray?
A pad can provide a stable base and distribute load while leaving the sides more open. It may suit groups that do not need tray walls but still need support through conveyors, lifting or stacking. The pad material, dimensions and position must be included in the trial.
Does a tray or pad change the tunnel process?
It can. A tray or pad changes pack mass, airflow access, support and the way film contacts the group. Use the complete production pack when setting speed, temperature and airflow, and prove the process under sustained loading rather than transferring a trayless recipe.
What film should be used for a trayless multipack?
The film must be selected with the supplier and machine provider for the real pack weight, geometry, sleeve-seal route, required open sides and handling duty. PE shrink film is commonly considered for robust bundles on this site, but the exact construction and gauge must be trialled rather than assumed.
How should multipack stability be tested?
After full cooling, repeat the intended lift, conveyor transfers, turns, accumulation, case or pallet placement and any defined transport simulation. Inspect product movement, film tears, base support, side openings and whether the accepted pack remains consistent after production gaps and restarts.
What information is needed for a tray or trayless quotation?
Send filled containers, count and pattern, complete weight, tray or pad drawing, production film, accepted bundle, target sustained output, line height, collation method, cooling distance and pallet or downstream handling. Include every container format expected on the machine.
Technical provenance
This Lancing Ltd guide supports initial pack-design discussion. Final tray, pad or trayless suitability depends on production containers, film, handling and agreed trial evidence. Send the multipack details to Lancing.
Multipack review
Test the bundle after it has cooled and entered the real handling route
Send containers, pack pattern, tray or pad, film, target output and downstream handling so the complete duty can be reviewed.