Making the right choice for your operation
In the world of logistics and warehousing, the humble pallet wrap will always play a critical role in ensuring products reach their destination safely and securely. As businesses face increasing pressure to optimise costs, improve efficiency, and meet sustainability goals – the choice between pre-stretched (also known as high-performance film)and traditional hand pallet wrap has become an important consideration. We take a look at the key differences, benefits, and applications of both product types to help you make an informed decision for your operation.
Understanding the basics
Traditional pallet wrap
Traditional stretch film, is designed to be stretched during application. Typically made from linear low-density polyethylene (LLDPE), this film is manufactured to stretch up to 300% of its original length when applied correctly. The stretching process activates the film’s holding or containment force, creating a tension that secures loads in storage or it transit.
Pre-stretched pallet wrap
Pre-stretched film, as the name suggests, has already undergone this stretching process during manufacturing. This film is first stretched and then wound onto a core, resulting in a product that requires minimal force to apply while maintaining its strong load containment properties. Most pre-stretched films have already been elongated to about 250% of the original length.
Key differences and considerations
Application method and ease of use
Traditional Wrap: Requires significant physical effort and technique for optimal application. The user must maintain consistent and constant tension while hand wrapping the pallet, which can lead to fatigue and inconsistent application, resulting in load instability.
Pre-Stretched Wrap: Offers significantly easier application with reduced physical strain. Since the film is already stretched, it requires approximately 50% less force to apply. This makes it ideal for manual pallet wrapping operations, reducing worker fatigue and potential injuries.
Film gauge and plastic usage
Traditional Wrap: Typically starts life as thicker gauge (often 20-23 microns) and then stretched as applied to the pallet. If not stretched properly, this can result in using more plastic than necessary.
Pre-Stretched Wrap: Is reduced to its optimal thickness (often between 8-12 microns, and can be as little as 4 microns) during manufacturing and importantly – before application to the pallet.This results in being able to use less plastic for an improved containment force, with some operations achieving plastic reductions of between 30-50%.
Cost considerations
Traditional Wrap: Usually has a lower price point per roll but may require more plastic to achieve the desired load stability. The true cost includes consideration of how efficiently the material is used so this becomes variable depending on skill and strength levels of the operator.
Pre-Stretched Wrap: Typically has a higher initial cost per roll, but the reduced material usage often results in overall cost savings. Combined with faster application times and reduced worker fatigue means there is less reliance on skill level or strength of the worker during wrapping. Businesses will also see reduced waste disposal costs due to the reduced amount of plastic on each pallet.
And it’s important to know that the true cost to pallet wrap spend to your business is cost per wrapped pallet – not price per roll.
Performance and load stability
Traditional Wrap: When applied with proper technique and tension, traditional wrap can provide good load stability. However, the variability in application can lead to inconsistent results and poor load stability. Traditional wrap once applied generally retains a large amount of ‘give’. It is this ‘give’ that contributes to load stability issues during transit. Imagine a van breaking sharply and the load shifts. Depending on how the pallet has been wrapped and the skill of the operator, the play still left in the wrap can result in products damaged in transit.
Pre-Stretched Wrap: Delivers more consistent performance and excellent load stability levels. This is down to the fact the optimal stretch has already been achieved during manufacturing. This means there is little ‘give’ retained in the plastic when the pallet is wrapped. This consistency translates to more reliable load containment irrespective of the strength and even skill level, to a degree, of the Operator. So this time when the van hits the breaks, the loaded pallet is held by a much stronger containment force as there is little if no play or stretch left in the wrap. This is the essence of high-performance wrap.
Environmental impact
Traditional Wrap: Generally has a much higher environmental footprint as more product is required working towards achieving pallet load stability
Pre-Stretched Wrap: Generally offers a reduced environmental impact through:
- Less plastic needed per pallet down to thinner yet stronger films
- Re-wrapping of pallets eliminated down to load stability and product damage issues
- Reduced transport emissions as refused delivery challenge’s are eliminated
- High performance film such as iWrap is available as a Carbon Free Purchase, supported by Carbon Neutral Britain
Making the right choice for your operation
Consider Traditional Film If:
- Your operation has highly trained staff with good wrapping technique
- You don’t wrap many pallets
- Initial purchase cost is your primary consideration
- Sustainability goals and plastic reduction is not a priority for your business
Consider Pre-Stretched Film If:
- Your operation involves significant manual wrapping
- Worker safety and reducing ergonomic strain are priorities
- You’re looking to reduce material consumption and waste
- Consistency of application across different operators is important
- Your sustainability initiatives include reducing packaging materials
- You’re willing to invest slightly more initially for long-term savings
The future of hand pallet wrapping
Is already here!
The latest innovation in hand wrapping pallets sees the development of a game changing combination of a high performance film and a new dispenser. Known as the iWrap Hand System – it is designed to reduce waste, improve safety and enhance operational performance.
The hand pallet wrap: pre-stretched iWrap EcoCore is a revolutionary 5mu smaller core, containing 30% recycled content that reduces waste by 57% and possesses all the expected load containment properties you’d expect from a high performance film.
The dispenser: designed to bring real safety to the manual wrapping process. It eliminates the need to twist, bend, stretch or walk backwards when wrapping pallets. It also means operators can wrap pallets of any height faster and at ease.
It’s the combination of this high performance film and innovative, ergonomic and lightweight dispenser that is changing the way pallets are wrapped.
Conclusion
The choice between pre-stretched and traditional pallet wrap isn’t simply about material costs—it’s a strategic decision that impacts operational efficiency, worker wellbeing, environmental footprint, and overall supply chain performance. By understanding the differences and aligning your choice with your specific operational needs and goals, you can optimise your pallet wrapping process for both immediate benefits and long-term value.
As the logistics industry continues to evolve, staying informed about innovations in packaging materials remains an essential aspect of maintaining competitive advantage and meeting increasingly demanding sustainability targets.
If you would like to know more about the benefits of pre-stretched film and the iWrap Hand Wrap System – simply pop over an email to [email protected] and we’ll get in touch.