What is pallet wrap film?

What is pallet wrap?

Pallet wrap film, also known as stretch film, is a highly stretchable plastic film used to wrap and secure goods. It works by being tightly stretched around items on a pallet, covering them to securely hold goods in place ready for storage or shipment. Films can be stretched by hand or machine and manipulated so that the tension, or holding force, of the wrap ensures load stability. The elastic pull in the wrap tightens the load which prevents the items from shifting whilst in movement. Pallet wrap is ideal for both square or irregular shaped palletised goods in transit.

In recent years pallet wrap has become more sustainable and stronger. New technology has advanced pallet wraps by creating a nano film that is made up of layers of polymers. These polymer layers are selected to create a strong nano film that optimises hold force, tear resistance and is ultimately much stronger and lighter than traditional films.

Is pallet wrap the same as shrink wrap?

No. Many people link the two together as they are used to protect objects, however they are very different. Shrink wrap must be used in conjunction with heat. It is loose when first applied and shrinks to mould around a product once the heat is applied. Shrink wrap is only used to protect products against elements but does not offer the same level of load stability.

Hand Wrap vs. Machine Wrap

Hand wrap

It is applied manually. The operator has to physically stretch the film to apply the wrap. Its flexibility makes it ideal for lower volumes, infrequent wrapping and small warehouse operations (typically for wrapping 15-20 pallets per day). Also it is portable so you can easily wrap anywhere in the warehouse. However if done incorrectly manual pallet wrapping can lead to poor load stability, as it has an inconstant containment force, or the stretch is wrong. Furthermore, it can put the operator at risk of manual handling issues, putting strain on their body. Hand wrapping pallet loads is a slow process and labour intensive, making it less efficient for higher volumes.

Wessex Packaging offers a great solution to this, our X-Pro nano hand film is easy to use with a built in ‘elastic memory’ technology. This means it holds the load tighter, but with less wrapping effort from the operator. It is also plastic tax compliant as it has 30% recycled content, making it sustainable too. Find out more here >X-Pro Hand Stretch Wrap

Machine wrap

It is applied using wrapping machinery that stretches the film to a precise level, improving efficiency. This method of pallet wrapping is more consistent with load stability, meaning accidents are less likely. It is suited for high-volume operations and bulky equipment that may be difficult to wrap by hand. It reduces the likelihood of back strain and other poor manual handling issues, which is a huge benefit to operators. Machine wrap also benefits the environment, as the stretch means it uses less plastic and reduces waste, as it does not need to be re-wrapped. Wrapping pallets using turntable or robot pallet wrapping machines does require an initial investment for a machine, although the return on investment (ROI) for a busy warehouse operation can be short.

To help warehouse and logistics managers utilise the benefits of a pallet wrapping machine, we offer some of our machines on a £ZeroCap leasing agreement, with no capital expenditure outlay.

Is the thinnest pallet wrap film always the best solution?

The thickness of a pallet wrap is measured in micron(μm) and typically a higher micron thickness means a stronger film. However many buyers assume thinner films cost less because you get more meters of film per kilo, but this overlooks some key factors.

Choosing the right pallet wrap film is about balancing three things:

1. How you wrap (by hand or machine and the machine’s capabilities)
2. What you’re wrapping (the load profile and what the film needs to do)
3. The type of film you are using

For example, if your product is inside a pallet box, the box itself provides most of the stability. In instances like this, thin pallet wrap might be the correct option as it is mainly acting as dust or water protection, and its requirements will differ from a load that relies entirely on film for stability in shipment.

This is why our experts at Wessex Packaging recommend benchmarking film based on cost per pallet wrapped, rather than price per kilo or metre. As films have evolved from heavy 17, 20, and 23 micron traditional films to pre-stretched nanotechnology, thinner films can reduce cost, but not always.

Finding the balance

With newer nanotechnology films provide excellent stretch capabilities making them thinner, while still offering great stability. However they still may not be the best for your product, so it comes down to four considerations:

1. Stability – which film will give your pallet the hold force it needs?
2. Speed – can you maintain or improve wrapping throughput?
3. Operation – does the film work efficiently with your equipment?
4. Cost – does it deliver good value per pallet wrapped?

In some cases, a thicker film is actually more cost-effective. A stronger, thicker film may allow fewer wraps, reducing total film weight and cost, and is less likely to snap. This would increase efficiency compared to a thin film that has to be wrapped multiple times to get the same strength as a few wraps of a stronger film.

This only works if you understand what your current film is achieving and what you need to achieve. That’s why we offer free audits and pallet wrapping machine demonstrations to trial our range of film wraps. Contact us for a pallet wrap film audit here >PowerWrap® audit