28 MARCH 2026 | Omni Group
Darrell Lea NSW Case Study: Less Plastic, Cleaner Pallets and Reliable Supermarket Compliance
For Darrell Lea NSW, wrapping pallets correctly plays an important role in keeping product moving smoothly into major supermarket networks.
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 tail dags, as these can lead to pallets being rejected.
Working with Omni, Darrell Lea introduced the Superplus Pallet Wrapping Machine, supported by Elite Machine Stretch Wrap, machine tape and labels. The result has been a more consistent wrapping process, a 20% reduction in plastic usage and costs, and zero non-conformances with supermarkets.
About Darrell Lea NSW
Darrell Lea is one of Australia’s most recognised confectionery brands, supplying well-known chocolate and liquorice products to retailers across the country.
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.
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.
A key issue was pallet finish. For supermarket deliveries, especially Woolworths, pallets cannot have tail dags. If the wrap is not finished properly, the pallet will be rejected, which creates delays, extra handling and excessive costs.
The team also wanted to reduce plastic use without creating any issues with load containment or pallet stability. Any change to the wrapping process needed to save material while still protecting the product and ensuring pallets were compliant with supermarket standards.
The Solution
Omni supplied the Superplus Pallet Wrapping Machine, tailored to suit Darrell Lea’s operation.
The machine was set up with custom-made ramps, making it easier to move pallets on and off the wrapper. It was also fitted with built-in scales, helping the team weigh pallets as part of the wrapping process rather than adding extra steps after the pallet was wrapped.
Another benefit of the Superplus is the clean wrap finish. The machine does not leave film tail dags, which is critical for Darrell Lea’s supermarket deliveries. This helps the team avoid pallets being rejected and gives them confidence that loads are leaving their site in the right condition.
To support the machine, Darrell Lea also uses Elite Machine Stretch Wrap, along with machine tape and labels supplied by Omni. This gives the site a more complete packaging solution, rather than treating machinery and consumables separately.
The Results
Since moving to the Superplus and Elite wrap, Darrell Lea has achieved a 20% reduction in plastic use and costs.
Importantly, this has been done without compromising pallet quality or supermarket compliance. The site has recorded zero non-conformances with supermarkets, with the Superplus helping deliver clean, consistent pallets with no tail dags.
The customised solution 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 in plastic and costs
- Zero non-conformances with supermarkets
- No tail dags, helping meet Woolworths requirements
- Custom-made ramps for easier pallet handling
- Built-in scales to support the wrapping process
- Use of labels, machine tape and Elite wrap
- Ongoing service and preventative maintenance from Omni
