Once products are packed and palletised, the pallet load must stay stable and protected through storage and transport. A collapsed pallet in a truck can mean hundreds of damaged products and an unhappy customer. The two main methods for securing pallets are stretch wrapping and shrink wrapping. Both use plastic film, but they work differently and suit different situations.
How Stretch Wrapping Works
Stretch film is wrapped around the pallet under tension. As it stretches, it tightly holds the load together. Machines rotate the pallet on a turntable or move the film around a stationary pallet with a rotating arm. Pre-stretch systems stretch the film before it reaches the load, using less film for the same holding force.
How Shrink Wrapping Works
Shrink wrapping uses a film hood or wrap placed over the pallet, which is then heated with a heat gun or in a shrink tunnel. The film shrinks tightly around the load, creating a rigid, sealed package.
Comparing Load Stability
Both methods provide good load stability when correctly applied. Stretch wrapping is adjustable in terms of film layers and tension. Shrink wrapping creates a very tight, uniform package, which can be stronger for some loads.
Weather and Dust Protection
Shrink hoods cover the top and sides of the pallet, protecting against rain and dust. This is valuable for outdoor storage or long transport. Stretch wrapping usually leaves the top open unless a top sheet is added.
Cost and Energy
Stretch wrapping is generally cheaper to run because it needs no heat. Modern pre-stretch machines use film efficiently. Shrink wrapping requires heating equipment and energy, adding to operating costs.
Speed and Automation
Both can be automated. Stretch wrappers range from simple semi-automatic turntables to fully automatic inline machines. Shrink hood machines are often used in high-volume operations.
Product Considerations
Heat-sensitive products may not tolerate shrink wrapping. Irregular loads may be easier to stabilise with stretch film. Products stored outdoors benefit from shrink hood protection.
Choosing the Right Method
For most indoor storage and regional transport, stretch wrapping offers a good balance of cost and protection. For outdoor storage, export or loads needing weather protection, shrink wrapping may justify its higher cost.
Testing Load Stability
How do you know if a pallet is wrapped well enough? Load stability can be tested by simulating transport conditions, such as tilting the pallet or applying sudden stops. Many film suppliers offer testing services. At a simpler level, inspect pallets arriving at customers and record any damage. If loads shift or cartons crush, review your wrapping pattern, film tension and the number of layers. Often, adding a few rotations at the base of the pallet, where the load meets the wooden pallet, solves stability problems without using much more film.
Stretch Wrapping Patterns
A good wrapping pattern anchors the film to the pallet base, applies overlapping layers up the load and adds extra wraps at the top. Programmable machines store patterns for different products, so each load receives the correct treatment. Semi-automatic machines can be set up with simple presets for common pallet types.
Sustainability Considerations
Both methods use plastic film. Thinner high-performance stretch films, recyclable materials and optimised wrapping patterns reduce plastic use. Some customers now request information on packaging materials, so keeping a record of film type and consumption per pallet is useful.
Optimising Film Use
Whichever method you choose, test different film types and settings to find the minimum film that provides adequate stability. Overwrapping wastes money and plastic.
Hilden supplies end-of-line packaging equipment including stretch wrapping machines, and can help you choose a solution that protects your loads efficiently.
