Pallet Wrapping Machines

Pallet wrapping has an essential role in transport and warehousing for goods which have been bottled, boxed, bagged or packaged in stackable containers. Once a pallet has been loaded to the appropriate height, the issue then arises of how to keep the full pallet as a single, stable unit. The answer lies in pallet wrapping.

Pallet wrapping machines and wrapping materials are supplied by a variety of PPMA members. At the annual PPMA Show, visitors can see live equipment demonstrations, and can discuss requirements with suppliers, as well as networking with other visitors.

In addition, if you're looking for labelling machinery to complement your packaging processes, you can find more information and PPMA exhibitors in the labelling machinery sector here.

What is pallet wrapping?

Pallet wrapping is the process of applying film around a loaded pallet. There are options on using machinery with varying levels of automation to dispense film around the stacked pallet, and the film can also be applied as a manual process.

Stretch wrap film is the simplest type of pallet wrap to apply. The elasticity in the film allows for a tight bind around the packages on the pallet, and the adhesion of both sides of the film creates a fully fastened layer of protection.

Shrink wrap film is a less common alternative to stretch wrap. In addition to the task of wrapping film loosely around the stacked pallet, shrink wrapping requires heat to form a tight fit. The way to do so is by means of a manually held heat gun to achieve the required amount of shrinkage.

Pallet shrink wrap vs pallet stretch wrap

The type of pallet wrapping you choose depends on the type of products on the pallet, and cost considerations. Stretch wrap is more commonly used because it is very versatile and can be used for products of almost all kinds, including heat sensitive goods. Stretch film comes in a wide variety of types, including coloured and UV options. It is simple to apply in a single stage process, manually or by machine, and is generally less costly than pallet shrink wrapping.

Shrink wrapping is useful for very large and irregularly shaped objects such as furniture or even boats, and has the advantage of fitting more tightly and being stronger, thereby providing higher levels of protection. The main use of shrink wrap, however, is for individual products and packages.

Why are pallets wrapped?

The most significant reason for wrapping pallets is to secure items in a tightly bound unit for transit. The stability of loaded pallets is essential for the efficient movement of goods, from taking pallets around warehouses to loading and unloading trucks, and positioning pallets in warehouses, including on racking systems. During transport too, the stability of loads is vital for safety reasons and to avoid damage.

Pallet wrapping also helps to reduce product loss and tampering. Goods are protected from dust and light debris. Stretch wrap can protect goods from sunlight, and to a certain extent offers protection from bad weather. Shrink wrap film offers greater protection, including against heavy rain and other moisture ingress.

How does a pallet wrapping machine work?

The key elements of pallet wrapping are dispensing and applying film. In a manual process film is pulled from a dispenser (also known as a film applicator) and stretched around the stacked pallet multiple times if needed. With sufficient stretching of the film and sufficient overlap, the elasticity and stickiness of the film create a firm, cohesive seal.

The process is accelerated by standing the loaded pallet on a turntable and revolving the pallet to pull film from a vertical dispenser. This can be achieved manually, or by using a mechanised turntable and dispenser. Another machinery option is a rotary arm stretch wrapper, in which the pallet remains static and the film dispenser rotates around it, driven by an overhanging arm.

If heat shrink film is being used, the process is completed by running a heat gun over all parts of the film to shrink it tightly around the packs on the pallet, and to bond the overlapping film together. Film hoods as opposed to sheets of film are also available in certain sizes for heat shrinking.

What are the types of stretch film?

Stretch film is either hand stretch or machine stretch film. The former is designed for manual wrapping and is designed for low volume packing operations, the latter for machine application.

Machine stretch film comes in a variety of types:

Blown stretch film is a premium quality product with high elasticity which keeps packages tightly bound. It is resistant to tearing, but has poor clarity and makes significant noise when unrolled.
Cast stretch filmis a lower cost alternative with greater transparency than blown film, but does not have as much holding power or tear resistance.
Pre-stretched filmhas been stretched before use, which means it takes less effort to apply and less can be used to achieve required coverage.

Speciality stretch films include
- UV stretch wrap for protection from ultra-violet light
- VCI (vapour corrosion inhibitor) stretch wrap for protection against rust
- Pallet wrap netting for air circulation (eg for onions, logs)
- Tinted stretch film for identifying type of product, date of inventory
- Heavy gauge film for maximum protection
- Opaque black stretch to hide contents and reduce pilfering
- Anti-static stretch wrap for a durable electrostatic barrier for sensitive devices and components

What is the most environmentally friendly pallet wrapping material?

The most commonly used material for pallet wrapping is LDPE (low density polyethylene). LDPE has limited recyclability in that it cannot be mixed with hard plastics for recycling, but it is possible to recycle at specific facilities.

The key to pallet wrapping which causes the least environmental damage is to use:

less wrap
lighter wrap
recycled, recyclable, compostable and biodegradable materials

Using less wrapping material means using enough to provide the stability you need in a wrapped pallet, but no more. Pre-stretched film is one solution, which delivers the performance packaging and logistics operations require from less material. Pre-stretching has the effect of thinning the film, so it is lighter, and compared to ordinary film, less is needed. For manual operators, it also has the advantage of being much easier to pull from the reel.

Recycled film usually consists of standard plastics blended with a percentage of recycled material. Plastic Packaging Tax which comes into effect in the UK in April 2022 applies to plastic packaging with less than 30% recycled material, and films are increasingly coming to the market which feature more than 30% recycled material.

Increasingly, packaging companies can find fully recyclable pallet wrap. Some is based on high-stretch papers, others on 100% recyclable green polyethylene material based on sugar cane. Biodegradable stretch films are also available which will fully break down in the natural environment after two to three years. In 2021, the world’s first fully compostable, industrial strength, machine grade stretch film came to the market.

Find Pallet Wrapping Machine Suppliers

See a full list of PPMA Member companies that supply a comprehensive range of pallet wrapping machinery.

Machinery Spotlight

Take a look at the processing and packaging machinery in the PPMA Show's Machinery Spotlight, where there's a variety of different machinery to fit any and all requirements.

Pallet wrapping FAQs

Is stretch wrapping the same as pallet wrapping

Pallet wrapping is a common type of stretch wrapping. Stretch wrap is also used for individual products and packages, and for much smaller bundles of packs or components than a fully stacked pallet.

What is the strongest stretch wrap

Heavy-gauge stretch wrap begins with 90-gauge film. Gauge, microns, millimetres or inches are measures of stretch film thickness. As the thickness of film increases, so does its strength and resistance to punctures, tears and other damage. The strongest films in wide use are 150-gauge, which equates to 38.1 microns, 0.0381 millimetres or 0.0015 inches.

How much does it cost to wrap a pallet?

The amount of film needed to wrap a pallet is dictated by the dimensions of the pallet, and also by how efficiently the stretch wrap or shrink wrap material is used. Using too much material could take the costs for a typical UK pallet (1200mm length x 1000mm width x 1200mm height) to over £1.50 in terms of wrapping material alone. A smarter, more efficient use of materials could bring the cost down to below 50p. However, any cost calculations need to take account of the durability of the packaging, and the avoidance of repackaging costs or the costs of damage. It is always worth fully engaging with suppliers and peers when projecting costs, and to use all the cost data you have from your own commercial experience.

How much does an automatic pallet wrapper cost?

Basic pallet wrapping machinery with a turntable and mechanical film dispenser should be possible to find for around £2,000. A step up to a semi-automatic machine will cost more like £4,000 to £5,000, stepping up to £10,000 or more for fully automatic equipment. The prices are dependent on size, controls and level of automation, and the prevailing prices at the time you buy. As with all capital equipment purchases, gathering information to form a short list for competitive quotations is the route to follow.

How do you manually shrink wrap a pallet?

The simplest approach to shrink wrapping is purely manual, with an operative pulling shrink film over the pallet, ensuring that it is completely covered, then using a hand-held heat gun to shrink the film over the entire pallet. It is simple manual process, but it is time-consuming and takes up a significant amount of staff time.