The 7 Best Pallet Wrapping Techniques and Tools You'll ...

Demand for shipping pallets is surging in response to the recent dramatic growth in e-commerce.

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Is your business one of the many needing to handle more pallet shipments than in the past? Are you looking for ways to improve your logistics?

Pallet wrapping is a critical part of the shipping process. It secures your goods to the pallet and prevents damage or loss during distribution. Efficient pallet wrapping depends on using the right tools and the right techniques.

Learn more here about the tools and supplies you'll need for pallet wrapping along with tips for wrapping pallets the right way. 

Types of Pallet Stretch Wrap

Pallet wrap is one of the most important tools you'll need for efficient pallet wrapping. Most stretch wrap is made from linear low-density polyethylene (LLDPE).

You can choose cast or blown wrap. You'll also need to select hand wrap or machine wrap depending on how you wrap your pallets.

Cast Wrap

Cast LLDPE film is the most common stretch wrap material. The production process is quick and inexpensive. This means cast film is usually the most economical option.

Cast stretch wraps are suitable for light- to medium-duty applications. Cast film stretches easily. It can stretch even after you apply it, though, which can allow the load to shift.

If cast film stretches too much, it will tear.

Blown Wrap

Blown LLDPE film has a higher stretch and higher load capacity than cast film. It's very tear-resistant and puncture-resistant. Blown stretch wrap is suitable for medium- to heavy-duty applications.

Blown stretch wrap has one-sided cling. Pallets won't stick to each other. Blown film won't keep stretching after you apply it. It has better stretch memory. However, it's harder to apply.

Blown wrap also makes more noise when you use it. The production process for blown film is more expensive, which makes the stretch wrap cost more.

Hand Wrap

Hand stretch wrap is designed for manual pallet wrapping. It's available in cast or blown wrap.

The rolls are smaller and lighter than for machine wrap. Hand rolls are usually - ft long and 5-9 lbs in weight. The width is typically 10-18".

You can choose different thicknesses and stretch rates. Thicker film is more resistant to punctures, but it takes more force to apply it.

Hand wraps typically have a stretch rate between 75% and 150%. The user has to keep constant tension on the roll to maximize the stretch rate and the wrap usage.

Machine Wrap

Machine stretch wrap rolls can be 20-80" wide. They can weigh more than 100 lbs. A range of thicknesses is available.

You get a higher stretch rate with machine wrap. The machine maintains constant tension on the roll. Stretch rates of 200% to 250% are standard, but you can often exceed these rates. This can significantly reduce your wrap costs.

Stretch Wrap Gauge Guide

This is an approximate guide for choosing the correct stretch wrap for your needs.

• 60 Gauge for loads up to lbs.

• 70 Gauge for loads up to lbs.

• 80 Gauge for loads up to lbs.

• 90 Gauge for loads up to lbs.

• 120 Gauge for loads up to lbs.

Manual vs Machine Pallet Wrapping

You can wrap pallets by hand or use a pallet wrapping machine.

Wrapping pallets by hand is a feasible choice if you wrap a small volume of products. Companies that wrap less than 50 pallets or so a day may choose to have their employees manually wrap pallets. Following best practices is very important to prevent employee injuries and avoid damaged goods.

Stretch wrapping machines are more efficient for businesses that need to wrap a higher volume of pallets. The most common types of stretch wrapping machines are turntable stretch wrappers, overhead wrappers, and robotic stretch wrappers.

Turntable wrappers and overhead wrappers are semi-automated. Robotic wrappers are fully automated.

How to Wrap a Pallet

Whether you wrap your pallets manually or using a machine, the basic steps are similar. These techniques help ensure your load gets to its destination safely.

1. Prepare the Load

Choosing the right pallet is the first step in pallet wrapping. The pallet should be the right size for the load and in good condition. It needs to support the full weight of the shipment.

When possible, the load should be stacked uniformly from the bottom to the top. Individual items should be as close together as possible. This makes the pallet easier to wrap and helps prevent the load from shifting.

2. Choose Your Equipment

For hand wrapping, a tool like a Nelson wrap dispenser makes pallet wrapping easier and more ergonomic.

If you need to ship large loads frequently, a pallet wrapping machine is probably a better option. You can choose the type of machine based on the degree of automation you want.

3. Attach the Stretch Wrap

Pull out some stretch wrap from the roll and twist it into a rope shape. You can weave it into the pallet slats or thread it through one corner and fold the rest over it.

You don't need to tie a knot. The film will stick to itself. Leaving the wrap without a knot makes unpacking the pallet easier.

4. Wrap From Bottom to Top

Wrapping starts at the bottom and spirals upward towards the top. You'll be doing a 360º wrap. Wrap the base several times to ensure the load is well-secured at the bottom.

As you move up the load, the stretch wrap should overlap itself by 50%. You can program stretch wrapping machines for specific overlaps. If you're wrapping manually, you'll need to estimate.

You should wrap the top of the load twice to improve stability.

5. Keep the Right Wrap Tension

Tension controls how tightly the stretch wrap compresses the load. It ensures the load is packed as tightly as possible.

Fragile products need a lighter tension to avoid crushing. Higher tension is important for heavy and solid loads to improve stability.

6. Double-Wrap if Necessary

When you get to the top of the load, you can either tie it off or spiral back down.

Double-wrapping is a good idea if the load could use additional stability. You use more stretch wrap, but you help prevent damaged products.

7. Tie off the Wrap

The final step in good pallet wrapping is tying off the wrap. Once the load is secure, you can cut the stretch wrap from the spool.

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One finishing option is to tie the end of the wrap to the load. This takes time when preparing and unpacking the pallet.

Folding the cut end of the wrap into a seam is more efficient. The film will stick to itself. Compression from the seam will hold the end in place.

For additional security, you can use pallet strapping. Tools like the StrapBandit make threading the pallet easier.

Finding the Best Pallet Wrapping Tools and Supplies

Quality tools and supplies make your pallet wrapping more efficient and more secure.

Pack Secure has the stretch wrap, dispensers, and other tools you need to optimize your warehouse logistics. We've been providing top brand products to our customers for over 20 years.

Contact us today to start designing your ideal pallet wrapping solution.

Whether your products travel by land, sea, or air, they run the very real risk of being damaged while in transit. Packaging Digest reports that anywhere from 2% to 11% of all shipments incur some form of damage by the time the products reach their final destination

Shipping products from point A to point B can be a risky journey. Vibration, impacts, and mishandling can easily damage goods along the way.

A semi or fully-automatic pallet wrapping machine helps prevent product damage&#;especially when wrapping pallets by hand.

Read on to learn how to properly shrink-wrap a pallet and keep your goods safe and secure.

1. Assessment and Loading

Use common sense and avoid overloading the pallet to save on shipping. Stacking too high can create an unstable load that is hard to wrap and secure properly. Following pallet wrapping guidelines for maximum load weight and height will ensure a secure wrap.

Before wrapping, check the load stability by calculating the pallet&#;s capacity. Ensure the products&#; total weight and height do not exceed the pallet&#;s load limits. Use more stretch wrap for heavier, less stable loads. The more the products shift or lean, the more you&#;ll need to secure them.

2. Initial Setup

Once the pallet is on the shrink wrapper, you&#;ll need to attach the film to the pallet. The best attachment point is in the lower corner of the pallet, further away from the carriage. Automatic pallet wrappers perform this step automatically, so workers don&#;t have to get off the forklift.

After you&#;ve attached the film, head over to the pallet wrapper control panel and make the following adjustments:

Revolution speed&#;Set the revolution speed appropriately. Too fast may topple the load, but it should still wrap quickly enough for production needs. Find the right speed that secures the products without slowing down wrapping.

Carriage ascent and descent speeds&#;Assess the pallet height and weight. Then adjust the carriage ascent and descent speeds accordingly:

• Set the speed slower for pallets over 6 feet tall to ensure thorough coverage of the entire load height. Going too fast can leave gaps.
• For heavier pallets, set the speed slower to allow for more top and bottom rotations to secure the load properly. Heavier loads require more rotations.
• Set a faster speed for lighter pallets since you&#;ll need fewer rotations to contain the load fully.

The goal is to optimize the speed to use just enough wrap to fully secure the load without wasting excess. Watch the coverage and adjust speed as needed.

Film force tension&#;Properly setting the tension is critical for a quality pallet wrap. Be careful not to over-tighten the pressure to prevent damage. This can lead to film tearing or crushed boxes on the bottom layers.

Start with moderate tension and observe the results. Adjust as needed based on the load weight. Use lighter tension for lighter loads to avoid damage. Increase tension for heavier loads to contain them securely.

*Note: Machines with the power pre-stretch feature tend to need less film force tension because it has memory. It will constrict back to the load after passing through the rollers.

Photo-eye delay setting&#;There is a control setting that causes the film to curl over the top of the load. Typically, for an A-load, you&#;ll want around 3-6&#; of overwrap to help contain the uppermost boxes on the pallet.

Assess the uniformity and weight of the pallet load. Then adjust the photo-eye delay setting accordingly:

• For uniform pallets with even sides, use a shorter delay. The machine can easily detect the top and bottom.
• For non-uniform pallets with uneven sides, use a longer delay. This prevents the eye from falsely detecting gaps at the top/bottom and stopping too soon.
• For heavier pallets, use a longer delay to allow for extra overwrap containment of the top boxes.

Watch the overwrap as you test your settings. Adjust the delay until you reach the proper overlap for the specific pallet.

3. How Much Is Too Much Stretch Wrap?

For a standard pallet of boxes under 2,000 pounds, set the top and bottom wrap settings to about three revolutions. This should be enough to secure lighter loads. If you need to apply more wrap, try to avoid overdoing it. You&#;ll wind up wasting time and money and won&#;t see an increased benefit.

4. Initial Test Wrapping

Perform an initial test wrap for the first pallet load. Yes, it might take a little longer at first. However, you&#;ll know exactly how fast or slow you must go when wrapping similar pallets.

Generally, it is better to start with slower speeds for both the turntable and the carriage. Gradually increase the speeds in small increments to find the optimal settings and ensure a safe and secure wrap.

Setting the tension at about halfway is a good starting point unless you have fragile boxes. In that case, start at around 20%. You&#;ll eventually get a sense of optimizing the cycle time and balancing the appropriate amount of wrap film.

5. Final Adjustments

Once the test wrap completes, pay particular attention to the bottom wraps to help secure the load to the pallet. Extra top wrap revolutions can also be helpful for unstable loads.

Finally, check the overall stability of the wrapped pallet. Does it seem stable and well-protected? If not, go back and adjust the stretch wrapper settings further. If so, cut the film and wrap it around the base of the pallet.

The Model Series semi-automatic stretch wrap machine cuts and tucks the wrap into the base of the pallet automatically. Automating this final step saves time and allows the operator to remain on their forklift.

Watch the Model 850PS Wrap a Pallet

See how quick and easy it is to securely wrap a pallet with the Handle It Model 850PS shrink-wrapping machine..

When it comes to wrapping a pallet of boxes with a pallet wrapper, there are several things that you can do that will help ensure a successful and secure wrap. Read on to learn more about how to properly shrink wrap a pallet and keep your goods safe and secure.

Assessment and Loading

When initially loading the pallet with your products, let common sense be your guide. Don&#;t try to stack too many boxes to save a few bucks on shipping costs. You could potentially create a situation where you&#;re hoping the wrap job will somehow be able to overcome the laws of physics.

Before you load the pallet onto the pallet wrapping machine, assess how stable your products are by learning how to calculate pallet load capacity. A general rule of thumb is that the heavier and less stable the load, the more stretch film you should apply.

Initial Setup

After you&#;ve loaded the pallet with boxes and placed it onto the pallet wrapping machine, head over to the control panel on the pallet wrapper and make the following adjustments:

Revolution speed &#; set this to an appropriate level. Too fast, and you can run the risk of toppling the load&#;however, you still want it to be fast enough to keep up with your production.

Carriage ascent and descent speeds &#; you should set them to optimize the film coverage throughout the load height. If you have the speed set too fast, you can leave uncovered gaps. Too slow, and you can be wasting film. Again, this depends on the pallet&#;s weight and stability&#; with more film needed with heavier and unstable pallets.

Film force tension &#; is another basic setting that you will want to dial in for a proper pallet wrap. Set the film force tension so that the film applied holds to the product but not so tight that you crush the load. Keep in mind that if you set it too tight, you can run the risk of film tearing, which can cause time delays or crushed boxes.

*Note that machines with power pre-stretch tend to need less film force tension because the film has memory and will constrict back to the load after being stretched through the film rollers.

Photo-eye delay setting &#; A setting within the controls allows you to get the film to curl over the top of the load. Typically, for an A-load, you&#;ll want around 3-6&#; of overwrap to help contain the uppermost boxes on the pallet.

How Much Is Too Much Stretch Wrap?

As a general rule of thumb, a standard load of boxes that weighs less than 2,000 lbs shouldn&#;t need more than ~3 revolutions for the top and bottom wrap settings. Certainly, there are situations where you need to apply more film but be cautious not to waste time and money with too much stretch film.

Initial Test Wrapping

For the first pallet load, you should perform an initial test wrap. Yes, it will take a tiny bit longer, but once you get things dialed in, you&#;ll have a good idea of just how fast (or slow) you need to go when wrapping subsequent pallets.

In general, it is better to start with slower speeds for both the turntable and carriage and then incrementally work up to faster speed. This will help reduce the chance of film tearing on the pallet or load and give you a better idea of how much film to apply.

Typically, setting the tension at about halfway is a good starting point unless you have fragile boxes. In that case, start at around 20%. Once you&#;ve wrapped a few pallets, you&#;ll get a sense of how to optimize the cycle time and balance the appropriate amount of film.

Once the wrap is complete, pay particular attention to the bottom wraps to help secure the load to the pallet. Extra top wrap revolutions can also be helpful for unstable loads.

Have Questions or Need Help?

Learning the correct way to use your wrapping machine will help ensure a safe and secure loading experience&#;and a happy customer. If you have any questions about wrapping your pallets or your current pallet wrapping machine isn&#;t up to par, contact us today to learn more about how Handle It can help solve your toughest wrapping challenges.

How Much Stretch Wrap Do I Need to Wrap a Pallet?

The amount of stretch wrap required depends on using pre-stretched or non-pre-stretched film. The pre-stretched wrap contains built-in tension and uses less material. Non-pre-stretched requires more revolutions and wrap to create tension around the load.

The weight, size, and consistency of the load you&#;re wrapping also play a factor. There are different types of stretch film to consider as well.

For a typical 40×48 inch pallet stacked around 5 feet high, you would need approximately 100-150 feet of non-pre-stretched film. However, with a pre-stretched carriage, you may only require 30-40 feet for the same size load.

This is due to the pre-stretching mechanism stretching the film as it applies it. This allows it to cover more area with fewer linear feet of wrap. Pre-stretching can dramatically reduce total wrap usage for the same coverage.

Should You Strap or Wrap a Pallet First?

You should strap pallets before stretch-wrapping them. Strapping first provides load stability and compression. Then you can apply the stretch wrap over the straps to seal and contain the pallet. Strapping before wrapping also helps optimize pallet integrity for shipping and handling.

How Many Times Should You Wrap a Pallet?

The number of wrap revolutions depends on the box size and weight. Uniform, lighter loads need 2-3 revolutions. Heavier or irregular loads require up to 4 revolutions to stabilize the pallet. Using more than 4 revolutions wastes film with little added benefit.

Generally speaking, avoid wrapping the same section more than 2-3 times. Instead, do 2-3 low wraps to stabilize the bottom, then 2-3 higher wraps to seal the top. Four total revolutions (2 down, two high) secure most pallets well without excessive wrap use.

Non-Standard Load Considerations

Adjust the photo-eye delay to ensure complete coverage when wrapping irregular-sized loads. Start with a longer delay to prevent an early cutoff at the top. Watch the wrap and refine the setting for a proper top overlay.

Use lighter tension settings initially on uneven loads to avoid wrap breaks. Progressively increase tension for better hold without crushing contents. For tall pallets, slow the carriage speed to cover the height fully. Thicker film or lighter tension prevents punctures from sharp edges.

Have Questions or Need Help?

Taking the time to dial in a stretch wrapping machine properly pays off through securely wrapped pallets and damage-free shipping. Get in touch with us below to learn how Handle It can help solve your toughest wrapping challenges.

Contact a Pallet Wrapper Expert

Contact us to discuss your requirements of Hand Pallet Wrap Machine. Our experienced sales team can help you identify the options that best suit your needs.