Are You Focusing on Film Thickness Instead of Film Performance?
- colin2629
- Jun 10
- 3 min read
Across the packaging industry, there is increasing pressure to reduce material usage, lower costs and improve sustainability. As a result, many businesses are actively searching for thinner stretch films as a way to achieve these goals.
But is film thickness really the most important factor?
In our experience, too many purchasing decisions are based on the assumption that thinner film automatically means better efficiency, while thicker film automatically means higher cost. The reality is far more complex.
Before selecting any stretch film, it's important to understand what the film is actually expected to do.
Is it simply acting as a dust cover?
Is it providing product protection?
Or is it playing a critical role in maintaining load stability throughout storage, handling and transportation?
The answer to these questions should influence every decision that follows.
The Film You Start With Is Not the Film You End Up With
One of the most misunderstood aspects of pallet wrapping is that the film thickness specified on the roll is only the starting point.
Modern stretch wrapping equipment effectively acts as a film converter.
As the film passes through the pre-stretch system, it is elongated before being applied to the load. This process changes the characteristics of the film and significantly reduces its thickness.
The performance of the wrapping system is therefore influenced not only by the film itself but also by how the machine applies it.
Factors such as:
Pre-stretch ratios
Gear configurations
Tension control systems
Film delivery settings
Machine capability
all contribute to the final result.
A film that performs exceptionally well on one machine may deliver very different results on another.
The illustration below demonstrates how film thickness changes as stretch is applied throughout the wrapping process. While the figures shown are examples, they highlight an important principle: the starting thickness of a film roll is only one part of the equation. Machine settings, pre-stretch levels and film application all influence the final thickness and performance of the film on the pallet.
Understanding the Forces Involved
To properly assess film performance, it's important to understand the forces acting on the film throughout the wrapping process.
The initial stretch applied by the wrapping equipment determines how efficiently the film is utilised.
The tension applied as the film is delivered onto the pallet then influences the containment force generated around the load.
This relationship is critical.
Focusing solely on the thickness of the film can overlook the factors that ultimately determine whether a pallet remains stable throughout its distribution journey.
The objective is not simply to apply film.
The objective is to apply the correct containment force for the specific load, product and distribution environment.
Why Thickness Alone Can Be Misleading
Two films with different starting thicknesses can produce surprisingly similar results when applied correctly.
Likewise, a thinner film that appears more economical on paper may fail to provide the required load stability if the application has not been properly assessed.
This is why successful film optimisation should never be based solely on micron reduction.
Instead, businesses should evaluate:
Load stability requirements
Film performance characteristics
Wrapping machine capability
Distribution conditions
Containment force requirements
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