Should You Stretch Pallet Wrap to Its Maximum Stretch Potential?

Should You Stretch Pallet Wrap to Its Maximum Stretch Potential?

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If you’re responsible for keeping pallets and shipments intact, then you’ll no doubt want to ensure your stretch wrap is both cost effective and reliable.

Getting the best of both worlds can often feel like a delicate balancing act and we’ve certainly noticed an uptick in questions around optimising their current set up for further efficiencies. One question we’re hearing a lot recently is ‘should you stretch pallet wrap to its maximum stretch potential’? 

So, with our latest blog, we thought we’d create a definitive answer to help guide you and your decision making on the subject…

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Understanding the Role of Stretch Potential

What Is Stretch Potential?

Stretch potential, sometimes referred to as the film’s elongation capacity, is a measure of how far the film can be pulled or extended before it reaches breaking point. Depending on factors like raw materials, film thickness, and manufacturing method, different types of stretch film will have varying capabilities. Most stretch films are designed to work within a certain “sweet spot,” where the film provides excellent holding force without tearing. However, the theoretical maximum stretch potential often sits just beyond that sweet spot, which raises the question: if it can stretch that far, why not do it?

Why Does Stretch Potential Matter?


When wrapping a pallet, the most important consideration is stability during transport and handling. Higher pre-stretch can reduce the amount of film needed per pallet, thereby cutting costs on a per-pallet basis. It can also help improve containment force, as the film exerts more tension on the load—like a giant elastic band holding everything in place.

However, going straight to maximum stretch can produce diminishing returns. If you’re not careful with machine settings or the type of film you’re using, you risk tearing, micro-perforations, or even damaging sensitive products because the film is simply too tight.

Pros of Maximising Stretch


Cost Efficiency


The most obvious benefit of stretching the film as much as possible is cost efficiency. You use less film per pallet when you stretch it to a higher percentage of its capacity. Over time, these savings can be substantial, especially in high-volume warehouses wrapping hundreds—or even thousands—of pallets a day.

Environmental Benefits


Using less film is not only good for the bottom line—it’s also beneficial for the environment. By reducing plastic usage, you lower the carbon footprint of your operation too. Companies today are increasingly pursuing sustainability targets, and optimising their stretch can be a simple, effective way to demonstrate a commitment to responsible resource usage.

Improved Pallet Containment Under Ideal Conditions


When the film is stretched properly, it can create a snug fit around the load unit, reducing the chances of product shifting. This means fewer issues such as toppling pallets or scuffed packaging. If you’re shipping heavy items like canned goods or beverages, that tight wrap can make a significant difference in maintaining load stability through a bumpy truck ride.

Cons and Potential Pitfalls


Film Failure and Tearing


Overstretching can compromise the film’s integrity. You might notice small tears appearing, often starting at load corners or sharp edges. Even tiny breaches can degrade containment force significantly. You might end up spending more time and film fixing the damage, effectively undoing any cost savings you anticipated from using less film in the first place.

Load Integrity Issues


Excessive film tension isn’t always beneficial, especially for fragile or easily compressed goods. Boxes might get crushed, labels might tear off, or the product itself could become misshapen. Imagine wrapping a pallet of delicate paper products—like tissue boxes—to the same tension you’d use for heavy canned goods; you’d risk damaging the product before it even leaves the warehouse.

Operational Challenges


Getting the maximum stretch from your film often requires high-quality equipment that has been calibrated correctly. If your wrapping machines aren’t maintained or operator training is lacking, you can end up with uneven wraps or inconsistent results. Operators might spend valuable time troubleshooting or adjusting the machine when maximum stretch is too close to the film’s limit, adding inefficiencies in day-to-day operations.

Finding Your Optimal Stretch Level

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Conduct Thorough Stretch Trials at Our State-of-the-Art Load Stability Testing Centre

 

Relying on in-house trial and error to determine the best stretch level can be time-consuming—and it may not capture every nuance of how your pallets behave in transit. That’s where our new state-of-the-art Load Stability Testing Centre comes in. Instead of relying solely on standard warehouse tests, you can harness our specialised facility to simulate real-world shipping conditions and gather comprehensive data on how different films, tensions, and wrap patterns perform.


We go beyond just checking for film usage or obvious tears. Our advanced testing protocols measure:

  • Containment Force – Using precise instrumentation, we assess how well each wrap configuration keeps pallets stable.

  • Film Integrity – We monitor for micro-tears, punctures, and other potential failure points throughout your shipment’s lifecycle.

  • Load Protection – By simulating the transit process, we gauge whether products sustain compression, corner damage, or other impacts.

  • Overall Performance – We compare multiple film types and stretch settings side-by-side, so you can see exactly which combination offers the best balance of cost and security.

Our experienced team will guide you through each test, explaining the data in practical terms. The result? You’ll gain clear insights into the ideal stretch parameters for your unique loads, backed by robust, real-world evidence—without the guesswork of trial runs in a busy warehouse environment.


It’s the most efficient way to identify the sweet spot for cost-effectiveness and product protection, ensuring that every pallet you wrap is truly road-ready. Learn more about it by booking a call with an expert at this link now.


Consider Load Profiles and Sensitivity

 

Not all loads are created equal. For example:

  • Heavy, uniformly shaped loads like canned drinks can handle—and may benefit from—more tension.

  • Irregularly shaped or fragile goods might need a gentler approach.

The wrapping methodology may even vary within the same warehouse. You might have one dedicated stretch film and machine setting for robust product lines and another for delicate goods. One-size-fits-all rarely applies well to load stability management.

On-Site Evaluations with Our Load Stability Specialists

 

Rather than wrestling with machine settings and film choices on your own, consider inviting one of our load stability specialists to assess your operation on site. Our experts will work directly with you and your team to evaluate your current wrapping processes, identify potential improvements, and recommend optimal tension settings, pre-stretch percentages, and wrap patterns tailored to your products. We’ll also look at key variables like pallet configuration, product sensitivity, and environmental factors that might affect wrapping performance.


By collaborating closely with your staff—right in your own facility—we can provide hands-on guidance and training. Well-informed operators are better equipped to adjust settings, troubleshoot issues, and make real-time decisions that keep your loads stable. Ultimately, this holistic, on-site approach ensures you’re getting the most out of your equipment and film investment, while minimising downtime and reducing the risk of product damage.

Balancing Cost, Efficiency, and Load Stability

 

Cost vs. Performance

 

While cost savings may drive the desire to stretch film to its limit, performance must remain a top priority. A single damaged pallet due to wrap failure could set you back far more than the price of using a slightly thicker film or a marginally lower stretch level.


Picture this: A procurement manager sees a spreadsheet showing a dramatic drop in film consumption after shifting to higher tension. It looks like a great win—until the warehouse starts reporting an uptick in returns and damaged goods. Balancing the ledger requires looking at total impact, not just the cost of film alone.

Continuous Improvement Approach

 

The world of packaging is always evolving, with new technologies, films, and wrapping equipment coming to market regularly. By regularly revisiting your stretch settings and doing follow-up testing, you can adapt to changes in product lines, shipping conditions, or customer requirements.

“I see so many businesses either overspending on film or risking damaged loads simply because they haven’t dialled in their stretch. With the right tweaks though, customers can cut costs and feel confident their products will arrive exactly as they left the warehouse. That’s what we’re here to help you achieve."

Conclusion and Recommendations


Maximising stretch potential sounds appealing at first glance—it offers immediate cost reductions and aligns with sustainability goals by using less plastic. However, like so many things in logistics, context is key. Film properties, load characteristics, and operational capabilities all determine whether stretching to the limit is truly the best approach for your warehouse.

  • Evaluate both short-term cost savings and long-term impact on load stability. A damaged shipment can easily overshadow incremental cost benefits.

  • Conduct trials. Don’t just set your stretch wrapper and forget it—test new film types and machine calibrations regularly to find the sweet spot.

  • Adopt a continuous improvement mindset. Monitor your process over time, make data-driven decisions, and remain flexible enough to respond to changes in product lines or shipping conditions.

Ultimately, the decision to stretch pallet wrap to its maximum capacity hinges on careful risk-benefit analysis. Under the right conditions and with proper equipment and training, pushing film closer to its limits can result in great savings and efficiency. But if you’re seeing increased film breakage or product damage, it might be time to dial back and find a more moderate approach.

By keeping these considerations in mind, you can strike the perfect balance—one that ensures stable pallets, happy customers, and a thriving bottom line for your business.