Stretch Film Best Practices, Common Mistakes, and Sustainability Tips

Why best practices matter

Stretch film seems simple, but how you select and apply it directly affects load safety, material cost, and environmental impact. Following a few practical best practices helps stabilize shipments, reduce waste, and save money over time. This article covers easy-to-adopt techniques, typical mistakes to avoid, and sustainability options for beginners.

Key best practices

• Anchor at the base: Start with several wraps around the pallet base to secure the product to the pallet. This prevents the entire load from sliding.
• Maintain consistent overlap: Overlap each layer by roughly 50% to ensure continuous coverage and even containment force.
• Use the right number of wraps: Adjust wraps based on weight and stability. A rule of thumb: lightweight, stable loads need fewer wraps; tall, top-heavy, or unstable loads require more.
• Set proper pre-stretch and tension on machines: Too little pre-stretch wastes film and reduces containment; too much can damage package corners. Follow manufacturer recommendations and test settings.
• Wrap tops and corners: Make multiple top passes to protect goods from dust and to prevent vertical movement. Use corner boards for delicate edges.
• Train staff: Consistent technique reduces film breaks, improves speed, and lowers injury risk. Use ergonomic dispensers for hand wrapping.
• Perform quick load tests: Push tests or skid tests help validate wrap strength before shipping high-value loads.

Common mistakes and how to avoid them

• Underwrapping — too few layers or insufficient base anchoring. Result: shifting and damaged goods. Fix: standardize minimum wrap counts and anchor at base.
• Overwrapping — excessive layers increase cost and waste. Fix: test higher-performance films that require fewer wraps, and optimize machine pre-stretch.
• Wrong film for the environment — using standard film in freezers can cause cracking. Fix: use cold-room rated films for refrigerated storage and transit.
• Poor film handling and storage — exposure to heat or moisture degrades film. Fix: store rolls away from direct sunlight, in a controlled environment.
• Ignoring sharp edges — punctures from corners cause film failure. Fix: use edge protectors, stretch hooding, or films with higher puncture resistance.
• Incompatible machine settings — wrong brake or pre-stretch settings cause inconsistent wraps and frequent breaks. Fix: document and lock machine settings for specific load types.

Ergonomics and safety

Hand wrapping can strain the back and shoulders. Use dispensers with handles and brakes to reduce effort. For high volumes, invest in a turntable or orbital wrapper to minimize repetitive motion injuries and improve consistency.

Sustainability tips for stretch film use

Stretch film is plastic, so sustainable use is an important consideration. Here are practical ways to reduce environmental impact without compromising load security:

• Right-gauging: Use the thinnest film that still meets performance needs. Machine pre-stretch allows thinner films with equal containment.
• Pre-stretched films: Using pre-stretched or power-stretch films can significantly lower film consumption per pallet.
• Recycled content: Many films now contain post-consumer recycled (PCR) content. These offer reduced virgin plastic usage with comparable performance.
• Film take-back and recycling: Partner with suppliers or recycling programs that accept used stretch film for industrial recycling. Keep film clean and separated from other waste to improve recyclability.
• Optimize roll sizes and cores: Wider rolls and longer lengths reduce core and changeover waste. Consider bulk buying to minimize packaging waste from suppliers.
• Alternative solutions: For some applications, consider stretch hooding, reusable pallet cages, or tray plus shrink film combinations that use less film overall.

Measuring success

Track metrics to monitor improvement: meters of film used per pallet, cost per pallet, damage rates, and the percentage of film recycled. Small improvements in film usage per pallet compound quickly—cutting film use by 10% across thousands of pallets yields significant savings and waste reduction.

Simple example calculation

If your operation uses a 20 µm machine film roll of 2,000 meters and wraps average 50 meters per pallet, each roll covers 40 pallets. If a better pre-stretch film reduces usage to 40 meters per pallet, you cover 50 pallets per roll. That’s a 20% reduction in film cost per pallet while maintaining the same containment.

Supplier partnerships

Work with film suppliers to trial options and receive training on machine settings. Many suppliers provide audits that benchmark film usage and recommend improvements that pay back in short order.

Conclusion

Good stretch film practice blends the right material, correct application technique, and attention to sustainability. For beginners, start by standardizing wrap procedures, training staff, and testing a small number of film options. Over time, measure results and refine choices to reduce cost, waste, and product damage.