The Difference Between Shrink Wrap and Stretch Film

The Difference Between Shrink Wrap and Stretch Film

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When it comes to securing products for transportation and storage, the options can sometimes be overwhelming—especially if you’re deciding between shrink wrap and stretch film. As transport packaging specialists, we have seen firsthand how choosing the right film can make a significant difference in preventing damaged goods, reducing costs, and keeping warehouse operations efficient.

In this article, we’ll take an in-depth look at shrink wrap versus stretch film, exploring their key differences, and offer practical tips to help warehouse managers and procurement teams make informed decisions when it comes to choosing between the two.

So, let’s get started…

STRETCH OR SHRINK

Introduction


Why the Right Film Matters


Pallet wrap plays a pivotal role in the logistics chain by protecting goods; whether that’s from environmental factors, tampering or stabilising goods during transport. In many warehouses, improperly wrapped goods often lead to damaged items, wasting not just the product – but the labour too. Over the years we’ve seen a number of distribution centres where the packaging choice literally determined whether products arrived at the end user intact, or in pieces.

We can’t stress this point enough, choosing the right film should never be about cost per roll. It’s about efficiencies, reducing damages and meeting the demands of the supply chain. All too often we see examples of choosing the short-term saving over the long-term benefits that make money and save far more.

So with that in mind, let’s explore the differences between two of the most common types of packaging film: shrink wrap and stretch film…

Defining Shrink Wrap


What Is Shrink Wrap?


Shrink wrap is a film made from materials such as polyethylene, polyolefin, or PVC that, when heated, contracts around an item to form a tight seal. You’ve probably seen shrink wrap extensively in retail multipacks—think about those multi-packs of water bottles neatly bound together in a transparent film. It can also be used for larger palletised loads, but it’s more common for smaller items or for bundling products together in attractive retail packaging.

How Shrink Wrap Works


Heat is crucial to the shrink wrap process. After the product is covered in shrink film, it is exposed to hot air—usually in a shrink tunnel or via a heat gun. The film’s polymer structure responds to heat by “shrinking,” tightly conforming to the product’s contours. This creates a secure, form-fitting seal that protects against dust, moisture, and tampering.

This method is particularly popular in certain industries where presentation matters and the product size or shape calls for a tight, protective seal. Because of the heat involved, however, some products or packaging materials could be damaged by high temperatures, making shrink wrap less ideal for heat-sensitive items.

Use Cases and Benefits of Shrink Wrap


    • Retail Presentation: Because it forms a neat seal, shrink wrap provides a clean, visually appealing look that is often used for consumer goods in stores.

    • Tamper Evident: Once the film is shrunk, any attempt to open or alter the package will be noticeable, making it a good choice for products needing extra security.

    • Dust and Moisture Protection: Items sealed in shrink wrap are protected from external contaminants.

    • Versatility in Product Shapes: The film can conform to products with unique shapes, ensuring a snug fit that doesn’t shift during handling.

Despite these benefits, shrink wrap can be more expensive to implement on a large scale, particularly because of the additional equipment needed (heat tunnels or heat guns) and the energy costs associated with running these machines.

Understanding Stretch Film


What Is Stretch Film?


Stretch film, also called stretch wrap, is commonly made from linear low-density polyethylene (LLDPE). Designed to be pulled and stretched around a pallet or product load, this film’s elasticity creates tension to hold items together. Compared to shrink wrap, no heat is required, making it a more energy-efficient option for most warehouse environments.

How Stretch Film Works


Applying stretch film can be done either manually or with a machine. When done manually, a worker walks around the pallet, pulls the film tight, and layers it around the load. Machine stretch wrapping systems automate this process by rotating the pallet on a turntable,  (or rotating the film carriage around a stationary pallet) while applying a pre-set tension level. The film’s “memory”—its ability to return to its original size—creates a tight, secure wrap around the product. This tension helps stabilise the load and reduce the risk of shifting during transport. Additionally, many stretch films have “cling” properties on one or both sides, which helps the layers of film stick to each other, improving the hold.

Use Cases and Benefits of Stretch Film


    • Load Stabilisation: Ideal for securing large, heavy, or tall pallets where load shifting is a major concern.

    • Cost-Effectiveness: Often less expensive per load than shrink wrap due to simpler application (no heat tunnels) and the possibility of using advanced films that reduce material usage.

    • Versatility: Works well across a wide range of product types and industries.

    • Efficiency: Machine wrapping can handle high volumes quickly, while manual wrapping is effective for smaller operations or irregular loads.

For many warehouses, stretch film is the go-to option for bulk logistics, particularly when shipping full pallets or preparing items for extended transit. Its ability to stabilise loads effectively is key in preventing costly product damage.

Stretch film

Key Differences Between Shrink Wrap and Stretch Film


1. Method of Application


  • Shrink Wrap: Requires heat to shrink the film around the product.

  • Stretch Film: Relies on tension created by stretching the film around the product, so no additional heat is required.

The difference in method has major implications for equipment costs, energy consumption, and speed of operation.

2. Performance and Load Stability


  • Shrink Wrap: Provides a form-fitting seal that’s excellent for smaller items, retail packs, or products requiring tamper evidence. However, it may not always deliver the highest level of load stability for larger or heavier pallets without specialised equipment.

  • Stretch Film: Delivers robust pallet stabilisation thanks to its elasticity. It’s generally considered more effective for securing and bundling large loads together, especially when used with the correct wrap force and techniques.

3. Cost and Operational Considerations


  • Shrink Wrap: Higher capital expenditure for heat tunnels, regular energy costs, and potentially more labour to handle specialised machinery. If you’re dealing with large volumes, these can add up.

  • Stretch Film: Typically lower in capital investment (especially if hand-wrapping), though automatic stretch wrap machines also carry a purchase or lease cost. However, they usually consume significantly less energy than heat-based shrink systems.

4. Suitability for Specific Products


  • Shrink Wrap: Best for smaller items, retail multipacks, or temperature-resistant products that can handle the heat application. Also ideal when a high-quality presentation is needed.

  • Stretch Film: Perfect for bulk items, heavier pallets, or irregularly stacked loads that require strong tension to prevent toppling.

Factors to Consider When Choosing


1. Product Nature and Sensitivity


Consider how fragile your products are and whether they can handle a certain level of tension (for stretch film) or heat (for shrink wrap). Temperature-sensitive products like chocolates or heat-sensitive electronics might be better suited to stretch film to avoid damage during the shrink-wrapping process.

2. Logistics and Supply Chain Requirements


Think about transport distances, handling frequency, and any environmental exposures your products might face. If your loads will be moved multiple times, or if you’re shipping via long-haul or overseas routes, stretch film’s strong hold can often provide more resilience against shifting.

3. Budget and Volume


  • Upfront Costs: Shrink wrap setups typically require bigger initial investments in heat machinery.

  • Per-Pallet Costs: Stretch film may often work out cheaper on a per-load basis, especially if you use a high-performance or pre-stretched film.

  • Usage Volume: If you’re wrapping thousands of pallets daily, even small cost differences per pallet can add up to substantial savings.

4. Sustainability Goals


With a growing focus on environmental impact, both shrink wrap and stretch film manufacturers are exploring recyclable materials and thinner films to reduce plastic use. Often, stretch film is easier to recycle at certain facilities, though this can vary based on local regulations. Opting for thinner gauges or pre-stretched films can also help cut down on total plastic consumption.

Practical Tips for Procurement Teams


1. Evaluating Suppliers and Quality


Look for suppliers with consistent film quality—from thickness and tear resistance to cling properties. A subpar film can lead to frequent film breaks, inefficiencies, and, in the worst case, compromised load stability. Ask these questions when vetting a supplier:

  • Do they provide technical data sheets or test results for their films?

  • What’s their tolerance for variance in film thickness, length or clarity?

  • Do they offer trial rolls or on-site demonstrations?

2. Trial and Testing Protocols


Never underestimate the importance of trial runs before you commit to a large-scale purchase. Of course, if you’re considering your operations, we’d be happy to welcome you to our Load Stability Testing Centre where you can simulate real world transit conditions and discover the best option with your specific needs in mind.

3. Training and Implementation


Even the best film can fail if it’s incorrectly applied. Make sure your warehouse staff:

  • Understands how to properly tension the film.

  • Follows recommended wrapping patterns (e.g., starting at the base, overlapping layers).

  • Uses tools or machines safely and correctly.

For shrink wrap, ensure your team knows optimal heat settings, safety protocols around heat tunnels, and how to address film shrinkage inconsistencies.

4. Cost-Saving and Efficiency Strategies


  • Pre-Stretched Film: This type of film has already been stretched, reducing the effort needed and the risk of over-wrapping.

  • Regular Machinery Maintenance: Keep your wrap machines well-calibrated to avoid film breakage, reduce waste, and maintain a consistent wrap quality.

  • Measure Your Results: Track film usage per pallet and monitor the rate of product damage. You might identify areas where you can cut costs or improve wrapping techniques.

“Shrink is most often employed as a secondary packaging measure, binding products together in multipacks. It can be used in bulk operations, but rarely is it efficient to do so. Particularly with the introduction of nano films, there's little reason to look further than the stretch for palletised goods."

Conclusion


Making an Informed Decision


Shrink wrap and stretch film each have unique advantages. Shrink wrap offers a neat, form-fitting seal suitable for smaller, presentation-focused packaging needs, while stretch film excels at stabilising loads for transit—especially when shipping heavier, bulk items. The choice ultimately comes down to your specific product requirements, logistics demands, budget, and sustainability goals.

Final Takeaway for Warehouse Managers and Procurement

 
  • Test Before You Invest: Conduct trials with both shrink wrap and stretch film to confirm which best meets your load stability and operational needs.

  • Consider the Total Cost: Don’t just compare the cost per roll; factor in equipment, labour, and potential product damage or returns.

  • Look for Ongoing Support: A knowledgeable supplier or consultant can help you continuously optimise your packaging methods as your business needs evolve.

Ultimately, whether you wrap your pallets with heat or with tension, ensuring your products arrive in one piece is the real bottom line. By carefully weighing the pros and cons of shrink wrap vs. stretch film—and by staying informed on best practices—you’ll keep your supply chain flowing smoothly, your products protected, and your costs under control. If you need more personalised guidance, reach out for a load stability assessment or to schedule a trial. Let’s work together to find the perfect film solution for your demands.