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WHY DOES MY PALLET WRAP SNAP?

Ben's Headshot

Written by

BEN THOMPSON

Load Stability

Pallet Wrap

Tips & Tricks

Table of Contents

Estimated read time: 21 mins

INTRODUCTION

In bustling warehouse environments, there are few things as frustrating as stretch film snapping. Particularly if you’re expected to wrap throughout the day and are faced with issue every single time.

We all know how important pallet wrap is to ensure the secure transport of goods, yet when it fails, the consequences can vary from damaged products to safety hazards for staff.

In one such instance, a client facing film snapping issues led to a toppled pallet of glassware. Which meant not just time spent clearing up, but hours on revising protocols too.

So, keep reading to discover why pallet wrap snaps, how to reduce film waste, and ultimately improve your performance.

COMMON CAUSES OF PALLET WRAP SNAPPING

close up of worker pulling a clear roll of stretch film that's tearing

So, why does pallet wrap snap? And how can you prevent such mishaps? Let’s start by looking at some of the most common causes…

1. Pallet Wrap Material and Storage

The integrity of your wrap is your first line of defence. From the film’s quality to the way that it’s stored in the warehouse, many stretch film snapping issues come down to material makeup.

  • Low Quality Pallet Wrap: Using subpar or expired wrap can compromise elasticity, as film stored for years often becomes brittle.
  • Temperature Matters: Extreme cold also makes wrap brittle, while excessive heat reduces tensile strength. We have found that ~15 – 20°C is the optimal temperature for storage.
  • Storage Conditions: Prolonged UV exposure or high humidity can degrade the film and ruin its adhesive properties.
  • The Right Specification: Choosing a wrap that is too thin for heavy or sharp-edged loads significantly increases the risk of tearing.

Want to make the most out of your film? Check out our guide on long term pallet wrap storage and stay up-to-date with the latest film storage techniques.

2. Load Dynamics and Application Technique

Even high-quality film will snap if the application is mismatched to the load. Once you’ve established your pallet wrap is high quality, and it’s being stored appropriately, take a look at how operatives are applying it to the pallet.

  • Load Type: We recommend optimising your pallet stacking pattern to reduce tension points, overhangs, or voids. Items with protruding parts or sharp corners often puncture the film, leading to a full snap.
  • Tension Balance: Wrapping too tightly overstretches the film, while wrapping too loosely fails to support the goods. The goal is to achieve optimal load containment, the force that holds goods together.
  • Pallet Wrapping Patterns: Random or haphazard wrapping patterns can lead to an uneven distribution of tension, while insufficient overlap create weak points that inevitably fail during transit.

3. Equipment Health

If your technique is perfect but the film still breaks, your machinery is the likely culprit.

  • Malfunctioning Equipment: worn-out parts often result in uneven application, damaging the film before it even meets the pallet.
  • Regular Servicing: Pallet wrapping machines need to be regularly serviced. Neglecting this can result in uneven application or excessive tension.

THE PALLET WRAP SNAPPING TROUBLESHOOTING CHECKLIST

When assessing the root cause of stretch film snapping, the load stability technicians at Castle follow a series of testing protocols that look at the whole picture.

For warehouse teams who are experiencing film breakages, use this checklist to troubleshoot some of the most common causes we see on-site:

Load Stability & Film Performance Checklist

PALLET WRAP TIPS FROM THE WAREHOUSE

So, with the causes identified, the next step is to start putting into place some preventative strategies for the road ahead…

QUALITY PALLET WRAP

Switching to high-performance polymers, like our Nano range, will reduce film snapping and product damages. While high performance, multilayer films may cost more per roll, we see many businesses make savings in the long run when measuring the total cost per safe delivery.

CORRECT APPLICATION TECHNIQUES

Regular training sessions can ensure that both new and experienced employees stay up-to-date with best practices. This is particularly helpful after the adoption of new film, or if your products or throughput changes.

UTILISE ADVANCED SOLUTIONS AND TECHNOLOGIES

As the packaging industry continues to evolve, innovative solutions offer the answers to some age-old problems.

  • Nano film:

The use of higher-grade polymers in their composition means added strength and flexibility when it comes to wrapping.

  • Pre-Stretch Films:

Pre-stretched during the manufacturing process, this film offers consistent tension and greatly reduces the effort required during application.

  • Precise Tension Control:

Some machinery offers the option to control the tension of your wrap, ensuring optimal tension and reducing the risk of snaps.

  • Consistent Application:

Machines, to an extent, eliminate human error as well, which provides uniform wrapping every time.

There are a number of reasons why a pallet wrap might snap, and not always because the pallet wrap is of poor quality. The key is to identify the common causes, review your process and choose the right wrap accordingly.

BEN THOMPSON

Load Stability Specialist

OPTIMISE YOUR WHOLE OPERATION

Pallet wrap snapping is more than just an operational nuisance; it’s a challenge that impacts safety, efficiency, and profitability. But, by understanding the causes, from material quality to application techniques, teams can implement effective strategies to mitigate these risks.

Remember, the key lies in proactive measures: choosing the right materials, training staff, maintaining equipment, and staying ahead of industry innovation.

Book Your On-Site Film Review

At Castle, we don’t just sell film; we help businesses optimise their entire pallet wrapping operation. If you’ve run through this checklist and are still facing issues, it might be time for a professional audit to identify the deep-rooted causes of your pallet instability.

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