Instead of sending every pallet load to a stretch wrapping machine Miller now secures most of its loads with a cohesive liquid that is applied by spray nozzles mounted near the end of the packaging lines. A photo-eye triggers the nozzles to spray the tops of corrugated cases as they pass down the conveyor. Treated cases are immediately stacked on a pallet where they bond or lock together as they dry. A case can be separated by lifting its corner straight up to break the seal. The company decided to test the new system after a review of its palletizing operations says Mike Rauh technical packaging coordinator of corporate quality assurance. "What we needed to do" he explains "was to eliminate the double handling required to wrap our pallet loads." At that time Miller relied on off-line wrappers to apply stretch film to secure pallet loads. That meant moving loads by forklift from the palletizer to the stretch wrapper and then moving from the stretch wrapper to the truck. The in-line spray system means loads are moved only once from the palletizer to the truck. Not only does that reduce labor costs but it also frees up floor space that had been occupied by the wrappers. Called Lock'N'Pop the system is manufactured by Key Tech Corp. (Mukilteo WA) and was first tested at the Trenton plant a couple of years ago. Since then Miller has reported a 20% reduction in handling costs and a 10% reduction in material costs.