OT: How to shrinkwrap

riredale wrote on 5/6/2008, 2:28 PM
Okay, so I invest thousands of hours in creating that attractive DVD or CD, complete with surround sound, liner notes, and artsy cover, but when someone buys it, something's not quite right. Of course! It's not shrinkwrapped!

In the past I would occasionally go to a fulfillment house or even a local Kinko's or OfficeDepot store, but doing so was not that much fun. For one thing, the results seemed to vary quite a bit. For another, many places charge a base price and then a unit cost. Plus, I actually had to drive somewhere in order to get it done.

Finally, last week I decided to try for myself. After a bit of on-line sleuthing, I settled on a kit provided by a merchant down in Los Angeles. The whole cost for the sealer, heat gun, a ton of bags, and even a power strip was about $84 (no sales tax here in Oregon).

Today the kit arrived, and I've put an hour or two into learning how to do this. No doubt many of you are old hands at this, but for the newbies, here's a few things I've learned so far:

For your $84 you get a really cool heat gun that looks just like a Soviet-era hair dryer. It puts out a ton of heat, though, and is very quiet in operation. Be careful. In addition you get an "impulse" wire sealer. This little guy has a jaw capacity of 8", which is smallish but perfectly suited to sealing up CDs and DVDs. Built like a tank and nearly as heavy, it contains circuitry to make your task error-free.

You can order a variety of heat-shrinkable bags. I chose the ones measuring 6.5 x 10.5 inches, suitable for either CD or DVD box. You get 500 (!), which should keep you going for a while. They also throw in a beefy-looking power strip. Okay, fine, don't need another one, but whatever.

Here's a photo of the stuff they shipped. Not shown are the small manuals and a wire replacement kit for the sealer.

Here's the drill. You put your DVD case inside a bag, set the impulse sealer to "2" on the dial scale, put the open end of the bag through the jaws so that about 1/2" of space is next to the DVD case, and press down the top lever. The electronics heat up a hidden wire for maybe 1/2 second, and a light goes out.. That's it. You remove the bag, unzip the excess bag end (it unzips away very nicely) and move to the heat gun.

Put the heat gun on "low" and while holding the bag up in the air by one corner, run the gun relatively slowly along two edges, about 6" away from the bag. The material miraculously squinches up as you go. Then hold the assembly by the opposite corner, and do the last two edges. Many times the shrinkage on the edges is enough to make for an attractive finished look, but if necessary, hit the front and back of the DVD box to tighten up the material there.

That's it! Your DVD and/or CD is now shrinkwrapped, and it looks very nice. Here's a photo of the edge of a CD case. Looks just like the ones you get in stores.

A couple of thoughts:

(1) Go easy on hitting the faces with the heat gun. Some wrinkles just don't want to come out, and if you apply heat a millisecond longer than necessary you get a hole in the shrinkwrap. Do it again.

(2) A hairdryer just can't cut it, at least the one I tried. It's rated at 1,800w, but it produces tons of warm air. The heat gun produces a modest amount of really hot air. Plus, the hair dryer racket will make you deaf.

(3) The CDs and miniCDs shrinkwrapped beautifully, with very clean edges and drum-tight faces. The DVD boxes don't come out quite as mirror-like on the faces, perhaps because of the soft plastic box overlay.

(4) You don't need to use bags; the conventional folded-over shrinkwrap material will work fine. It just means you will have to seal on more sides, that's all.

I should have done this years ago.

Comments

craftech wrote on 5/6/2008, 6:01 PM
Thanks Riredale,

That was much appreciated. Makes me want to try it myself.

John
farss wrote on 5/6/2008, 6:10 PM
Thanks from me too, if I could get one that runs on 240V locally for a reasonable price I'd be buying it real quick. I do have 110V AC available but going by the weight of that unit shipping it down under might be very expensive. I do have a real hot air gun though. The ones made for use as paint strippers / for heats shrink tubing should work just fine. As you've noticed hair dryers are useless.

Bob.
richard-courtney wrote on 5/6/2008, 6:52 PM
Thanks for the info.
Between my wife and me we have done almost everything including silk screening,
this completes it.
TGS wrote on 5/6/2008, 7:22 PM
Although thin, I've heard Saran wrap works too. I've never tried it. Somebody told me.
Probably better with a hair dryer.
DGates wrote on 5/6/2008, 8:01 PM
I eventually abandoned this process because, as you noted, the heat will cause ripples in the DVD case cover. But it would work great for DVD jewel boxes or CD's.

The good alternative for standard DVD cases is to use a cold-wrap. These are snug fitting sleeves that have a adhesive strip. Pull the strip, press down and you're done. No heat required.

http://www.meritline.com/145mm-dvd-case-opp-clear-bag.html
CClub wrote on 5/6/2008, 8:32 PM
With both the heat and cold wrap options, this is an incredibly helpful post. I'm doing a project at the end of the month, with only 50 discs, but at discmakers it was going to cost me about $500. I was going to subcontract that to them, but now I'm likely going to burn them myself on nice waterproof printable discs for maybe $75 or so (?), I already have a huge box of cases, and I pick up either sealing system and I'm up about $300 additional dollars and I have a heat sealing system for the future. Thanks for a great post. What a great forum.
Coursedesign wrote on 5/6/2008, 9:41 PM
the heat will cause ripples in the DVD case cover

There's a reason shrink wrap film comes in different thicknesses...

(I bought my machine at an L.A. trade show from an East Coast manufacturer. It was a booth demo and I just offered to save them the cost of return shipping (it was a larger machine, which I needed). Used for five days, I got it for 35% off plus they threw in a huge roll of super quality shrink wrap for free :O).
farss wrote on 5/6/2008, 10:41 PM
For those who don't live in the USA:

I exchanged a couple of emails with Jay from The Shrink Wrap Store, really nice people, anyone who even replies is the exception these days!

More than happy to ship anywhere however the freight cost about doubles the price. I can buy a sealer and heat gun pretty cheaply locally that does run on 240V. I can also get rolls of shrinkwrap 'tube'. It's expensive but given how thin it is one roll would do 1,000s of DVDs. Downside is you've got to seal three sides and then shrink it.

The Shrink Wrap Store came to the rescue. They're more than happy to sell just the bags and a LOT of them will fit into a cheap to ship Fedex bag. I might give this approach a try. I've already got a heat gun so only need to buy the sealer.

One tip. Also handy of you need to store kit for a long period.

Bob.
riredale wrote on 5/7/2008, 12:10 AM
Farss:

The 500 bags weigh 44oz (just under 3lb), or about 1.25 kilos if I did my math right.
farss wrote on 5/7/2008, 5:27 AM
Thanks,
seems you can fit 3,000 into a UPS flat rate box and it's only USD 38 to ship to Australia. I imagine it's no more to ship anywhere else in the world, well maybe Mongolia would cost more.

Bob.

David Settlemoir wrote on 5/7/2008, 12:19 PM
I use the meritline non-shrink ones too. Clients seem to like them because they are resealable.