How to Wrap a Pallet with Stretch Film: Step-by-Step Guide

Reviewed and updated by ICD - Week 44/2026

Wrapping stretch film correctly means anchoring the film tail on a pallet leg, wrapping 3 turns at the base so the film grips the whole pallet, spiraling upward with each turn overlapping about half the film width, adding a reinforcing turn at the top, then cutting and pressing down the tail. For a 1200 x 1000 mm pallet loaded 1.5 m high, this takes about 10 turns, or roughly 44 m of 500 mm wide film. This guide covers hand wrapping step by step, machine wrapping, how to calculate film use, and the mistakes that leave pallets loose in transit.

Why does stretch film technique matter?

Pallet film binds cartons into one block with the pallet. Wrapped badly, the load shifts when a forklift brakes hard, when a container jolts, or when pallets are stacked; wrapped excessively, the warehouse wastes film without making the pallet any safer.

Correct wrapping holds the load fixed to the pallet through storage and transport, keeps off dust and light rain, and reduces scuffing on carton surfaces. The warehouse also uses only the film it needs, the operator works faster and more evenly, and the pallet stays tidy and easy to count at handover.

The packaging industry measures how secure a pallet is by containment force, the force the film presses onto the load. According to a Virginia Tech thesis, containment force is commonly measured under ASTM D4649 using a 15.2 cm wide plate slid under the film layer. Research from Cal Poly shows that adding wraps, using thicker film, or stretching the film harder during wrapping all raise containment force, so the number of turns and the tension are the two things the operator controls.

Preparation before wrapping

Choose the right PE film

Film thickness is measured in microns. ICD Vietnam hand rolls are 17 microns thick, 500 mm wide, weigh 2.1 - 5 kg depending on the type (MPE21, MPE30, MPE38, MPE50), with a 76 mm or 54 mm core. ICD-MPE150 and ICD-MPEM machine rolls are 20 - 30 microns thick, weigh 7 - 18 kg, have a 76 mm core, and fit only on wrapping machines. A machine roll is too heavy to wrap by hand, and a hand roll is too short for continuous machine runs.

Most pallet film today is made from LLDPE (linear low-density polyethylene), a resin that stretches well, is tough, and clings to itself between layers, common in PE film packaging. When comparing films, ask for the thickness, maximum stretch, and cling stated on the supplier’s spec sheet instead of relying only on the resin name or the roll color.

Check the pallet and the load

Film can only hold a load that is already stacked neatly. Before wrapping, do these 4 things:

• Stack the load within the pallet edges, heavy cartons at the bottom, columns of cartons aligned, nothing hanging over the edge.
• Check that the pallet has no cracks, broken boards, protruding nails, or sharp edges that could tear the film.
• Wipe the load and the pallet dry; film clings poorly to wet or dusty surfaces.
• Put cardboard corner pieces or edge protectors on sharp edges and on carton corners that dent easily.

Step-by-step hand wrapping

Hand wrapping suits warehouses that wrap few pallets a day or handle loads of unusual sizes. The order below applies to a 1200 x 1000 mm pallet about 1.5 m high with 500 mm wide film.

1. Load the film roll into the hand-held dispenser, or hold the roll with both hands through its core, and pull out about 1 m of film.
2. Anchor the film tail: thread it through a slot or tie it around one corner of the pallet leg, or pinch it between two cartons on the bottom layer.
3. Wrap 3 turns at the base, with the lower edge of the film covering down onto the pallet legs to lock the load to the pallet.
4. Work upward, each turn overlapping the previous one by about half the film width; a 1.5 m pallet needs about 6 body turns.
5. Add 1 reinforcing turn at the top layer of cartons, and fold the film edge lightly over the top face if you wish.
6. Keep the pulling force even throughout: the film should hug the cartons, with no wrinkles and no slack at the corners.
7. Cut the film and press the tail onto the layer beneath so it clings, leaving no loose end flapping.
8. Final check: press a hand into the middle of the pallet, the film should feel taut; rock a corner gently, the load should not shift.

A dispenser with a brake gives more even tension and spares the operator from bending to the floor on the base turns. Hand wrapping has no pre-stretch: pre-stretch is a set of rollers in a wrapping machine that stretches the film before it reaches the pallet. When wrapping by hand, the stretch comes from the operator’s pull, which is usually far lower than a machine’s.

How many turns does a pallet need?

The number of body turns depends on load height and film width. With 500 mm film overlapping by half, each turn adds only about 250 mm of coverage, so a 1.5 m load needs about 6 body turns to be fully covered. Add 3 reinforcing turns at the base and 1 at the top, and the total is about 10 turns. This is the calculation used consistently across ICD Vietnam’s guides.

Heavy loads, tall loads, or loads going a long way should get 1 - 2 extra turns at the base, because the base is where a load is most likely to slide off the pallet. Irregular loads can take 1 extra diagonal turn across the corner. For a shorter pallet, reduce the body turns accordingly; for example, a 1 m load needs only about 4 body turns.

What is the right film tension?

The right tension is enough for the film to hug and hold the load without crushing cartons or shifting them at the corners. Too loose and the film sags and the load shifts; too tight and the film punctures at the corners and cartons get squeezed out of shape.

Tension when wrapping by machine

ICD Vietnam pallet wrappers have a pre-stretch unit that stretches film up to 250% on models such as the Ultra Wrap 2000BF, X100, T1650FZ, and X0PS: 1 m of film on the roll becomes 3.5 m on the pallet. Cal Poly research describes the same principle at 200%: 1 inch of film becomes 3 inches. Force on the load is adjusted separately by the brake or the film-feed motor, independent of the pre-stretch level.

How to check tension when wrapping by hand

When you pull, you should feel clear resistance and the film width should narrow slightly, a sign that the film is stretching. After wrapping, the film must be flat, wrinkle-free, and hugging the carton faces. If the film tears at the corners, reduce the pull or use corner protectors; if it sags, pull harder. After a few pallets, compare the tension between wrappers so the warehouse works to one standard.

Step-by-step machine wrapping

An automatic PE film wrapping machine is used in factories and warehouses with many pallets a day. With a turntable machine, a forklift places the pallet on the turntable, and the turntable rotates on its axis while the film carriage travels up and down the mast.

The machine film roll fits into a film carriage with pre-stretch that stretches the film before wrapping. The operator sets the number of base turns, top turns, climb speed, and wrapping force, then the machine repeats exactly those settings for every pallet. ICD Vietnam turntable models reach 20 - 50 pallets per hour depending on the model.

The biggest benefits of a machine are saving film and even tension. By ICD Vietnam’s calculation for a 1200 x 1000 mm pallet 1.5 m high, a machine with only a brake-based stretch of about 40% uses about 31 m of film per pallet, while a 250% pre-stretch machine uses about 13 m. The operator also no longer has to bend or walk around the pallet.

5 common stretch film mistakes and how to avoid them

The five mistakes below often leave pallets loose or waste film:

• Wrapping too loose: film sags and the load shifts. Pull harder and add base turns.
• Wrapping too tight: cartons dent and film tears at the corners. Reduce the pull and use corner protectors.
• Uneven overlap: gaps appear between turns. Climb slowly and keep the overlap at about half the film width.
• Skipping the base turns: the load slides off the pallet. Always wrap 3 base turns around the pallet legs.
• Choosing the wrong roll: a machine roll is too heavy for hand wrapping, and a hand roll runs out too fast on a machine. Use 17 micron for hand wrapping and 20 - 30 micron for machines.

How to calculate the film you need

Film length equals the pallet perimeter times the number of turns. The load height is not added to the perimeter; it is already counted in the number of body turns. Film weight equals length x width x thickness x LLDPE density (about 0.92 g/cm³).

Worked example

• Pallet 1200 x 1000 mm: perimeter (1.2 + 1.0) x 2 = 4.4 m.
• 1.5 m load, 500 mm film: 3 base turns + 6 body turns + 1 top turn = 10 turns.
• Film length: 4.4 x 10 = about 44 m.
• Weight for hand wrapping with almost no stretch, 17 micron film: 44 m x 0.5 m x 17 microns x 0.92 = about 345 g.

By ICD Vietnam’s calculation, a 2.1 kg roll holds about 1.8 kg of film, about 230 m long, enough to wrap about 5 pallets like the one above. If you can stretch it about 150%, each pallet uses only about 138 g of film and the same roll wraps about 13 pallets. Actual figures vary with the number of reinforcing turns, the overlap, and each wrapper’s pull.

Tips for safe and efficient wrapping

WorkSafe Victoria (Australia) classes hand pallet wrapping as work with a risk of musculoskeletal injury to the back, shoulders, knees, and wrists, because the wrapper has to bend, reach, twist, and exert force continuously. The agency advises using an automatic or semi-automatic wrapper, or lifting the pallet onto a lift table with a turntable. If you still wrap by hand:

• Use a hand-held dispenser so you do not have to bend to the floor on the base turns.
• Walk forward around the pallet, watch your path, and clear obstacles around the wrapping spot.
• Wear gloves to grip the roll firmly and avoid cuts when cutting the film.
• Rotate wrappers when many pallets have to be wrapped in a row.
• Inspect the pallet right after wrapping and before handling.
• Store film rolls in a dry, cool place away from direct sun and from sharp objects that could puncture the roll.

When should you use a wrapping machine?

A common threshold is about 50 pallets a day: above it, hand wrapping becomes a bottleneck at the dispatch area and heavy work for the wrapper; below it, a semi-automatic machine is usually enough. A machine is worth buying sooner when the warehouse needs faster dispatch at peak hours, needs consistent wrapping quality on every pallet (especially export cargo), or wants to cut film cost and labor over the long term.

Frequently asked questions

How much does stretch film stretch?

It depends on the film; the maximum stretch is stated on the supplier’s spec sheet. When wrapping by machine, the pre-stretch unit on ICD Vietnam wrappers stretches film up to 250%, meaning 1 m becomes 3.5 m. When wrapping by hand, the stretch comes from the person pulling and should be much lower.

Can used PE film be reused for wrapping?

It should not be. Film taken off a pallet has already been stretched, picked up dust, and may have tears, so it stretches poorly, breaks easily, and holds the load less securely. Collect used film for recycling and use a new roll for each new pallet.

Can stretch film be recycled?

Yes. LDPE and LLDPE fall under plastic resin code 4. Clean film, free of tape and paper labels, is more readily accepted by buyers; keep clear film and colored film separate.

What should you watch when storing film?

Keep rolls in a dry, cool place away from direct sun and heat sources, on a shelf or in a box so sharp objects cannot puncture them or deform the core. Use the oldest stock first.

Does hand wrapping affect your health?

The main risk is musculoskeletal injury from repeated bending, reaching, and twisting, according to WorkSafe Victoria, plus cuts when trimming the film with a knife. Use a hand-held dispenser, wear gloves, rotate wrappers, or switch to a wrapping machine at high volumes.

How many pallets can a 2.1 kg hand roll wrap?

By ICD Vietnam’s calculation, a 2.1 kg roll holds about 1.8 kg of 17 micron film, about 230 m long, enough to wrap about 5 pallets of 1200 x 1000 mm, 1.5 m high, at 10 turns per pallet when hand wrapping with almost no stretch.

Conclusion

Wrapping stretch film correctly comes down to three things: lock the base to the pallet firmly, cover the body with an even overlap, and keep the tension steady. Follow the order above and a 1.5 m pallet needs about 10 turns and 44 m of film, with no need to over-wrap.

If you need quality PE film or a professional wrapping machine, contact ICD Vietnam for detailed advice.

Contact ICD Vietnam - specialists in Plastic Pallets and packaging supplies

References

• Principles and techniques of pallet stretch wrapping in logistics - Material Handling Industry (MHI) - Stretch Wrapping Fundamentals.
• Stretch wrapping pallets, safety guidance, WorkSafe Victoria.
• Cernokus (2012), stretch wrap containment force, Cal Poly thesis.
• Bisha, elastic properties of stretch film and unit load containment, Virginia Tech thesis.
• ASTM D4649, guide for selecting stretch film.
• Dunno, Symanski (2021), stretch film holding force and temperature, Journal of Applied Packaging Research, RIT.
• ICD Vietnam product pages: MPE21 - MPE50 hand rolls, ICD-MPE150, ICD-MPEM, hand-held film dispensers, pallet wrapping machines (accessed Oct 17, 2026).