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Pallet Wrap Guide

If you are choosing between cast, blown, or fusion stretch film, this guide will help you match the right wrap to your load type, warehouse conditions, and wrapping volume. You will also find quick links to hand wrap, machine wrap, and pallet wrappers.

The 3 main types of pallet wrap

Most operations choose between cast, blown, and fusion style films. The best choice depends on load shape, pallet weight, edge sharpness, storage temperature, and required stability.

Cast film
Best all-rounder for general wrapping
Pallet wrap being applied, cast film example

Cast pallet wrap is a clear, smooth-unwinding stretch film used to stabilise and protect loads during transport and storage. It is popular because it is easy to apply and suits a wide range of pallets.

Pros
  • Great clarity for identifying pallet contents
  • Quiet unwind and easy application
  • Strong general-purpose performance
Cons
  • Not as puncture-resistant as blown for very sharp loads
  • May need a heavier gauge for tougher applications
Blown film
Tougher film for sharp edges and heavy loads
Machine stretch film roll used for blown film example

Blown pallet wrap is produced through a blown extrusion process, creating a film with strong puncture resistance and excellent cling. It is a common choice for heavier loads, irregular shapes, and sharp corners.

Pros
  • High puncture and tear resistance
  • Great cling for difficult loads
  • Often performs well in colder environments
Cons
  • Usually higher cost than cast
  • Lower clarity and can unwind noisier
Fusion film
High-stretch film designed to reduce usage
Fusion stretch film product image

Fusion high stretch wrap is designed to stretch significantly further than standard films, helping many sites reduce film used per pallet. It can be a good option when you want performance with less plastic used.

Good for
  • Sites looking to reduce film usage per pallet
  • Consistent wrapping methods and stable loads
  • Operators that want easier application with less roll changeover
Tip
Film performance depends on load shape and wrapping settings. If you tell us pallet weight and product type, we can point you in the right direction.

Quick comparison

Film type Best for Key strength Trade-off
Cast General loads and everyday wrapping Clarity and easy unwind Less resistant to sharp corners than blown
Blown Heavy, awkward, sharp-edged loads Puncture resistance and cling Lower clarity and typically higher cost
Fusion Sites aiming to reduce film usage High stretch and efficiency Needs the right application and load match

How to choose the right pallet wrap

  • Light to medium cartons: cast is often the first pick
  • Sharp edges or heavy loads: consider blown, or heavier gauge cast
  • Cold storage: blown is commonly used, but the right cast can also work depending on the load
  • High volume sites: machine wrap and pallet wrappers reduce labour and increase consistency
  • Trying to reduce film usage: ask us about fusion options and settings

What is pallet wrap made of?

Pallet wrap is usually made from polyethylene, chosen for its stretch, cling, and durability. It helps protect loads from dust and moisture while keeping product stable in transit. Some films include additives for specific performance needs.

Can stretch wrap be recycled?

Stretch wrap can often be recycled, but it usually needs to be collected clean and kept free from labels, tape, and contaminants. Because it is thin and flexible, not every recycling stream accepts it. If you tell us how you dispose of film today, we can suggest practical options.

FAQs

What are the benefits of pallet wrap?
Pallet wrap helps stabilise the load, reduce shifting in transit, and protect goods from dust and light moisture. A tighter, consistent wrap can also improve safety when moving pallets.
What is the difference between hand wrap and machine wrap?
Hand wrap is applied manually and is common for lower volumes. Machine wrap is designed for pallet wrapping machines, typically with longer rolls and more consistent application for higher throughput sites.
What is the difference between stretch wrap and shrink film?
Stretch wrap is pulled tight around a load using tension. Shrink film requires heat to shrink down and conform to the product shape.
Which is better, cast or blown stretch wrap?
Cast is commonly chosen for clarity and smooth unwind. Blown is commonly chosen for puncture resistance and cling. The best option depends on load type, sharp edges, and required stability.
How many times should you wrap a pallet?
A common approach is multiple wraps around the base with consistent overlap as you work up, then reinforcing back down if required. The right method depends on pallet weight, product shape, and transport conditions.
Not sure what you need?
If you tell us pallet weight, product type, and whether you wrap by hand or machine, we can recommend the best film and gauge.
Explore Pallet Wrap Range