Machine Pallet Wrap: Why the Cheapest Roll Can Cost You More

A cheaper roll of machine stretch film may look like an easy saving. But if the wrapping machine uses more film on each pallet, or the finished load needs extra wraps to stay stable, the cheaper roll could cost more in use.

To make a fair comparison, look beyond the price per roll and measure what happens on the wrapping machine.

Start with the film specification

Ask each supplier to confirm the film width, nominal thickness, net film weight, reel length and intended level of pre-stretch. Check the core size and maximum reel dimensions against your machine.

Compare like with like. A heavier reel may contain more film, but the stated weight might also include the core. If one quote is per kilogram and another is per roll, you need the net film weight before you can compare them properly.

Understand what pre-stretch means for your machine

A pre-stretch wrapper stretches the film before applying it to the pallet. The level achieved depends on the machine and its settings, as well as the film.

A film offered for 250% pre-stretch should be assessed on the wrapper and load it is intended to run on. The specification alone does not tell you how much film you will use per pallet or whether the finished load will meet your requirements.

Measure film used per pallet

For a useful comparison, select representative loads and record the weight of film used per wrapped pallet; the number of top and bottom wraps and wrapping pattern; machine settings, including pre-stretch and film tension; film breaks, stoppages and adjustments; and whether the finished pallet meets your agreed handling and transport requirements.

Run enough representative pallets to identify variation. A single successful pallet may not reflect a normal shift or a mix of load shapes.

Calculate cost per wrapped pallet

Multiply the kilograms of film used per pallet by the delivered film price per kilogram.

For illustration, Film A costs £1.80/kg and uses 0.25 kg per pallet: 45p per pallet. Film B costs £2.00/kg and uses 0.20 kg per pallet: 40p per pallet.

In this example, the film with the higher price per kilogram costs 5p less per pallet because less is used. Across 1,000 pallets, that is a theoretical difference of £50 in film cost.

That saving only counts if Film B performs acceptably. Include the cost of breaks, extra wrapping, damaged loads and downtime where you can measure them.

Consider load stability before reducing film

Using less film is not automatically an improvement. Different loads place different demands on the wrap: a regular, stable box pallet is not the same as a tall load with sharp edges or uneven products.

Agree what an acceptable wrapped pallet looks like and how it will be checked through your normal handling and distribution process. Any change in film or settings should be tested against those requirements.

Review your pallet wrapping costs

Stretchband Packaging supplies machine stretch film in a range of specifications. If you would like to review your current film, send us your wrapper make and model, existing reel specification, typical pallet loads and approximate usage.

We can discuss a suitable film and the information needed to make a meaningful trial comparison.