Start with the load and the wrapping method
For warehouse and procurement managers choosing a stretch wrap specification, start with the load's shape and stability, then match film to hand or machine application. Compare gauge, width, roll length, and case quantity only after checking puncture risk and equipment settings. Test a wrapped pallet under your own handling conditions: gauge alone cannot establish how securely a load will travel.
Stretch film holds grouped cartons or products together through tension around the load. A regular stack of cartons, an uneven stack, and a load with exposed corners can place different demands on the same film. Before standardizing a roll, record what the load looks like, how it is wrapped, and whether the current wrap tears, loosens, or allows movement.
Key takeaways
- Choose hand or machine film to match the application equipment.
- Treat gauge as a thickness measurement, not a load rating.
- Check corners, load shape, and film breaks before changing specifications.
- Measure pallets wrapped per roll before estimating an order.
Sources: Intertape Polymer Group, Stretch Smarter: G7 Film ebook
Hand and machine film serve different workflows
Hand film lets an operator wrap a pallet without a wrapping machine and suits operations that need flexibility across load sizes. Machine film is made for a wrapper, where film and machine settings must work together. Confirm the wrapper's film width and pre-stretch settings before selecting a machine roll; a matching width alone does not establish that the film will run well.
The table shows specifications from One Pack's catalog, not interchangeable performance ratings. For example, its 18 in cast hand film at 60 gauge and its 20 in cast machine film at 80 gauge differ in application method as well as thickness. Use the hand stretch film category to review the format you actually apply.
| Format | Catalog example | Roll and pack details | Reason to trial |
|---|---|---|---|
| Cast hand film | SKU 501127: 18 in, 60 gauge | 1,500 ft per roll; 4 rolls per case | A hand-wrapped, regular load |
| Blown hand film | SKU HW1890: 18 in, 90 gauge | 1,500 ft per roll; 4 rolls per case | A hand-wrapped load prone to punctures |
| Pre-stretched hand film | SKU 502211: 14.5 in, 30 gauge | 1,476 ft per roll; 168 rolls per skid | A hand-wrap process being evaluated for operator effort |
| Cast machine film | SKU 500152: 20 in, 80 gauge | 5,000 ft per roll; 40 rolls per skid | A load wrapped on compatible equipment |
Sources: Intertape Polymer Group, Stretch Smarter: G7 Film ebook
Gauge describes thickness, not containment
Stretch wrap gauge describes film thickness. An Intertape Polymer Group technical sheet equates 60 gauge with 0.60 mil and 100 gauge with 1.00 mil; those figures explain the unit, not how much weight a wrapped pallet can hold. Film formulation, stretch, applied tension, wrap pattern, and the load itself also affect the result.
One Pack's catalog includes 18 in hand film at 60, 80, and 90 gauge, along with machine film at several gauges. Start a trial with the current gauge and record its failure mode before moving thicker or thinner. A thicker choice may help a puncture problem, but it will not correct a loose wrap, poor overlap, or an unstable stack by itself.
Width and footage matter alongside gauge. A narrow 3 in or 5 in hand film can bundle smaller items, while a wider roll covers more of a pallet's height per pass. Compare the specified roll length and the number of rolls in the quoted pack so that two gauge options are assessed on actual use per load.
Sources: Intertape Polymer Group, SF1 Machine Grade Stretch Film technical data sheet; Intertape Polymer Group, Load Containment Strategies for Pallet Shipping
What changes between cast, blown, and pre-stretched film?
Cast film is a useful trial for regular loads when clear film and a quiet unwind help the wrapping process. Blown film is worth testing when corners or irregular shapes repeatedly puncture the current wrap. These are starting points: a particular film's construction and application settings matter more than a blanket claim that one process is always stronger.
Pre-stretched hand film has already been stretched before the operator applies it. That changes the effort needed during application, so its listed gauge should not be used as a direct performance comparison with a conventional hand roll. One Pack lists a 14.5 in, 30 gauge pre-stretched hand wrap; test it on the same load and record both handling and containment.
Keep stretch film distinct from shrink film when preparing a specification. One Pack's catalog lists both stretch wraps and polyolefin shrink films, but they are different product categories. Naming the application, equipment, and intended load prevents a request for 'wrap' from pointing to the wrong material.
Sources: Intertape Polymer Group, Stretch Film brochure; Intertape Polymer Group, Load Containment Strategies for Pallet Shipping
A repeatable wrap pattern makes trials useful
The wrap pattern determines where film supports the palletized load. Start at the base so the film engages the pallet and bottom tier, maintain consistent tension, and overlap successive passes as the wrap rises. Intertape Polymer Group recommends at least 50% overlap as a starting application principle, with extra attention to irregular corners.
When film tears, note where the break begins before changing rolls. A recurring break at one corner suggests a concentrated contact point; breaks at the wrapper may call for a check of machine settings or the film path. If cartons shift without a tear, review the stack, base wraps, overlap, and tension rather than treating gauge as the only variable.
Run each candidate on the same representative load and record the settings, operator method, film breaks, and condition after normal handling. Change one factor at a time where practical so the result can guide a purchasing decision. These are packaging setup guidelines, not cargo-securement or compliance advice.
Sources: Intertape Polymer Group, Load Containment Strategies for Pallet Shipping; Intertape Polymer Group, Stretch Smarter: G7 Film ebook
Measure use per pallet before requesting a quote
Film consumption is easiest to estimate from a representative trial: record the number of pallets wrapped with a roll under the chosen settings. For an illustration, if a 1,500 ft roll wraps 24 comparable pallets, the observed average is 62.5 ft of roll footage per pallet. A four-roll case would then cover about 96 similar pallets at that observed rate, before allowing for setup loss or changes in load.
That calculation is an estimate, not a promised yield. A taller load, more overlap, extra corner passes, or a different pre-stretch setting can change the number of pallets per roll. Keep the test conditions with the estimate so procurement can revisit the quantity when the load or process changes.
For a quote, provide pallet and load dimensions, approximate load weight, load shape, pallets wrapped per period, current film specification, observed problems, and any wrapper model and settings. Include the roll or case quantity you expect to use, then request a quote. If the load needs a broader packaging redesign, the plastic strapping guide covers another material to evaluate.
Sources: Intertape Polymer Group, Stretch Smarter: G7 Film ebook
Frequently asked questions
Does a higher gauge always make a pallet more stable?
No. Gauge measures thickness, while load stability also depends on film properties, application tension, overlap, and the stacked load. Compare candidate films on the same representative pallet and record what changes.
Can hand film be used on a wrapping machine?
Select film intended for the application method and confirm the machine's width and pre-stretch requirements. A hand roll's gauge or width alone does not establish that it will run correctly on a wrapper.
When should I trial blown film instead of cast film?
Trial blown film when an irregular load or exposed corners repeatedly puncture the current wrap. Check the result on the actual load, since film construction and application conditions affect performance.
How many pallets will one roll wrap?
There is no reliable universal count. Wrap representative pallets with a known roll, record the number completed and the settings used, then use that measured rate to estimate the quantity needed for a quote.
Sources: Intertape Polymer Group, SF1 Machine Grade Stretch Film technical data sheet; Intertape Polymer Group, Stretch Film brochure; Intertape Polymer Group, Load Containment Strategies for Pallet Shipping
