Plastics logistics : Securing Pallets in Transport with stretch wrap

Stretch wrap is a highly elastic, thin plastic film,typically made from linear low-density polyethylene (LLDPE) that is designed to secure products to pallets during storage, handling, and transportation. 

It works by creating tension as it's stretched around a load, then using its recovery properties to maintain constant pressure that holds items together.

Linear Low-Density Polyethylene (LLDPE) is a type of plastic characterized by its flexibility, durability, and relatively high strength.

It features and improved tensile strength and puncture resistance compared to regular LDPE (Low-Density Polyethylene is a soft, flexible plastic made from petroleum. Flexibility and transparent, its is used in plastic bags, squeeze bottles, food wrap, and flexible packaging), while maintaining good flexibility. It's commonly used for plastic bags, stretch film, food packaging, and flexible containers.

 
Key functions:

• Load containment: binds multiple items together, preventing shifting during transit
• Protection: shields products from dust, moisture, and minor impacts
• Tamper Evidence: provides visual indication if packages have been accessed
• Load Stability: increases stacking capability and reduces tip-over risk
• Efficiency: Reduces handling of individual items

Types of stretch wrap:

Hand stretch film:

• Applied manually using a hand-held dispenser
• Typically 12-20 microns thick
• Available in different colors, with or without handles
• Often used for smaller operations or occasional shipments

Machine stretch film:

• Applied using automated wrapping machines
• Thinner (8-15 microns) but stronger due to consistent application
• Can be pre-stretched by the machine for maximum efficiency
• Used in high-volume operations

Specialty stretch films:

• Colored/Opaque: for UV protection or security (concealing contents)
• Ventilated: contains small perforations for products needing airflow
• Anti-slip: features a tacky surface to prevent load shifting
• Reinforced: contains fibers or strands for extra strength

Real-life applications:

Food and beverage industry:

A major soft drink manufacturer ships pallets containing 2,000+ plastic bottles to distribution centers.

Each pallet is wrapped with 80-gauge stretch film in a specific pattern:

• Five wraps at the base for foundation support
• Three spiral wraps up the height of the pallet
• Three wraps at the top
• Three final spiral wraps down to the base

This pattern prevents bottles from falling during the jolting movements of truck transportation, reducing damage rates by 30% compared to their previous method.

Vertical wrap is a stretch film application method where the plastic film travels up and down the height of a pallet load in a continuous spiral pattern, creating overlapping layers that secure the load for shipping and handling.

Building Materials:

A brick manufacturer uses high-performance 100-gauge stretch wrap with UV inhibitors to secure pallets of bricks that may be stored outdoors for extended periods.

Their wrapping pattern includes:

• Corner boards to prevent film tearing on sharp edges
• Seven wraps at the base where weight concentration is highest
• Special attention to the top layer to prevent shifting

This system has allowed them to reduce breakage during transit from 3.2% to 0.5%.

Corner boards are L-shaped protectors made of paperboard, plastic, or metal that are placed on the vertical edges of palletized loads. They distribute pressure, prevent stretch wrap from tearing on sharp corners, improve stacking strength, and protect products from damage during shipping and handling.

E-commerce Fulfillment:

An online retailer uses an automated stretch wrapping machine that applies a precisely calibrated 15-micron film to mixed-product pallets.

The system:

• Pre-stretches film by 250% before application, maximizing material efficiency
• Applies variable tension based on load sensors that detect product fragility
• Wraps 120 pallets per hour with consistent containment force

This system reduced their plastic usage by 40% while improving load stability.

Best Practices:

Proper tension: too loose fails to secure; too tight can damage products
Wrap pattern: overlapping spiral pattern provides best containment
Layer coverage: minimum 50% overlap between spiral revolutions
Film selection: match film gauge and type to load weight and characteristics
Sustainability: use the minimum amount of film required for adequate protection

Stretch wrap represents one of the most cost-effective methods for securing pallet loads, with material costs typically ranging from $0.50 to $2.00 per pallet while potentially preventing hundreds or thousands of dollars in potential damage.