What stretch film does on a pallet

Stretch film is LLDPE film that is stretched around a palletised load. When applied, it pulls the load together and keeps it secure on the pallet. This helps to prevent movement during transport.

Stretch film keeps out dust and moisture, protecting goods until they arrive at their destination.

When you stretch the film around a pallet, it tries to return to its original length. This tension is what keeps the load tightly together. For best results, always wrap the film around both the goods and the pallet itself. This secures the load to the pallet, so it moves as a single unit. If you only wrap the goods, the load may slide off the pallet when the forklift brakes or turns, or during transport.

Extra turns at the base and top of the load help resist the forces from braking and cornering during transit. The film clings to itself, so you finish by pressing the end onto the last layer, and it stays in place without needing parcel tape. Clear film, such as the 3 kg hand film here, allows you to read labels and count boxes through the wrap without opening it.

Hand stretch film or machine stretch film

Hand stretch film is supplied on 3 kg and 5 kg rolls for manual wrapping. The 3 kg rolls are packed six per carton and 40 cartons per pallet; the 5 kg rolls are supplied 120 per pallet.

Machine stretch film is supplied on 16 kg rolls for use with a pallet wrapping machine. Both Standard A and PRESTRETCH POWER types are available, each with 46 rolls per pallet. All films are 500 mm wide and 23 microns thick.

The 3 kg hand film rolls are lighter and easier to handle for extended periods, especially if one person is wrapping several pallets a day. The 5 kg rolls last longer before needing to be changed, but are heavier to carry around each pallet.

Machine stretch film rolls weigh 16 kg and are designed for use in a pallet wrapping machine. These rolls are too heavy for manual use; they are placed in the film carriage of the machine. All films in this category have the same width and thickness, so your choice is based on roll weight and your wrapping method.

Film is supplied by the pallet, with the 16 kg machine roll also available individually. Keeping a pallet of film near the wrapping area saves time and reduces the risk of damage from moving rolls around. If you switch from hand wrapping to a machine, any hand rolls you have in stock are still useful for single pallets that do not go through the machine, such as mixed or irregular loads.

Comparison table of pallet wrap products

The table below compares the five pallet wrap products in this category. It shows the use, width and thickness, roll weight, quantity per pallet, and the film suitable for the HOLD3 dispenser.

To use the comparison table, first decide whether you wrap by hand or with a machine. Then check which roll weight fits your process: 3 kg or 5 kg for hand use, 16 kg for machine use. The number of rolls per pallet tells you how much film you receive per order and how long it will last. The HOLD3 row shows the film the dispenser takes: 300–500 mm wide, on a 76 mm core, up to 510 mm long. Check the core and length of your rolls before ordering the dispenser.

How much pallet stretch film a load needs

The amount of pallet stretch film required depends on the number of layers, the overlap, and how much the film is stretched during wrapping. There is no set number of pallets per roll, as these factors vary by load and application.

With a machine, the number of layers and the stretch are set once and repeat for every pallet; by hand, they depend on the person wrapping.

To measure your film use per pallet, weigh a roll before and after wrapping a known number of pallets. Divide the difference by the number of pallets to find the average film use per pallet in your warehouse. This method works for both hand and machine wrapping, helping you plan orders and check the consistency of your wrapping process.

A tight wrap with good stretch secures the load better than loose layers, so a well-stretched wrap with fewer turns often uses less film than a loose wrap with more. Each turn overlaps the previous one. Decide in advance how many turns go at the base, in the middle and at the top, and apply the same to every pallet.

Heavy loads require more turns and tighter wrapping than lighter ones, especially at the base where the load meets the pallet.

Thickness and width of pallet wrap film

All pallet wrap film in this category is 500 mm wide and 23 microns thick. Sharp edges or corners on a load may tear the film, so using corner boards or applying extra layers can help in those areas. Inspect the film on your first pallets: if it tears at the corners, add corner boards before increasing the number of film layers.

Standard pallet wrap film offers only limited protection against ultraviolet light. If pallets will be stored outside for extended periods, choose a UV-stabilised film.

A width of 500 mm is standard for pallet wrap film, with the pallet wrapped in overlapping layers from bottom to top. 23 microns is a typical thickness for general use: strong enough for most palletised goods, yet thin enough to stretch easily by hand or machine. When each layer overlaps the previous by about half the film width, as recommended in the HOLD3 instructions, each turn adds roughly 250 mm to the total wrapped height.

When storing pallets outdoors, a cover placed on top of the load will keep out rain and dust, as the film wrapped around the sides does not seal the top.

Selecting a stretch wrap roll

Hand stretch wrap rolls are available in 3 kg and 5 kg sizes, while machine rolls are 16 kg; the number of rolls per pallet is listed in the table above.

Both the HOLD3 dispenser and the SMARTWRAP X2 pallet wrappers use film that is 500 mm wide on a 76 mm core. Always check the core diameter required by your machine or dispenser before ordering.

Wrapping several pallets a day with 5 kg rolls can be tiring. 3 kg rolls or a dispenser like the HOLD3 make the task less strenuous.

A pallet of 5 kg hand film will last a long time in a warehouse with moderate use, so compare your monthly usage with the number of rolls per pallet before placing an order. Order your next pallet before the last cartons are opened, as film is supplied by the pallet, not by the roll. Film is the main ongoing cost of wrapping, so compare film usage per pallet, as described above, when considering heavier rolls or a machine.

Each roll should remain in its carton or box until needed. The carton protects the film edges from knocks and drops. If wrapping takes place at several packing stations, the 3 kg rolls in cartons of six are easy to distribute: one carton per station.

Machine stretch film for pallet wrappers

Machine pallet wrap is designed for use in pallet wrappers. It is available in two types, Standard A and PRESTRETCH POWER, both supplied on 16 kg rolls; quantities per pallet are shown in the table above.

Our SMARTWRAP X2 PRE-STRETCH machines stretch the film by 250 % before it is applied to the load, so a roll of pre-stretch pallet wrap covers more pallets than hand-applied film.

A pallet wrapper sets the number of layers, the overlap, and the tension, ensuring every pallet is wrapped identically. This consistency helps prevent errors that can occur with manual wrapping, such as missing layers at the base or insufficient stretch.

On a machine with powered pre-stretch, such as the SMARTWRAP X2 PRE-STRETCH, the film passes from the 16 kg roll through pre-stretch rollers and onto the load already stretched, so less film is used per pallet. A machine without powered pre-stretch, like the standard SMARTWRAP X2, stretches the film mechanically using a brake. The suitable film type depends on your machine’s film carriage and pre-stretch capability; let us know your machine model and we will confirm compatibility.

Before loading a new roll into the machine, check the edges. A crushed or torn edge will tear as soon as the carriage stretches the film, regardless of the load, wasting both film and time. Unwind and remove any damaged outer layers before loading the roll.

Using stretch film rolls with a dispenser

The HOLD3 stretch film dispenser is designed for hand rolls 300–500 mm wide on a 76 mm core, up to 510 mm long. It allows up to 35 % stretch, with film tension adjusted manually using the brake.

The HOLD3 pallet wrap dispenser features a soft foam handle and an adjustable holder height. The frame is made of metal with a rust-resistant coating.

With the HOLD3, the roll rotates on the holder, so you do not have to grip the roll itself, avoiding friction burns and cuts that can result from holding the roll directly.

The brake sets the film tension. Begin with a loose brake and tighten it until the film secures the load firmly without tearing, up to the 35 % stretch allowed by the HOLD3. If the brake is too tight, the film may snap or tear at the corners. Adjust the tension for each load type, using less for soft boxes and more for solid goods.

Walk around the pallet at a steady pace, keeping the film level with each turn and raising it for the next, so each layer overlaps the previous one. The holder height is set to match the roll, so the film feeds straight off the roll without folding at the edge. Adjust it when changing to a roll of a different width.

Pallet wrap or strapping for securing loads

Pallet wrap holds the load together and protects it from dust and moisture. Strapping secures the load to the pallet with tension. Some heavy or unstable loads use both pallet wrap and strapping for added security.

Strapping is best when a heavy load needs to be held down on the pallet, such as heavy boxes or long items; the wrap then keeps the layers together and prevents dust ingress.

Film secures the load by gripping the entire surface, while straps apply force along a few lines. Straps alone leave the sides exposed, so small boxes may slip out between them; film closes the sides. A light load of boxes that only needs to stay together for transfer to another warehouse usually requires only film.

Boxes that must not be crushed are safer wrapped with film, as strapping can damage corners or deform soft packaging. Conversely, heavy goods such as metal parts or stone are better secured with straps, which hold the load down on the pallet. Corner boards placed under the straps distribute the pressure, preventing the straps from cutting into the top boxes.

We also supply strapping machines, tools and strap, so you can purchase both solutions from one supplier.

Wrapping by hand or with a pallet wrapper

Hand wrapping is suitable for a small number of pallets each day: the operator walks around the pallet with a roll or a dispenser.

For higher volumes, a pallet wrapper saves both time and film: settings are made once and every pallet is wrapped in the same way.

When wrapping by hand, the operator circles the pallet several times and bends down for the lower layers. The outcome depends on the individual, as each person may use a different number of layers or stretch the film differently. This can result in some pallets being wrapped more tightly than others, affecting load security during transport.

A pallet wrapper wraps the pallet automatically once started, allowing the operator to work elsewhere nearby. It requires a clear area with space to move around it, and a way to bring pallets in and out using a pallet truck or forklift. Consider the time as well: a few minutes spent hand wrapping each pallet can add up to hours each week if many pallets are processed daily.

A machine with powered pre-stretch stretches the film much more than a hand dispenser, so each roll covers more pallets.

Walking backwards around a pallet with a roll is a trip hazard, especially in busy areas. Using a machine removes this risk. When several people wrap pallets daily, switching to a machine can improve safety and reduce film usage.

How pre-stretch works

Pre-stretch refers to the film being extended before it is applied to the load. This allows the film to cover more area and provides a tighter hold. Our SMARTWRAP X2 PRE-STRETCH pallet wrappers stretch the film by 250% prior to wrapping.

With a 250% pre-stretch, one metre of film from the roll becomes up to 3.5 metres on the pallet. This is achieved in the film carriage, where the film passes between two rollers rotating at different speeds. The speed difference stretches the film before it is wrapped around the pallet.

When wrapping by hand, the film is stretched by the brake on a dispenser such as the HOLD3, up to 35%, or by pulling the roll directly. Excessive stretch or tension can crush soft cartons or cause the film to tear at corners. Adjust the stretch and tension to suit the load, especially when wrapping goods with sharp edges or delicate packaging.

Storing and handling film rolls

Keep film rolls indoors, dry, and away from heat and direct sunlight, stored in their cartons. Handle them carefully to avoid damaging the edges, as a damaged edge will tear when the film is stretched.

Store the pallet of film in the warehouse, away from loading areas exposed to rain or sunlight. Use older rolls first, so none remain in stock for too long. If a hand roll is dropped and the edge is damaged, it can still be used for lighter loads; for machine rolls, unwind the damaged layers before loading. Stack cartons only as high as they remain stable, to prevent rolls from falling.

Film taken directly from a cold storage area will stretch less and may not secure the load as effectively. Allow the rolls to reach room temperature in the packing area before use, particularly in winter or if the film is kept in an unheated space. Bringing the next day’s rolls into the packing area the night before is sufficient.

Checklist before ordering pallet wrap

Before ordering pallet wrap, check whether you use hand or machine wrapping, and which film width and core size your machine or dispenser requires. Also consider whether your loads are heavy or light, and if pallets are stored outside for long periods or sent on lengthy routes.

The comparison table above shows which film or dispenser matches your wrapping method.

Count how many pallets are wrapped each day and how much time staff spend on this task. This helps you decide if hand wrapping is sufficient or if a machine is needed. Plan a dry, accessible place for storing the film. Measure your current film use per pallet, so you can compare after changing film or method.

For hand wrapping, consider using a dispenser such as the HOLD3 to make the task easier. Assign responsibility for wrapping and demonstrate the method: how many turns at the base, in the middle, and at the top, applied consistently to every pallet. Ask current staff how many turns they use per pallet and whether the film tears; this will indicate where a change of film or method could be most beneficial.

Questions about pallet wrap

What does 23 my mean in pallet wrap?

23 my refers to the thickness: 23 microns (µm), with ‘my’ representing the Greek letter µ. All films in this category are 23 microns thick.

How many rolls of pallet wrap are on a pallet?

A pallet contains 40 cartons of 3 kg hand film rolls, 120 rolls of 5 kg hand film, or 46 rolls of 16 kg machine film. The 16 kg machine film is also available as a single roll. Each product listing provides the exact quantity.

Does the machine film fit all pallet wrappers?

All machine film here is 500 mm wide. Check the film width and core diameter required by your machine; our SMARTWRAP X2 machines use 500 mm film with a 76 mm core. Let us know your machine model and we will confirm if the roll is suitable.

Is pallet wrap film recyclable?

The film is recyclable where local collection schemes accept it. Please check with your local recycling programme to confirm if LLDPE stretch film is collected.