Flexible Packaginglearns more about roll handling and roll packaging solutions from Tom Duffy, national sales manager, Badger Plug.



Q: Are any roll protection solutions designed to minimize labor applied in preparing roll shipments?

A: Roll protection solutions that unitize multiple rolls reduce time and materials. Products like single-piece pad plugs combine core plug with suspension ends to simplify assembly and packaging. Some products, like double plugs for unitizing slit rolls, are well-suited to robotic handling. Through innovative product design, labor costs can be reduced or eliminated.

Q: What are the current trends regarding the recycling of roll packaging components?

A: Recycling of roll packaging products is very popular today. With high disposal costs and a keen eye on the environment, recycling really pays off. A large segment of Badger Plug’s business focuses on recycling. We collect product from most areas of the country, which is then inspected, refurbished and sold at significant cost savings. It is vital that these products be recycled through a reputable vender to assure that the used product meets the expected standards. Inferior roll protection, whether with new or used components, creates nothing but headaches.

Q: How does one determine the best roll packaging solution?

  A: Roll packaging should provide efficient handling and proper protection. To determine the best solution, one must consider a number of criteria, including roll weight, material type and cost of protection versus exposure to damage costs. Today we can provide many solutions that unitize small- to large-sized rolls for palletized shipping. Custom solutions, like the patented Roll Handler that unitizes and protects larger rolls, are also cost effective options.

Q: What questions should customers ask when seeking roll handling solutions?


A: The most common misconception about roll protection is that the best solution must be the most inexpensive option. As with most things, you get what you pay for. Every roll shipment or package is different. That’s why we produce more than 500 different models, sizes and configurations of “basic” roll protection products. Talk to a professional to attain the best advice and, in the end, the right solution. 

Q: Why is roll protection important today?

A: With the increased cost of roll goods, the need for better protective packaging continues to grow. The costs to rectify damaged product is more expensive today than ever. In addition, there is the immeasurable cost of diminished customer satisfaction when receiving damaged product.

Q: How would you describe roll handling trends today?

A: Roll sizes have been increasing for a number of years. The pace of this change is not quite what many in the market expected. Increased roll sizes present a number of obstacles for roll producers and downstream converters. Ultimately, roll size restrictions are controlled by the equipment needed to run the rolls.

Today’s larger rolls need better, more robust protective packaging. In the last 3 to 5 years, we’ve introduced solutions for individual and multiple large-roll shipments. One was engineered specifically to meet the challenges of long-distance/overseas transport. 

Badger Plug
(920) 757-7300; www.badgerplug.com