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Pallet wrap is essential at ensuring protection during transit, but the question is &#; how do you choose the right one?
In this article, we will guide you through the process of selecting the ideal pallet wrap for your business.
Factors to consider when choosing pallet wrap
Using inadequate or inappropriate wrap may result in product damage during transit, leading to potential financial losses. Additionally, poor wrapping can cause instability, increasing the risk of pallets toppling over and damaging other goods or causing workplace accidents. To ensure you select the most appropriate option, consider the following factors:
Load type and size
The first step in selecting the right pallet wrap is assessing the weight, shape, and dimensions of your products. Heavy loads may require a high-strength wrap, while irregularly shaped items might benefit from flexibility or specialist wraps.
Environmental conditions
Always factor in the environment in which your pallets will be stored or transported. If your goods are exposed to certain conditions, opt for a wrap with UV resistance, moisture resistance, or temperature stability. This ensures the wrap maintains its integrity and protects your products effectively.
Film thickness
Pallet wrap thickness is measured in microns and ranges in thickness from 5 to 30mu, depending on your application. For example, you'll want to use thicker film for heavy or irregular loads, or loads that might be more prone to puncture and scratching during transport.
Thicker films offer increased load stability and protection against punctures, but they may require more material, which adds to the cost. To help you find the right wrap for your line of work, we can conduct a pallet wrap analysis and recommend the most suitable product.
Dimensions
The standard width of pallet wrap is typically between 380mm and 510mm, or 15 to 20 inches. Wider films generally cost more per roll. In terms of length, longer rolls generally cost more. However, shorter rolls need to be replaced more frequently, potentially impacting the efficiency of your warehouse operations.
Material
Pallet wrap is typically made of polyethylene, polypropylene, or PVC. The majority of our pallet wraps are made from polyethylene because it is stretchable and wound on a cardboard core.
Stretch
Stretch wrap provides a secure and tight grip around the pallet by combining tension and elasticity. High stretchability enables better load containment, reducing the risk of shifting and damage during transit. Consider the stretch percentage and elongation properties of the wrap to ensure it suits your load requirements.
Containment force
Pallet wrap containment force is the pressure the wrap subjects the contained objects to. This is what holds the items together and stops them from shifting during transportation. If you apply too much containment force, you're wasting pallet wrap and you could damage the goods within.
If you don&#;t use enough containment force, you run the risk of goods falling out or becoming unstable, resulting in lost stock and ancillary damage to transporters or people.
Application method
Hand pallet wrap is manually applied and is generally used for lighter work with a lower volume of pallets per day. You can use these wraps in conjunction with wrap dispensers and Grip Systems for an ergonomic application process.
Machine pallet wrap is most suited to high-volume users that are dispatching over 15 pallets a day. It also helps to reduce plastic consumption and therefore lowers costs.
Another key consideration is determining whether you will be applying the pallet wrap manually or with a wrapping machine. Machine wraps are designed for automated systems and offer consistent tension and application speed. On the other hand, hand wraps can be more versatile and suitable for smaller-scale operations or irregularly shaped pallets.
Cast and blown pallet wrap
Pallet wrap is made in two different ways &#; cast or blown. Cast film is made when the resin is pressed through chilled rollers to be flattened. Most stretch film is created using this method.
Blown film is created by making a thick layer of resin and then blowing air within to create a bubble. The size of the bubble and the original film dictates the thickness of the film. The bubble enables the material to cool steadily and is then collected by rollers.
Colour
The colour of your pallet wrap can make it easier for staff to identify pallets and reduce warehouse errors. For extra security, opt for black pallet wrap to keep valuable items hidden from view.
Pallet wrap accessories
As well as the wrap itself, there are a few other products to consider investing in. Firstly, you may wish to protect your products from the elements and the rough surface of the pallet by laying down a pallet pad. Additionally, pallet tops are ideal for protecting the top of your load.
If your load is fragile or you simply want to soften any movements, you can use pallet cushions underneath each corner. For pallets that are double or triple-stacked, corner protection goes a long way. Edge boards help to stabilise loads and strapping, reducing movement and damage during transit.
How to wrap a pallet
We have created a guide outlining all the necessary steps on the proper pallet wrapping technique, ensuring your pallets are wrapped efficiently and securely.
Step 1: Gather the necessary materials
- Pallet wrap: Choose a pallet wrap suitable for your pallet's size, weight and the materials it is holding.
- Pallet: Ensure the pallet is sturdy and in good condition.
- Pallet jack or forklift: Use the appropriate equipment to move and position the pallet in the correct place.
Step 2: Prepare the pallet
- Ensure the load is properly stacked and stable on the pallet.
- Check for any loose or overhanging items that could cause instability or interfere with the wrapping process.
- If necessary, use corner protectors to prevent the film from tearing against sharp edges.
Step 3: Start the wrapping process
Manual Method
Start the wrapping process by holding the loose end of the stretch film against the bottom of the pallet. Walk around the pallet while unwinding the film, keeping it taut. Continue wrapping upward with overlapping layers, paying attention to corners and edges.
Pallet Wrap Machine Method
Insert the loose end of the stretch film into the machine's film holder or dispenser. Activate the machine and adjust the settings for tension, rotation speed, and the number of wraps desired. The machine will automatically wrap the stretch film tightly around the pallet, starting from the bottom and moving upward. Monitor the wrapping process to ensure an even and secure application.
For both methods, pay extra attention to corners and edges, reinforcing them with additional film layers if needed. Maintain consistent tension and overlap each layer as you continue wrapping upward.
Step 4: Apply the first layer of film
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How can a multi lane packaging machine benefit my business?
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As you walk, make sure the film is pulled tightly around the pallet.
Wrap the film around the base of the pallet, overlapping the bottom layers by a few inches. Continue wrapping upward, ensuring each layer slightly overlaps the previous one.
Step 5: Wrap the corners and edges
- When reaching the corners, use additional layers of film to reinforce them.
- Pull the film diagonally across the corner, creating a 45-degree angle, and continue wrapping to secure it.
- Repeat this process for all corners and edges of the pallet.
- If you&#;re using a machine to wrap the pallet, this step will be done for you.
Step 6: Continue wrapping upward
- After wrapping the corners, continue moving upward while keeping the film taut.
- Aim for consistent tension throughout the wrapping process, avoiding excessive slack or overstretching.
- Maintain a slight overlap between each layer to provide strength and
stability.
- If you&#;re wrapping the pallet by machine this will be done for you.
Step 7: Ensure load integrity
- Pay attention to any loose or protruding items during the wrapping process.
- Use additional layers of film or banding if necessary to secure irregularly shaped or fragile items.
- Check for any gaps or weak points and reinforce them with extra film layers.
Step 8: Complete the wrapping process
- Once you reach the top of the pallet, tear the film and ensure the end is securely tucked under a previous layer.
- Use a film cutter or knife to cut the film, leaving a small tail for easy unwrapping later if needed.
- Apply pressure to the film to ensure it adheres to the load.
Step 9: Inspect and label
- Inspect the wrapped pallet for any potential weaknesses or areas that need reinforcement.
- Attach any necessary labels or documentation to the pallet for identification and tracking purposes.
By following these steps, you can wrap your pallets efficiently and securely, minimising the risk of damage or shifting during transportation or storage. If using a pallet wrap machine, deactivate it once wrapping is complete.
Pallet wrap NZ
Every load has unique dimensions and requirements which is where our team can help. We have a wide range of pallet wraps and accessories and can help you select the most appropriate products for your operations. Contact us today or browse the full pallet wrap range:
- Pallet stretch wrap
- Pre-stretched pallet wraps
- Plant-based pallet wrap
- Coloured pallet wrap
- Ventilated pallet wrap
- Pallet toppers
- Pallet bags and nets
- Pallet wrap dispensers
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Reconsidering your pallet wrapping options in the light of new materials and technologies
Pallet wrapping is one of the most foundational processes in logistics, but as demand picks up, it&#;s worth a review. Warehouses today face more pressure than ever to ship goods safely, quickly and often with fewer workers. In light of these rising standards, businesses should consider if they&#;re using the best pallet wrapping techniques.
As with many things, the best wrapping method depends on the warehouse and even the specific shipment at hand. Here is a rundown of the most common approaches and when they might be the best option.
Pallet Wrapping Techniques by Approach
There are a few ways to divide pallet wrapping techniques. The first and most straightforward is by the actual workflow, whether it&#;s manual or automated.
Manual Pallet Wrapping
Manual wrapping &#; also called hand wrapping &#; is the most straightforward approach. While these approaches have fallen out of favor in many circles, they can still provide some advantages. Humans are more flexible than machines, so if a pallet has an unusual shape or size or requires more delicacy, hand wrapping may be ideal.
On the other hand, 73% of employers today cite difficulty finding enough staff. Consequently, some facilities may not have enough employment levels to maintain peak productivity while manually wrapping pallets.
Generally speaking, manual wrapping is sufficient for smaller operations or those with many unusual pallet loads. However, in most cases, automation is the better option.
Machine Pallet Wrapping
Machine wrapping comes in many forms, but they all share a significant advantage &#; they&#;re far faster than manual methods. Because they don&#;t require as many employees, these machines also help mitigate labor shortages. While they don&#;t perform as well with unusually sized or shaped loads, they offer more precision with standardized pallets.
Automated wrapping machines generate data as they work, leading to ongoing improvements. This technology helps validate load wrapping performance by revealing trends over where errors arise, which warehouses can use to adjust the process.
The most considerable downside to machine wrapping is its high upfront costs. The efficiency savings will compensate for that over time, but the return on investment may be too slow for smaller operations to justify it.
Pallet Wrapping Techniques by Material
Another way to divide pallet wrapping techniques is by the material they use. There are more wrapping materials on the market today than many businesses may realize, each with unique strengths and weaknesses. Here are a few of the most notable.
Cast Film
The unofficial industry standard for pallet wrapping is cast film. This material &#; mostly made from linear low-density polyethylene (LLDPE) &#; offers uniform thickness throughout the roll, quiet unrolling and high clarity, which is helpful for barcode scanners. Its quick production process also means it&#;s typically inexpensive, which is particularly helpful amid rising industrial rents and other high expenses.
Cast film is technically less stretchable than blown film &#; the other major category &#; but it requires less force to stretch. Consequently, it&#;s often the stretchier material in practice. However, it has lower stretch memory, making it less durable. Wrapping in several layers can help account for that loss, but that incurs higher material costs.
Blown Film
The other of the two largest groups of pallet wrapping materials is blown film. As the name implies, this wrap comes from a process that blows hot resin to stretch and cool it. While the process takes longer and costs more, it gives blown film some unique advantages.
Blown film is more tear and puncture-resistant than cast film. It also clings better and produces less waste in manufacturing, making it a leaner material. However, it&#;s also more expensive and difficult to apply. Many facilities also note it&#;s much louder when unrolling, which can disrupt the workplace.
Engineered Cast Film
As the most popular pallet wrapping technique, cast film is a broad category covering several unique subtypes with specific advantages and disadvantages. One of the most important of these is engineered cast film. Engineered film uses far more layers than standard cast wrap, increasing its strength, even at lower gauges.
Engineered film uses a blend of high-performance materials that conventional wraps may not offer. As a result, it stands up better to tears and punctures and clings to material better. Considering as much as 11% of some loads arrive at distribution centers damaged, that advantage is hard to ignore. However, it&#;s less widely available and may come at a higher cost, making it less accessible for smaller operations.
Pre-Stretched Film
Another essential type of cast film to know is pre-stretched film. As its name implies, manufacturers stretch this material before wrapping it around the roll. This pre-stretching makes it far easier to handle, which can help reduce material consumption and save costs.
Because workers don&#;t have to pull as hard to apply pre-stretched film, it can prevent overexertion injuries. Workplace injuries cost employers $163.9 billion in , so this accident prevention carries cost benefits, too. The only major downside to pre-stretched film is it&#;s only suitable for manual wrapping techniques, so automated processes can&#;t capitalize on it.
Paper Wraps
While LLDPE and similar materials are the most common wrapping materials, some promising alternatives have emerged recently. Paper wraps use flexible, durable paper to keep pallet loads in place while minimizing companies&#; plastic consumption. This provides more strength and durability than conventional alternatives.
Paper wraps also shield shipments from sunlight, which is vital for some more sensitive products. Some vendors may also cite environmental benefits given their recyclability, but businesses should analyze these claims carefully. Paper requires extensive energy to produce and contributes to deforestation. As strategies like closed-loop supply chains become more popular, companies must be careful to avoid &#;greenwashing&#; &#; or claiming to be more sustainable than they are.
Choosing the Best Pallet Wrapping Techniques
Given each material and process&#;s unique characteristics, there&#;s no one answer to the best pallet wrapping techniques. That varies depending on the specific operation at hand.
Generally speaking, machine wrapping is preferable to manual wrapping, as it&#;s far faster and more affordable long term. With freight demand expected to grow by 40% by , that efficiency will become increasingly important. Even lower-volume facilities should consider automation amid this trend, starting by automating a single process before slowly increasing it to offset upfront costs.
Considering this rising demand, high-volume facilities should also consider low-cost, easy-to-implement wrapping materials. Engineered cast film is often one of the best choices, though standard cast film may be sufficient if engineered wrap is too expensive. Contrastingly, blown film may be best for low-volume but high-value shipments, given its reliability.
Companies with unique needs should consider unorthodox alternatives like paper wraps. These may come with higher upfront costs but can provide valuable benefits that other solutions don&#;t, like protection from sunlight.
Find the Best Technique for Your Business
Finding the best pallet wrapping techniques means understanding what&#;s available and what different shipments need. When you know your budget, all available options and goals, you can make a more informed decision.
Are you using the most suitable wrapping materials and processes to optimize your operations?
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