Single Wound Sheeting: High-Speed, High-Precision Packaging for Modern Production Lines

It’s a high-speed world. Everything’s connected. Even your fridge wants your WiFi password these days. And change happens so fast you can miss the next big thing in the time it takes to make your morning coffee.

The pace isn’t slowing down – and the same is true on the factory floor. Across food, pharma and e-commerce, automated packaging systems are running faster than ever, just as inflation and low consumer confidence are putting margins under huge pressure.

In high-volume packaging, every second of uptime counts. And every millimetre of material matters when already razor-thin margins keep getting squeezed.

That’s why more manufacturers are switching to single wound sheeting (SWS) – a simple, flexible film format that unlocks higher speeds, cleaner automation and long-term cost savings.

What Is Single Wound Sheeting?

Single wound sheeting is a continuous roll of flat film, wound as a single layer. On automated lines it’s typically formed, filled and sealed on demand into bags, lids or webs – instead of relying on pre-made bags, lay-flat tubing or manual loading.

Because SWS is just one, flat layer of polythene or polyolefin film, it:

• Feeds cleanly into high-speed packaging equipment

• Is less prone to jamming or misfeeding

• Can be extruded in precise gauges and widths to match your products and machines

If you’re still getting to grips with flexible packaging formats more broadly, it’s worth exploring the basics in our guide to flexible packaging materials.

The Operational Advantages of Single Wound Sheeting

1. Continuous, High-Speed Operation

On automated lines running hundreds of cycles per minute, small interruptions add up to serious lost output.

Single wound sheeting supports:

• Continuous feed – film runs through as one web, rather than stopping to load individual bags

• Faster changeovers – roll-to-roll splicing systems keep lines running during reel changes

• Minimal downtime – fewer stoppages for clearing misfeeds, as the film path is simple and predictable

Because SWS is such a straightforward format, it’s also less prone to static-related issues. With antistatic additives, the film is less likely to cling, stick or double-feed – keeping high-speed automation running smoothly.

For a broader overview of how different packaging films behave on fast lines, see our article on the different types of film used in packaging.

2. Less Machine Complexity, More Repeatability

At first glance, specifying SWS systems can feel complex. You’re dealing with:

• Forming tools

• Sealing jaws

• Servo control

• Film tension and registration

But once the system is dialled in, single wound sheeting actually simplifies the overall machine configuration:

• One consistent web to control (rather than multiple pre-formed SKUs)

• Repeatable, predictable behaviour for every pack size or product

• Easier scaling: add more lanes or lines without redesigning your packaging format

The result? Faster packaging, higher quality and more predictable costs.

Cost & Material Savings vs Pre-Formed Packaging

Pre-made bags, sleeves and lay-flat tubing all carry conversion costs – you’re paying for another process before the film even reaches your line. At industrial volumes, these extra costs add up quickly.

With single wound sheeting:

• You buy plain film on a roll, not converted formats

• Your form-fill-seal or thermoforming equipment does the converting in-line

• You can use ultra-thin, high-strength films that are precisely optimised for your product and process

Over time, the cost-per-unit reduction usually far outweighs the initial investment in forming or sealing machinery – especially in high-volume operations.

If you’re working with narrow formats, our dedicated guide to narrow width polythene (50–180mm) shows how tighter widths can reduce waste even further on multi-lane lines and collating applications.

Why Single Wound Sheeting Is Ideal for Pharmaceutical Packaging

The pharmaceutical sector faces unique challenges:

• Tight regulatory control over packaging and processes

• Serialisation and traceability requirements

• High demands around cleanliness, particulate control and validation

Single wound sheeting is a natural fit.

Consistent, Pharma-Ready Film

Modern blister, tray and thermoforming systems (from leading OEMs such as Uhlmann and Pester Pac) demand extremely consistent film to maintain forming depth, seal integrity and registration. High-quality SWS delivers that consistency across the whole roll:

• Tight control of gauge and width

• Stable tension and flatness across the web

• Clean edges and reliable unwinding

Because Stretchband Packaging extrudes and prints polythene film in-house in the UK, we can tightly control these variables for pharmaceutical and medical device applications. StretchbandPackaging

For pharma teams weighing up options, our article on stretch banding vs shrink wrapping in pharma packaging explores where each method fits, especially for heat-sensitive products.

Cleanroom Compatibility & Additives

Single wound sheeting can be tailored for:

• Cleanroom production and low particulate generation

• Antistatic properties to reduce dust attraction and static discharge

• High-temperature performance for sterile barrier systems

• UV-resistant formulations to withstand intensive UV sterilisation

And because it’s a continuous roll, there are fewer separate components and handling steps – helping maintain cleanliness on validated lines.

Smarter Pharma Packaging with Printed Tracking & Security

Single wound sheeting can be printed and coded before forming, enabling:

• Serialisation codes and barcodes for full traceability

• Anti-counterfeiting features (special inks, micro text, covert marks)

• Tamper-evident patterns that break when packaging is opened

Embedding these into the film itself helps align with MHRA, EU and FDA requirements while building consumer and patient trust.

Material Innovation & Sustainability Benefits

While single wound sheeting is a long-established format, material science is evolving rapidly.

Using MDPE and advanced blends, SWS can now deliver:

• Barrier performance that rivals more complex laminate structures

• High puncture and notching resistance even at lower gauges

• Options that incorporate post-consumer recycled (PCR) content

That means:

• Reduced material usage per pack

• Improved recyclability for mono-material PE structures

• Lower overall carbon and energy footprint across the lifecycle

If sustainability is a priority for your team, it’s worth reading our blog on the challenges of recycling LDPE and how smarter film specifications can support circular-economy goals.

Specifying Single Wound Sheeting for Your Packaging Line

To get the most out of single wound sheeting, it’s important to match the film precisely to your application and machinery.

Typical specification levers include:

• Polymer type & blend – LDPE, MDPE, LLDPE or custom blends for clarity, stiffness or toughness

• Gauge (micron) – optimised for product weight, protection level and line speed

• Width & lay-flat – tuned to your forming tools, lanes and sealing geometry

• Additives – slip, anti-block, antistatic, UV, or special heat-seal layers

• Print & coding – brand graphics, dosing information, barcodes and serialisation marks

If you’d like a broader grounding in how different flexible films behave, our explainer on flexible packaging materials is a handy reference for packaging engineers and buyers alike.

High-Performance Single Wound Sheeting, Made in the UK

Looking for single wound sheeting for a new or existing packaging line?

At Stretchband Packaging, we’re a UK manufacturer of stretch banding, shrink films and polythene packaging – with full in-house extrusion and printing capabilities. StretchbandPackaging

That means we can:

• Design custom polythene blends that perform exactly as your process demands

• Supply films that integrate cleanly with existing automated and thermoforming systems

• Help you reduce waste, cut material usage and improve line efficiency

• Offer options that support your sustainability and Plastic Packaging Tax strategies (including PCR content)

Our packaging specialists understand both the material science and machine integration aspects of industrial packaging. We’ll work with your operations, engineering and quality teams to:

• Specify the right single wound sheeting for your products and equipment

• Optimise for speed, seal integrity and pack appearance

• Build in the track & trace, security and sustainability features you need

Ready to Upgrade Your Packaging with Single Wound Sheeting?

If your business is:

• Struggling to keep up with demand on existing lines

• Under pressure to reduce per-pack material and energy usage

• Planning a new automated or pharma-grade packaging project

…then single wound sheeting could transform your operation.

Talk to the Stretchband Packaging team about how high-performance SWS can deliver:

• Faster, more reliable throughput

• Lower material costs over time

• Cleaner, more sustainable packaging – without compromising on protection or compliance

Get in touch today for a free consultation or sample and let’s design a single wound sheeting specification that works perfectly for your line.