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LONG-TERM PALLET WRAP STORAGE: EXPERT TIPS FROM THE WAREHOUSE

Written by

ELLIE CHALMERS

Load Stability

INTRODUCTION

Here’s what most operations miss: you can buy the best pallet wrap on the market, but if it’s stored badly, you’ve just wasted your investment.

After all, proper storage isn’t just about keeping your stock tidy, it’s about protecting your pallets and ensuring optimal load stability.

Alarmingly, studies show that load containment force in stretch wrap can decrease by up to 55% when exposed to higher temperatures. Whether businesses are managing a high-turnover warehouse, or maintaining strategic stock levels, long-term storage for pallet wrap is an important part of the operation.

In this guide, we’ll share everything you need to know about pallet wrap storage for the long term, so your operation can maximise the performance of every roll.

WHY PROPER STRETCH FILM STORAGE MATTERS

Before we dive into the specifics of how to store pallet wrap, let’s talk about why it’s so important to correctly store film: to maintain the film’s performance properties.

1. Stretch Film Memory

Stretch film memory is pallet wrap’s ability to maintain tension once it’s been wrapped around a pallet. Memory is a vital stretch film property as it ensures the wrapped pallet stays secure, and products are tightly bound together during transport. When storage conditions degrade film memory, you lose that critical tension, and with it, your load stability.

2. Film Elasticity

Elasticity determines how far your film can stretch without breaking, and how well it recovers. When environmental factors compromise elasticity, you’ll notice increased film breaks, difficulty achieving proper pre-stretch percentages, and inconsistent wrap patterns that leave loads vulnerable.

3. Film Thickness

While film thickness (also known as gauge) is determined during manufacturing, storage conditions can affect how that thickness performs in practice. Temperature extremes, UV exposure, and moisture can all cause dimensional changes or material degradation that make your film behave differently than expected.

CONDITIONS FOR LONG-TERM STRETCH FILM STORAGE

Let’s get specific about the environmental conditions that matter most for long-term pallet wrap storage. Here’s what you need to know:

Storage Factor	Optimal Condition	Dangers
Temperature	~15 – 20°C Consistent temperature is more important than hitting a specific number.	Cold film becomes brittle, loses elasticity and is prone to snapping. Heated film becomes tacky and can fuse itself on the roll.
Humidity	~30 – 50% relative humidity Avoid condensation-prone environments and areas with humidity fluctuations.	Moisture affects the film’s tackiness and promotes dust accumulation.
Sunlight	Store in a dark or shaded area, minimising direct sunlight.	UV radiation breaks down polymer chains in the film, causing discolouration, reduced elasticity, and weakened film.

These three factors work together: a warehouse that’s too hot and receives afternoon sunlight, for example, will degrade film much faster than one with just moderate temperature variation. Where possible, treat your film storage area with the same attention you’d give to storing any other critical warehouse material.

HOW TO STORE PALLET WRAP

Beyond controlling environmental conditions, the way stretch film is stored long-term makes a real difference to the performance over time.

Here are our top recommendations:

Storage Position: Upright vs. On the Side

Always store stretch film rolls upright on their flat base, never on their side. When stored horizontally, the weight of the roll causes uneven compression across the film layers, which can lead to ‘flat spots’ that create tension inconsistencies during application.

Upright storage distributes weight evenly and maintains the cylindrical integrity of the roll. If your floor space is at a premium, we suggest investing in proper racking designed for upright film storage.

Rotation System: Use Older Stock First (FIFO)

If you aren’t already, implement a first-in, first-out (FIFO) inventory system for your stretch film. Even under ideal storage conditions, film doesn’t improve with age.

Mark incoming shipments with receipt dates and position newer stock behind older stock in your storage area. This simple practice prevents film from sitting for extended periods and ensures you’re always using material within its optimal performance window.

Protecting Film from Physical Damage in Storage

Physical damage is often overlooked but can be just as problematic as environmental factors. Keep rolls away from sharp edges, protruding nails or screws in racking, and high-traffic forklift routes where impacts might occur.

If your storage area also houses other materials, maintain clear separation. Cardboard dust, packaging debris, and chemical residues can all interfere with film performance.

By storing film in clean, stable, temperature-controlled environments, and rotating stock correctly, we can protect the pallet wrap’s consistency and maximise performance.

This leads to fewer load failures, reduces waste and leads to a more cost-effective transport organisation.

WAYNE LAKEY

WAREHOUSE MANAGER

COMMON STORAGE MISTAKES TO AVOID

Even experienced warehouse teams can fall into these pallet-wrap-storage traps:

Storing film in extreme temperatures or direct sunlight: Loading dock areas, areas near external doors, or in uninsulated spaces can expose film to temperature swings that degrade performance in the long run.

Overloading rolls or stacking improperly: We’ve seen operations stack six or seven rolls high to save floor space, only to find the bottom rolls crushed and unusable. Weight limits exist for good reason.

Leaving film exposed to dust or chemicals: Airborne contaminants settle on film over time. If your storage area doubles as a maintenance zone or cleaning station, it might be time to relocate your film.

Ignoring manufacturer storage guidelines: Different film formulations may have specific requirements. Specialty films (coloured, vented, or high-performance grades) often need more controlled storage than standard hand film.

For a broader look at pallet wrapping issues, see our guide on common pallet wrapping mistakes.

LONG-TERM STORAGE FOR IMPROVED LOAD STABILITY

Let’s connect the dots between what happens in your storage area and what happens when loads hit the road. Proper storage isn’t just about film quality in isolation; it directly impacts the load stability and security of every pallet you wrap.

Correctly stored stretch film means predictable pre-stretch ratios, reliable film memory, and tension distribution around the load, even after months in storage. Operators can dial in their wrapper settings knowing the film will behave the same way from roll to roll. This consistency translates to loads that stay tight through handling, transport, and delivery.

Expert Tips For Busy Warehouses

We understand that not every operation has the luxury of dedicated, climate-controlled film storage. If you’re working within constraints, here are practical tips that’ll still make a significant difference:

Zone your warehouse: Even without climate control, some areas are more stable than others. Interior zones away from loading docks and external walls tend to have less temperature variation.

Use thermal blankets or tarps: If extreme cold or heat is unavoidable, covering film pallets with insulating materials can buffer temperature swings. It’s not perfect, but it’s better than direct exposure.

Reduce safety stock levels: High-turnover warehouses often don’t need months of film inventory. Work with your supplier to establish more frequent deliveries with smaller order quantities. Fresher stock means less time in storage and fewer performance issues.

Monitor and document: Place a simple thermometer in your film storage area and check it weekly. If you spot concerning trends (consistently above 30°C or below 10°C), you’ll know to take action before film quality degrades.

Train your team: Make sure warehouse staff understand why film storage matters. When the whole warehouse team knows that leaving film in the sun causes problems down the line, compliance will improve naturally.

KEY TAKEAWAYS

Long-term stretch film storage doesn’t need to be complicated, but it does need to be intentional.

When you treat stretch film storage as a critical part of your warehouse operations (and not just an afterthought) you protect your investment, reduce waste, and ensure every pallet leaves your facility with the load stability it needs to arrive safely.

For more expert guidance on pallet wrapping, load stability, and getting the most from your stretch film, explore our resources:

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