Pallet Stretch Wrap: Film Specs for Load Stability

Pallet Stretch Wrap: Film Specs for Load Stability

Pallet stretch wrap is bought on price far more often than it is bought on performance, and the cost of that shows up later — as shifted loads, torn film on arrival, and claims that are almost impossible to win because nobody recorded what film was used. Load stability is not a property of the film alone. It is the result of a film specification matched to a specific load, applied with the right wrap pattern and the right amount of stretch.

This guide sets out the stretch wrap film specs that actually control whether a pallet survives a container journey, and how to specify them for export packing rather than for a warehouse floor. If you have not yet chosen between hand-applied and machine-applied film, start with our comparison of hand stretch film vs machine stretch film and come back to this page for the specification detail.

What Makes a Pallet Load Stable in Transit?

A pallet stays together because the film holds the load under continuous tension. That tension is produced by stretching the film as it is applied, and it is maintained by the film's elastic recovery — the film's tendency to pull back towards its original length after being stretched. Four factors decide how well that works.

Factor	What it controls	Set by
Film thickness	Puncture resistance and holding force per layer	Film specification
Pre-stretch	How much tension is stored in the film	Machine setting or operator technique
Wrap pattern	Coverage of corners, base and top	Wrapping programme
Containment force	The resulting pressure holding the load	The three above combined

The practical point is that thickness alone does not make a load stable. A heavier gauge applied with too little pre-stretch can hold less securely than a lighter gauge applied correctly. Conversely, a film stretched beyond its elastic limit will relax, and the load will loosen in transit no matter how many layers are applied.

Which Film Specs Actually Control Load Stability?

Five specification lines appear on every stretch film quotation. Knowing what each one does tells you which to negotiate and which to leave alone.

Thickness and gauge

Machine Stretch Film thickness is normally quoted in microns. Our films are produced across an 8–23 micron range. Thin film gives more metres per kilogram, which lowers cost per pallet; thicker film resists punctures from sharp corners and irregular loads. For a uniform load of cartons, a mid-range gauge applied at high pre-stretch is usually the most economical answer. For pallets with protruding edges, brick packs or metal components, step up the gauge rather than adding layers.

Roll width

Stretch film gauge and width work together. A narrow roll concentrates force but needs more revolutions to cover the load; a wider roll covers faster but wraps around irregularities less tightly. Our rolls are supplied from 5 cm to 100 cm wide, which covers everything from small hand rolls to full-width machine film. Match the width to your pallet height and to the number of wraps your programme is designed to apply.

Roll length and core

Length runs from 5 m to 2000 m. Longer rolls mean fewer roll changes and less downtime on an automated line, but a heavier roll to lift on a manual one. Core diameter has to match the machine's chuck — this is a common cause of a first order being unusable, so confirm the core size against the wrapper manual before ordering.

Pre-stretch ratio

Modern wrappers pre-stretch film before it reaches the load, typically in the region of 150% to 250%. Higher pre-stretch uses less film per pallet and increases holding force, up to the point where the film starts to whiten or tear. Ask the machine manufacturer for the film's maximum recommended pre-stretch, and ask your film supplier to confirm the film is specified for that ratio rather than for hand application.

Cling and one-sided tack

Machine film usually carries cling on one side only, so the film bonds to itself as layers overlap without sticking to the machine rollers. If your line jams or the film blocks on the roll, the cling configuration is the first thing to check.

What Is Containment Force and How Do You Measure It?

Pallet wrap containment force is the pressure the film exerts on the load once wrapping is complete. It is the number that correlates most closely with whether a pallet arrives intact, and it is the number almost nobody records.

It is measured with a force gauge: the probe is pushed against the side of the wrapped pallet and the force needed to deflect the film is read off. Take readings at several heights and on more than one face, because corners and the top layer behave differently from the middle of a flat side. Record the readings, the film specification, the pre-stretch setting and the wrap pattern together — that combination is your packaging standard, and without it a damage claim has no baseline.

If you do not have a gauge, the practical substitute is to film a trial pallet, transport it over a realistic route, and inspect it on arrival. It is cruder, but it still produces a written record, which is more than most exporters have.

What Changes When the Load Goes to Sea?

Stretch film for export packing has to survive conditions a domestic pallet never sees. Three differences matter, and each one argues for a specification slightly stronger than the warehouse version.

• Transit duration. A container journey of several weeks gives film far more time to relax and lose tension than a same-day delivery. Higher initial containment force compensates for the loss.
• Temperature cycling. Containers on deck or in direct sun can reach high internal temperatures, softening the film, while night-time conditions cool it again. Film that relaxes in heat will not recover its original tension.
• Handling. Container stuffing, port cranes and destination unloading all involve more rough handling than a warehouse. Corners are where film fails first, so corner protection or additional wraps at the base and top layers earn their cost.

Humidity is a further consideration for hygroscopic goods, though here the film is doing a secondary job: it keeps moisture out as much as it keeps the load together. If your product is moisture-sensitive, say so when specifying — it changes how much of the pallet needs covering, including the top.

Hand Roll or Machine Film for Your Operation?

The choice is decided by pallet volume, not by film price. Hand-applied rolls need no machinery and suit low volumes, irregular loads and sites where a wrapper is impractical. Machine film needs a wrapper but produces consistent, repeatable containment force and uses less film per pallet once volumes justify the equipment.

A useful rule of thumb: if more than a handful of pallets a day leave your site, the film saving from machine pre-stretch usually repays the wrapper. Below that, a stretch film hand roll is the more sensible specification. Our machine pallet wrap film is produced from LLDPE in the same thickness and width ranges as the hand rolls, so a move between the two does not force you to re-engineer the load.

What Should a Stretch Film Order Specify?

A stretch film roll for palletising is quoted against whatever information you provide. Send all of the following and the quotation will be usable; omit them and you will be comparing prices for different products.

Item to specify	Why it matters
Thickness in microns	Sets strength, puncture resistance and cost per pallet
Width	Must suit your pallet height and wrapping programme
Length per roll	Drives roll changes and handling weight
Core diameter	Must match the machine chuck
Hand or machine grade	Determines cling configuration and stretch performance
Carton count	2, 6 or 12 rolls per carton — sets your outer case and pallet count
Load type and weight	Lets the supplier recommend a gauge instead of guessing

Our stretch films are cast from PE and supplied with EU and LFGB certification, packed in standard export cartons and shipped from Shenzhen or Guangzhou. Tell us the load and the route and we will quote the specification that fits it, rather than the specification that happens to be in stock.

Frequently Asked Questions

What thickness of stretch film should I use for export pallets?

It depends on the load rather than the destination. Uniform cartons on a stable pallet can use a thinner gauge at high pre-stretch; sharp, heavy or irregular loads need a heavier gauge to resist punctures. Tell the supplier what you are wrapping and the route, and specify from there.

How many layers of stretch wrap does a pallet need?

Layer count is the wrong way to think about it, because two layers at low tension hold less than one at high tension. Set the containment force you need, then adjust layers and pre-stretch together until the gauge readings reach it.

Can I use hand rolls on a machine?

Generally no. Hand rolls are not designed for the pre-stretch a wrapper applies, so they tend to tear or whiten and the result is worse than wrapping by hand. Specify machine grade film for a machine.

Does stretch film have to be food grade?

Only if the film comes into direct contact with food, or if the pallet is being wrapped in a food production area where cross-contamination rules apply. Otherwise a standard industrial grade is sufficient, and it will be cheaper.

Conclusion

Load stability stretch film works when the gauge, width, pre-stretch and wrap pattern are chosen together for a specific load. Thickness on its own tells you very little. The exporters who get this right are the ones who record their film specification and their containment force readings, then hold both constant — so that when a pallet does arrive damaged, they can tell whether the film changed or the load did.

Send us the pallet dimensions, load weight, route and machine details. We will come back with a film specification and the carton and pallet configuration to go with it.