The Complete Guide to Stretch Film
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THE COMPLETE GUIDE TO
STRETCH FILM
Everything you need to know about cast vs. blown film, gauges, hand vs. machine wrapping, and specialty films, so you can pick the right wrap for your pallet loads.
WHAT IS STRETCH FILM?
Stretch film, also called stretch wrap or pallet wrap, is a highly elastic polyethylene plastic used to secure pallet loads for shipping and storage. Wrapped under tension, it clings to itself and holds your load together without tape or strapping. It provides moisture protection, UV resistance, and tamper-evident security. Whether you're wrapping by hand or using a machine, understanding your options saves time, film, and money.STRETCH FILM VS. SHRINK WRAP
These are not the same product, despite the names sounding similar. Stretch film (also called stretch wrap) is wrapped around pallet loads using tension; no heat is involved. Shrink wrap is a different material, usually polyolefin or PVC, that is applied loosely around a product and then heated with a heat gun or tunnel until it contracts tightly.
Stretch film is for unitizing pallet loads. Shrink wrap is for packaging individual products like food, retail items, or bundled goods. Putting stretch film through a heat tunnel is a fire hazard. A simple rule: if it needs heat, it's shrink wrap.
STRETCH FILM CONSTRUCTION
Most stretch films are made from LLDPE (linear low-density polyethylene), which gives the film its elasticity and cling. There are two manufacturing methods, cast and blown, each with different performance characteristics. Film is wound around a cardboard core and sold in rolls; shorter rolls are for hand wrapping, longer rolls are made for stretch wrap machines.
Once applied, the film's elastic memory causes it to retract slightly and create firm, consistent tension around the load, which is also why people sometimes mistake it for shrink wrap.
CAST VS. BLOWN STRETCH FILM: WHAT'S THE DIFFERENCE?
Standard stretch films come in two types: cast and blown. Cast film is the go-to for about 90% of users; it's quieter, clearer, and easier to work with. Blown film is better for heavy or sharp-edged loads.| CAST FILM | |
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Clear, easy to scan barcodes and read labels Quiet unwind, better in busy warehouses Clings without sticking to hands Works well in most environments Lower upfront cost Standard pallet loads and high-volume facilities |
| BLOWN FILM | |
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Hazy, harder to read labels through Noticeably louder when unwinding Better, ideal for sharp edges Better in cooler temps, adhesive won't transfer Higher upfront, but offsets cost over time Sharp-edged loads, cold storage, and heavy pallets |
If your pallets have corrugated boxes with sharp edges, irregular shapes, or heavy loads, blown film's puncture resistance is worth the extra cost. For everything else, cast film is the easier, more cost-effective choice.
HOW DO YOU CHOOSE THE RIGHT STRETCH FILM GAUGE?
Gauge (ga) refers to film thickness: higher gauge means thicker and stronger. Films range from 24ga to 120ga. The visual scale below shows how gauges map to load weights.
Not sure which gauge fits your operation?
Use this quick reference to find your starting point based on load weight and wrapping method.
LIGHT LOADS: UNDER 1,500 LBS
40-60ga cast film
Standard boxes with no sharp edges. Down-gauged cast film saves cost without sacrificing performance. Try the Grip Premium 35ga.
STANDARD LOADS: 1,500 TO 2,400 LBS
80ga cast (hand) or 47-50ga (machine)
The industry standard. Hand wrapping: Hexfilm Defender 80ga. Machine: pre-stretch machine film covers more pallets per roll at a lower cost.
HEAVY LOADS: OVER 2,400 LBS
100ga blown (hand) or 80-90ga (machine)
Heavy loads need strong stretch memory and puncture resistance. If wrapping this volume by hand, it's worth considering a machine wrapper.
HAND WRAPPING VS. MACHINE WRAPPING: WHICH IS RIGHT FOR YOU?
The decision comes down to volume. If you're wrapping a handful of pallets a day, hand wrapping is fine. If you're doing 20 or more pallets daily, a stretch wrap machine will save you significant time and film cost.
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HAND WRAPPING
Best for: Low volume (under 20 pallets/day) or occasional wrapping needs.
No equipment investment
Flexible, wrap any pallet, anywhere
Easy to train workers
Labor-intensive without a dispenser
Inconsistent tension if done freehand
More film waste per pallet
Tip: Always use a film dispenser; it improves tension, reduces fatigue, and speeds up wrapping.
MACHINE WRAPPING
Best for: High volume (20+ pallets/day) with consistent load requirements.
Consistent wrap tension on every pallet
Faster throughput
Less film waste
Less physical strain on workers
Equipment cost upfront
Requires a trained operator
Tip: Benchmark's Free Stretch Wrapper Maintenance Program keeps your machine running and reduces costly downtime.
WHAT IS LOAD CONTAINMENT FORCE (LCF)?
Load containment force is the amount of inward pressure your stretch film applies to a pallet load. It's what actually keeps your product from shifting, leaning, or falling during transit. Gauge and film type alone don't tell the whole story; how you apply the film matters just as much.
WHAT AFFECTS LCF
Three factors determine how much containment force your wrap delivers:
Film gauge: Thicker film holds more tension before breaking.
Stretch percentage: The more you stretch the film during application, the higher the containment force, up to a point. Over-stretching causes tears.
Number of wrap passes: More layers at the base and top significantly increases containment at the load's weakest points.
LCF BY LOAD TYPE
Different loads need different levels of containment force:
Light, stable loads (e.g. cartons of paper): Lower LCF is fine. A single spiral pass with moderate tension is sufficient.
Mixed or irregular loads: Higher LCF needed. Add extra passes at mid-height and reinforce corners.
Heavy or unstable loads: Maximum LCF. Use heavier gauge film, higher stretch, and reinforce the base with 3-4 anchor passes.
SIGNS OF WRONG LCF
Too little containment force:
Load shifts or leans in transit. Film feels loose when you push the pallet. Boxes arrive displaced.
Too much containment force:
Film tears during application. Product is crushed or deformed. Film cuts into box corners.
Not sure if your wrapping is dialed in? Contact a Benchmark rep; we can assess your current setup and recommend the right film and technique.
HOW TO WRAP A PALLET BY HAND
Follow these steps for a secure, stable hand-wrapped pallet every time.
THE PALLET
Start with a sturdy pallet. Inspect for broken boards or protruding nails before loading.
HEAVY ITEMS
Stack heavy items at the bottom. Lower center of gravity prevents tipping in transit.
PALLET GAPS
Eliminate gaps between boxes. Fill with dunnage or void fill if needed.
DISPENSER
Use a film dispenser. Reduces fatigue and gives better, more consistent tension.
ANCHORING
Anchor the film at the base. Wrap around a bottom corner of the pallet 2 to 3 times to lock it before moving up.
SPIRAL & LAYER
Spiral up and down. Overlap each pass by about 50%. Wrap to the top, then spiral back down for a double layer.
TUCK OR TIE
Tuck or tie the tail. Tuck excess film under the bottom wrap. Never leave it loose in transit.
TESTING
Test the load. Push gently from multiple sides to confirm nothing shifts before sending it out.
WRAP PATTERNS: HOW YOU APPLY FILM MATTERS
Simply spiraling film from bottom to top is a starting point, not a strategy. The pattern you use determines where containment force is concentrated, and most pallet failures happen at the base or the top, not the middle.
BASIC SPIRAL
Wrap from base to top, overlapping each pass by 50%. Good for stable, uniform loads. The minimum acceptable pattern for most shipments.
DOUBLE WRAP
Spiral up to the top, then back down to the base. Doubles the film layers across the full load height. Recommended for most standard pallet loads.
REINFORCED BASE
Apply 3-4 extra passes at the bottom of the load before spiraling up. The base is the most common failure point; reinforcing it prevents the load from sliding off the pallet during forklift handling.
ROPE / BANDING
Twist the film into a rope at the top and bottom of the load for extra tensile strength at the most vulnerable points. Used for heavy, tall, or unstable loads where maximum containment is needed.
SPECIALTY STRETCH FILMS FOR UNIQUE APPLICATIONS
Standard cast or blown film handles most jobs. These specialty options solve specific problems.
PRE-STRETCH FILM
Film that's already been stretched during manufacturing. Less force is needed to apply it, reducing worker fatigue. You also use less film per pallet, lowering material cost while maintaining strong load retention.
Best for: High-volume hand wrapping, reducing film costs, ergonomic wrapping programs.
COLORED STRETCH FILM
Available in black, blue, red, green, yellow, and orange. Black film conceals load contents and provides UV protection. Colored films simplify load identification, transit color-coding, and consistent branding throughout your facility.
Best for: Concealing loads, color-coding by destination, brand consistency.
VENTED / AIR-FLOW FILM
Stretch film with die-cut holes that allow air to circulate through the wrapped pallet. Compatible with conventional stretch wrappers. Prevents moisture buildup and spoilage. Maintains integrity in cold storage with no freeze break point.
Best for: Produce, food manufacturing, agricultural products, cold storage applications.
FIBER REINFORCED STRETCH FILM
Standard stretch film with embedded fiber reinforcement strips that block tear propagation. If the film is punctured, it won't unravel across the load. Delivers higher strength with less material, lowering your cost per pallet without sacrificing containment force.
Best for: Heavy, sharp-edged, or irregular loads; furniture, machinery, metal.
STRETCH FILM AND THE ENVIRONMENT
Stretch film is plastic, and reducing its environmental impact is a real concern for many operations. The good news: there are practical steps you can take without compromising load security.
CAN STRETCH FILM BE RECYCLED?
Yes. Stretch film is made from LLDPE (plastic #4), which is recyclable, but it cannot go in curbside recycling bins. It must be collected separately and dropped off at participating retail or industrial collection points.
For high-volume operations, stretch film baling is the most practical approach. Baled film takes up less space and is easier to transport to a recycler. Many waste haulers will collect baled stretch film directly from your facility.
What to avoid: Never mix stretch film with other recyclables in a single-stream bin. Contaminated film bales are rejected at processing facilities.
HOW TO REDUCE FILM USE
The most impactful thing you can do is use less film per pallet without sacrificing load security:
Down-gauge: Modern 40-60ga cast films perform like traditional 80ga. Switching saves significant material over time.
Pre-stretch film: Already stretched during manufacturing, so you use less film per pallet with the same containment force.
Machine wrapping: Machines apply film at consistent, optimized tension, eliminating the over-wrapping that hand wrapping often produces.
HOW TO CALCULATE YOUR COST PER PALLET
The sticker price on a roll of stretch film is not your real cost. What matters is how much it costs to wrap each pallet, and that number can vary significantly depending on your film choice, gauge, and wrapping method.
THE FORMULA
Cost per pallet = Roll cost / Pallets wrapped per roll
For example: a roll that costs $12.00 and wraps 20 pallets = $0.60 per pallet.
A more expensive roll that costs $18.00 but wraps 35 pallets = $0.51 per pallet, a lower real cost despite the higher price tag.
This is why down-gauging and pre-stretch films often cost less in practice than their price suggests. More footage and higher stretch ratios mean more pallets per roll.
WHAT AFFECTS YOUR COST
Wrapping method: Machine wrapping typically cuts film use by 20-30% compared to hand wrapping at the same load size, due to consistent tension and no over-wrapping.
Gauge: Down-gauging to a high-performance cast film can reduce material cost without changing performance.
Damage costs: The cheapest film is not always the lowest cost. A roll that saves $0.10 per pallet but causes one load failure per month can easily cost more than the savings.
Contact a Benchmark rep! We can run the numbers for your operation and identify where you can save.
BENCHMARK'S BEST SELLERS
Not sure where to start? These are our most popular stretch film options.
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COMMON QUESTIONS
Answers to the questions we hear most.
What gauge stretch film do I need?
Start with 80ga; it handles loads up to 2,400 lbs and works for most applications. If your loads consistently arrive in good shape, you may be able to step down to a 40-60ga cast film at lower cost.
How many pallets does one roll cover?
A standard 80ga 1500' hand film roll typically wraps 15 to 25 pallets depending on load height and how many layers you apply. A 5000' machine roll covers significantly more.
Can I use hand film on a stretch wrap machine?
No. Hand film and machine film are not interchangeable. Using hand film on a machine can damage the equipment.
What's the difference between pre-stretch and regular stretch film?
Pre-stretch film is already stretched during manufacturing, so less force is needed to apply it. This reduces worker fatigue and uses less film per pallet.
Is colored stretch film as strong as clear film?
Yes. Colored stretch films are made with the same high-strength materials as clear cast or blown films. The color does not affect puncture resistance or load containment.
How do I know if my wrapping is working?
A properly wrapped pallet should be firm with no shifting when you push from the side. If layers separate or boxes arrive shifted, you likely need a higher gauge, more wrap passes, or better tension control.
KEEP READING
Explore more packaging guides from Benchmark Industrial.Securing Pallet Loads
How to keep product contained and prevent shifting during transport.
Hot Melt vs. Acrylic Tape
Which carton sealing tape is right for your boxes, environment, and shipping volume?
Corrugated Boxes Guide
Flute types, wall construction, strength ratings, and how to choose the right box.
Free Stretch Wrapper Maintenance
Benchmark's maintenance program keeps your stretch wrap machine running.
Need help choosing the right stretch film? Browse Benchmark's full selection of hand film, machine film, specialty wraps, dispensers, and stretch wrap machines.