28 MARCH 2026 | Omni Group
Darrell Lea NSW Case Study: Less Plastic, Cleaner Pallets and Reliable Supermarket Compliance
For Darrell Lea NSW,ย wrapping pallets correctlyย plays an important role in keeping product moving smoothly into major supermarket networks.ย
Overview
The team needed a wrapping solution that could reduce plastic use, improve pallet presentation and meet the strict requirements of retailers such as Woolworths. One of the biggest priorities was avoiding tailย dags, as these can lead to pallets being rejected.ย
Working with Omni, Darrell Lea introduced theย Superplusย Pallet Wrapping Machine, supported byย Elite Machine Stretch Wrap,ย machine tapeย andย labels. The result has been a more consistent wrapping process, aย 20% reduction in plasticย usage and costs, andย zero non-conformances with supermarkets.ย
About Darrell Lea NSW
Darrell Lea is one of Australiaโs most recognised confectionery brands, supplying well-known chocolate and liquorice products to retailers across the country.ย
At the NSW site, pallets are prepared for supermarket distribution, where presentation, load stability and compliance all matter. Every pallet needs to leave site wrapped correctly and ready to meet retailer expectations.ย
The Challenges
Darrell Lea needed more than a standard pallet wrapper. The machine had to suit the way the site operated and help the team meet supermarket standards day in, day out.ย
A key issue was pallet finish. For supermarket deliveries, especially Woolworths, pallets cannot have tailย dags. If the wrap is not finished properly, the palletย willย be rejected, which creates delays,ย extra handling and excessive costs.ย ย
The team also wanted to reduce plastic use without creatingย anyย issues with load containment or pallet stability. Any change to the wrapping process needed to save material while still protecting the product andย ensuringย pallets were compliant with supermarket standards.ย
The Solution
Omni supplied theย Superplusย Pallet Wrapping Machine, tailored to suit Darrell Leaโs operation.ย
The machine was set up withย custom-made ramps, making it easier to move pallets on and off the wrapper. It was also fitted withย built-in scales, helping the team weigh pallets as part of the wrapping process rather than adding extra stepsย after the pallet was wrapped.ย
Another benefit of theย Superplusย is the clean wrap finish. The machine does not leaveย filmย tailย dags, which is critical for Darrell Leaโs supermarket deliveries. This helps the team avoidย pallets being rejectedย and gives them confidence that loads are leavingย theirย site in the right condition.ย
To support the machine, Darrell Lea also usesย Elite Machine Stretch Wrap, along withย machine tapeย andย labelsย supplied by Omni. This gives the site a more complete packaging solution, rather than treating machinery and consumables separately.ย
The Results
Since moving to theย Superplusย and Elite wrap, Darrell Lea has achieved aย 20% reduction in plastic useย and costs.ย
Importantly, this has been done without compromising pallet quality or supermarket compliance. The site has recordedย zero non-conformances with supermarkets, with theย Superplusย helping deliver clean, consistent pallets with no tailย dags.ย
The customisedย solutionย has also made the wrapping process easier for the team. The ramps support better pallet handling, while the built-in scales help streamline the process on site.
Key Outcomes
- 20% reduction inย plasticย and costsย
- Zero non-conformances with supermarketsย ย
- No tailย dags, helping meet Woolworths requirementsย ย
- Custom-made ramps for easier pallet handlingย ย
- Built-in scales to support the wrapping processย ย
- Use of labels, machine tape and Elite wrapย ย
- Ongoing service and preventative maintenance from Omniย
