How to Reduce Polythene Packaging Film Usage with Stretch Banding & Shrink Film
- Stretchband Packaging
- Feb 27
- 3 min read
Rising material costs, sustainability targets, and the UK Plastic Packaging Tax are driving businesses to reduce plastic consumption. For companies using stretch banding film and shrink film, there are significant opportunities to reduce polythene packaging usage without compromising load stability or protection.
At Stretch Band Packaging, we work with UK manufacturers and logistics operations to reduce film thickness (micron), increase PCR content, and optimise shrink and stretch banding systems for measurable savings.
Why Reducing Polythene Film Matters
Reducing shrink and stretch banding film usage delivers:
Lower packaging costs
Reduced Plastic Packaging Tax liability
Lower carbon footprint
Improved ESG reporting
Reduced environmental impact
For many businesses, optimisation leads to 20–40% material reduction.
1. Reduce Film Thickness (Micron Downgauging)
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One of the most effective ways to reduce polythene packaging film usage is through micron reduction.
What Is Micron?
Micron (μm) measures film thickness. Traditional specifications often include:
80–120 micron shrink film
60–150 micron stretch banding film
Modern multi-layer co-extruded films allow businesses to switch to thinner film while maintaining strength, tear resistance, and load containment.
Example Saving
Switching from:
100 micron shrink film to
70 micron high-performance shrink film
Can reduce plastic usage by up to 30% per load.
Many companies are using outdated film specifications simply because they haven’t been reviewed.
👉 Explore our shrink film range: Polythene Films UK | LDPE/LLDPE Packaging Supplier
👉 Discover stretch banding solutions: StretchBanding Film UK | Manufacturer & Supplier
2. Increase PCR Content (Post-Consumer Recycled Plastic)
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Increasing PCR content is another powerful way to reduce environmental impact.
Why PCR Is Important
Under UK legislation, plastic packaging must contain at least 30% recycled content to avoid Plastic Packaging Tax.
Using shrink or stretch banding films with higher PCR content:
Reduces virgin polymer usage
Lowers carbon footprint
Supports circular economy targets
Improves sustainability reporting
Modern films now offer 30–50% PCR content while maintaining strong mechanical performance.
👉 Learn more about our sustainable packaging solutions: Sustainable Packaging Solutions by Stretchband | Recycled & PCR Films
3. Replace Full Shrink Wrapping with Stretch Banding (Where Suitable)
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In many pallet applications, full shrink wrapping may not be necessary.
Stretch banding stabilises loads by applying targeted film bands rather than full coverage. This approach:
Uses significantly less material
Eliminates excessive overlap
Reduces heat energy consumption
Speeds up packaging operations
In suitable applications, stretch banding can reduce film usage by 50% or more compared to full pallet shrink wrap.
4. Optimise Shrink Film Application & Bag Sizing
Excess film usage often comes from:
Oversized shrink bags
Excessive overlap
Incorrect heat settings
Over-specification of thickness
Optimising bag dimensions and machine calibration can produce immediate material savings without changing film type.
5. Upgrade to High-Performance Multi-Layer Film
Advances in film engineering mean modern shrink and stretch banding films offer:
Higher tensile strength
Improved puncture resistance
Controlled tear propagation
Better load containment
This enables downgauging (micron reduction) without performance loss.
Businesses still using older mono-layer films may be missing significant reduction opportunities.
6. Conduct a Film Usage Audit
You cannot reduce what you do not measure.
A packaging audit should review:
Micron thickness
Film weight per pallet
PCR percentage
Machine settings
Application consistency
At Stretch Band Packaging, we help businesses identify over specification and implement measurable reduction strategies.
The Commercial Case for Reducing Polythene Film
Reducing shrink film and stretch banding film usage isn’t just about sustainability.
It directly impacts:
Cost per pallet
Annual material spend
Plastic Packaging Tax exposure
Corporate sustainability reporting
Customer procurement requirements
For high-volume operations, even a 10-micron reduction can represent substantial annual savings.
Frequently Asked Questions (FAQ)
How can I reduce shrink film usage without compromising load security?
By switching to high-performance multi-layer film and reducing micron thickness following load testing. Optimising heat settings and bag sizing also reduces waste.
What is the best micron for shrink film?
There is no universal answer. The correct micron depends on load weight, transport conditions, and containment requirements. Many businesses can safely downgrade by 15–30%.
Does increasing PCR content affect film strength?
Modern PCR-enhanced films are engineered to maintain performance. However, testing is recommended when increasing recycled content levels.
Can stretch banding replace shrink wrapping?
In many stable pallet applications, yes. Stretch banding uses significantly less film and eliminates heat, making it both cost-effective and environmentally beneficial.
If your business is looking to reduce polythene packaging film usage, lower micron thickness, or increase PCR content, our team can provide a tailored assessment.
Or contact us to arrange a packaging optimisation review.
