When it comes to packaging, stretch film might seem like a small detail—but choosing the right one can make a big difference in load security, cost-efficiency, and even sustainability. Whether you’re wrapping pallets by hand or using an automatic machine, understanding what type of stretch film you need is essential for smooth operations and safe product delivery.
Manual vs. Automatic Applications
If your team wraps pallets manually with a dispenser or by hand, you’ll need hand stretch films. It’s flexible, easy to use, and ideal for low-volume operations. However, hand wrapping can be inconsistent and physically demanding for your staff.
On the other hand, automatic or semi-automatic stretch wrappers use machine stretch film. These films are designed for high-speed, high efficiency wrapping with consistent tension and superior load containment. Machine application reduces labor and improves safety, making it a smart investment for growing operations.
Key Factors to Consider
Choosing the right stretch film goes beyond manual or machine use. Here are some essential aspects to evaluate:
1. Load Type
- Type A loads are uniform and easy to wrap.
- Type B loads are moderately irregular and need a more durable film.
- Type C loads are highly irregular and demand the highest puncture resistance.
The more irregular your load, the stronger your film should be.
2. Weight
Heavy pallets need stronger, thicker films or high-performance thin films that maintain strength while reducing material usage.
3. Film Gauge (Thickness)
Traditional films range from 60 to 120 gauge, but modern films achieve the same performance at lower gauges—cutting down on plastic use and cost.
4. Pre-Stretch Capability
Machine films are designed to be stretched before application. Choosing a film that matches your equipment’s pre-stretch capacity is crucial for preventing film breaks and reducing waste.
5. Film Memory and Load Retention
Some films snap back tightly after being stretched—helping your load stay secure during transit. If you’re shipping long distances, this feature matters.
6. Puncture Resistance
Loads with sharp edges or odd shapes need film that won’t tear on contact. Always test the film against your real-world conditions.
7. Cling Properties
Some films cling on both sides, while others are one-sided to avoid pallets sticking together. Choose based on how your loads are stored and transported.
8. Environmental Conditions
Cold storage? Dusty warehouse? Outdoor exposure? There are specialty films for each of these. Make sure your film holds up in your working environment.
9. Sustainability Goals
Look for stretch films with recycled content or engineered to use less plastic. Small changes in film selection can lead to big sustainability wins.
10. Cost Efficiency
Always consider cost per load, not just cost per roll. A high-performance film might be more expensive upfront but save you money in the long run by using less material or reducing damage.
Best Practices & Common Pitfalls
- Match the film to your equipment and load. The right film for a high-speed machine is very different from what works best for manual wrapping.
- Train your team. Proper tension, wrap patterns, and film orientation make all the difference.
- Avoid over-wrapping. More film doesn’t always mean more security—choose a stronger film instead.
- Store film properly. Heat, dust, and poor handling can reduce performance.
- Re-evaluate often. As your operation evolves, your stretch film strategy should too.
Sustainability and Cost-Efficiency Considerations
Stretch film plays a bigger role in sustainability than most people realize. The good news? Choosing the right film can help your business cut costs and reduce its environmental impact at the same time.
Use Less Without Sacrificing Strength
Today’s high-performance films are designed to do more with less. By switching to a thinner but stronger film, you can reduce the amount of plastic used per pallet—often by 20–40%—without compromising load integrity. For example, a 60-gauge high-performance film might perform just as well (or better) than a traditional 80-gauge option, meaning less material, less waste, and lower costs.
Recycled Content Options
Some stretch films now include post-consumer recycled (PCR) content, allowing you to reduce your use of virgin plastic. Films with 10%–25% PCR offer nearly the same strength and performance while supporting circular economy goals. It’s a practical way to make your packaging greener without changing your equipment or process.
Recyclability
Most stretch films are made from linear low-density polyethylene (LLDPE), which is recyclable in facilities that accept film plastics. If you generate high volumes of used stretch film, it’s worth exploring recycling partnerships or take-back programs. Keeping film out of landfills is not just good for the environment—it can also lower your disposal costs.
Total Cost per Load
One of the biggest mistakes companies make is focusing only on the cost per roll. A lower-cost roll might require more wraps or break more often, increasing labor, waste, and potential product damage. The right film—especially one tailored to your application—can reduce film usage, downtime, and freight claims. Always calculate the cost per pallet wrapped, not just the price tag on the box.
Smarter Automation
Automated stretch wrappers with controlled pre-stretch systems can drastically improve film efficiency. When paired with a film that’s optimized for pre-stretch, your system can deliver more consistent containment with less material. That means safer loads and a lower environmental footprint.
Partner with Brexia
Choosing the right stretch film isn’t just about wrapping pallets—it’s about protecting your products, optimizing your costs, and making your team’s job easier. At Brexia, we work closely with industry leaders to offer high-performance solutions for every kind of load, from lightweight boxes to irregular, high-risk shipments.
Need help selecting the right film for your operation? Our team is ready to assist with technical advice and tailored product recommendations.
How to Choose the Right Stretch Film for Manual and Automatic Packaging