How to Choose the Ideal Stretch Film Based on Your Load Type

Selecting the right stretch film is critical for stable pallet loads, especially in high-throughput manufacturing environments. Loads are often categorized by profile: Type A (uniform, stable) through Type C (very irregular, with protruding edges). Understanding your typical load profile (stable vs. irregular, heavy vs. light, sharp vs. smooth) helps narrow down film choice.

In general, stable, uniform loads can be wrapped with standard film, but irregular or sharp-edged loads demand specialty films with extra strength. Similarly, heavy loads need thicker, high-performance film, whereas light loads can use thinner or pre‑stretched film to save material.

Common Load Profiles

Uniform/Stable Loads (Type A): Flat, evenly stacked boxes with no protrusions. These can usually be secured with standard or mid-gauge film. A basic 80–90 gauge cast film (0.8–0.9 mil) often suffices for loads up to ~2,400 lbs. Because these loads have few sharp points, puncture resistance is less critical.
Light/Delicate Loads: Pallets under ~1,000–1,200 lbs. or fragile items. Pre-stretched films (already tensioned at ~90% on the roll) are ideal for light loads. These allow workers to wrap easily with less effort and waste. A thinner film (60–70 gauge) can work if the load is light and stable.
Irregular/Unstable Loads (Type B/C): Pallets with boxes sticking out, uneven shapes, or mixed items. These require tougher film. Blown film is often recommended because it provides high containment force and strong puncture resistance. Use 80–100 gauge blown machine film or a high-performance cast film to grip odd shapes tightly. For very odd loads, corner boards or roping might be needed.
Sharp-Edged Loads: Pallets carrying metal parts, lumber, or items with exposed corners can easily tear film. Use films specifically rated for puncture or tear resistance. Blown films generally offer better protection for sharp or irregular surfaces.
Heavy Loads: Very heavy or dense pallets (2,500+ lbs) require thicker films. Use 100–150-gauge machine film or multi-layer reinforced film. For example, a 100-gauge cast film may be suitable for loads up to ~3,000 lbs. For heavy loads with sharp edges, blown film is preferable.

Key Stretch Film Specifications

Gauge (Thickness): Thicker films (100+ gauge) offer greater strength. Modern multi-layer films can match older film strength at lower gauge, reducing resin usage and roll weight.
Pre-Stretch Capability: Machine wrappers can stretch film up to 300%, maximizing coverage and reducing material use. Hand wrapping typically achieves 100–150% stretch. Pre-stretched films are ideal for manual applications.
Cling (Adhesion): Determines how well the film sticks to itself. Single-sided cling prevents pallets from sticking together. Higher cling improves load stability but may increase noise during application.
Film Memory (Elastic Recovery): The film’s ability to contract after stretch. Good memory maintains tight load containment during transit and after settling.
Puncture and Tear Resistance: Essential for sharp or irregular loads. Blown and reinforced films offer superior resistance and are ideal for high-risk applications.

Cast vs. Blown Film

Cast Film: Clear, glossy, quiet, and consistent. Suitable for uniform loads. Offers good memory and easy handling. Lower puncture resistance compared to blown film.
Blown Film: Hazy, noisy, clingier, and tougher. Superior for sharp or heavy loads. Provides high puncture resistance and strong containment. Typically, more expensive, but more durable.

Manual vs. Automatic Wrapping

Manual (Hand) Wrapping: Suitable for low-volume operations. Limited pre-stretch, higher labor and material use. Requires heavier film to avoid tearing.
Automatic (Machine) Wrapping: Ideal for high-volume operations. Pre-stretch up to 300%, reducing film usage by up to 50%. Improves consistency, reduces labor, and increases throughput. Requires machine-grade film with high stretch capacity.

Cost, Efficiency, and Waste Reduction

Down-Gauging with Performance Films: Multi-layer films allow using thinner gauges without sacrificing strength. Test before switching to avoid wrapping failures.
Material Savings via Pre-Stretch: Proper stretch dramatically reduces film use. Automated wrappers maximize efficiency and consistency.
Reducing Damage Costs: Using the right film prevents load shifts, returns, and rework. High-performance film reduces breakage and claims.
Process Efficiency: The right film speeds up operations and reduces downtime. Lighter rolls and higher stretch capacity improve productivity.
Sustainability: Optimized film use lowers waste and reduces carbon footprint. High-performance films and automation contribute to more sustainable packaging.

Final Recommendations

Match film type to load profile.
Use blown film for heavy, sharp, or irregular loads.
Use cast film for clean, fast wrapping of uniform pallets.
Choose machine film for automated wrappers and take advantage of high pre-stretch.
Down-gauge only with high-performance films and after proper testing.
Invest in automation when volume justifies it to reduce labor and material waste.

Looking for Reliable Industrial Stretch Film?

At Brexia, we supply high-performance stretch film engineered for the demands of any manufacturing company. Whether you're wrapping light, uniform pallets or securing heavy, irregular loads.

All our films are compatible with standard wrapping equipment and backed by technical support to help you select the optimal solution for your operation.

Contact us to get a product recommendation tailored to your load profile and throughput requirements. Optimize your packaging. Reduce cost. Secure every shipment.

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