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When to Switch from Hand Wrapping to Machine Wrapping

When to make the switch

Do you feel that you are spending more on stretch film and labour than you should be? Our automated form below can help you uncover how much you could save by switching to machine film. In just a few quick steps, you’ll see whether your operation has reached the tipping point where automation makes financial and operational sense.

Note: These figures are based on optimal hand wrapping conditions. In real operations, film waste is often higher due to inconsistent tension, overlapping, and operator variability, meaning your actual savings from switching to machine wrap could be even greater.

Hand Wrap to Machine Wrap Calculator

Answer a few quick questions about your current hand-wrap process. We’ll estimate weekly savings, payback period, and a general recommendation. You can save a PDF of your results.

Current Hand-Wrap Profile

Walking time + wrapping time
Enter your average roll price (e.g., $22–$28)
How many pallets do you typically get from one roll?
Leave blank to use $14,000

Benefits of machine film

Reduced
Film Usage

Pre-stretch up to 300% allows you to use less material per load without sacrificing performance.

Consistent Load Containment

Delivers uniform tension and wrap patterns to prevent load shifting and product damage.

Lower
Labour Costs

Reduces manual wrapping time and operator involvement, freeing staff for other tasks.

Improved
Operator Safety

Reduce operators’ strain and injuries by removing the need to walk around pallets.

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Learn how to cut film usage, increase throughput, and improve load security. Available to Canadian companies.

Impak Packaging
110A Iron St, Etobicoke, Ontario M9W 5L9
Phone: 416-299-0960   |   Fax: 416-299-0961   |   Email: info@impakpackaging.com

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IN Packaging Solutions

How we reduced a Companies stretch film usage by 68% while improving their containment force

Many assume that using more film means better containment. But in reality, piling on extra layers often leads to waste, higher costs, and little improvement in load stability.

At Impak, we have a team of experts who can conduct stretch wrap audits with cut & weigh tests, tilt and vibration tests, and more, to help you optimize your stretch wrapping operations.

In this case study, we will go over how we optimized a customer’s stretch wrapping operations with the AXIS Lean 80 Gauge Stretch wrap, in turn reducing their total stretch film usage by 68%, while improving containment strength, lowering costs, and future-proofing their stretch wrapping operations.

CONTACT US FOR A STRETCH WRAP AUDIT

A pallet stretch wrapped and on a conveyor.

Challenge: Improving the stretch wrapping process for damage-free shipping

Two pallets with very different load profiles were delivered to our warehouse for our team of experts to test. The first pallet was tall and irregular, holding products of varying sizes, and the second was shorter and more uniform, with evenly stacked products. These pallets were being wrapped with a semi-automatic stretch wrapper at nominal tensions. Both pallets looked to have been poorly wrapped, with numerous punctures and tears in the film. . This was due to an excessive amount of stretch wrap applied, combined with significant inboard distance between the pallet edge and the product, which left the loads unstable, wasteful, and vulnerable to damage during transit.

OPTIMIZE

We needed to find a way to optimize their stretch wrapping operations, from the type of stretch wrap they should use to and any additional materials needed.

PALLET 1 - TALL & IRREGULAR

Excessive amount of film, cardboard top sleeve does not match the contour of the product beneath it​.

Tearing and punctures appear to be from handling and transit, primarily forklift damage and abrasion damage from an external source (another skid)​.

Product appears to be undamaged from the transit to our facility. However, there appears to be some load shift of the smaller coils stacked at the top of the load.

PALLET 2 - SHORT & UNIFORM

Punctures appear to be from both handling damage and from the current film being stretched over sharp corners. All 4 corners had film punctures.

Punctures at the corners of the pallet are likely due to the dramatic inboard distance from the pallet corner to the product.

The difference between the forklift puncture and the corner puncture are visible here. One did not cause the other.

Our Approach: Testing, Auditing & Process Optimization

To start, we needed to know all we could about the load containment so that we could provide a solution. That meant measuring the weight of the pallet overall, and each section of the pallet, as well as the cut & weigh.

A cut & weigh test measures exactly how much film is being used to wrap a load. When a pallet is wrapped, a section of the film is cut off and weighed, which reveals the true film consumption in ounces. These tests are used to identify waste and to set a baseline for improvement.

Pallet 1 – SPECIFICATIONS
Gross Pallet Weight 1436 lbs
Top 4.62 lbs
Middle 14.88 lbs
Bottom 9.25 lbs
Cut & Weigh 25.07 oz
Pallet 2 – SPECIFICATIONS
Gross Pallet Weight 1226 lbs
Turntable Speed 7.25 lbs
Turntable Size N/A
Weight Requirements 5.10 lbs
Maximum Load Size 7.7 oz

The next step was a tilt and vibration test to see how both pallets would currently hold up in transport. The current methods of stretch wrapping proved to be insufficient. Both pallet tests resulted in containment failure. If the load had been exposed to any additional forces, damage to the product was certain, and the potential for injury may have been possible.​

 

Pallet 1

  • The stretch film tore at the pallet corners on the side opposite the tilt.
  • The wrap pulled up one of the pallet boards, which exposed nails and a sharp edge.
  • Inside the load, the products weren’t tight; there were gaps and movement, which caused the load to shift.

Pallet 2

  • The film tore at the pallet corners and continued ripping during the test until it completely detached from the pallet.
  • Once the film failed, the load slid off the pallet, and only the sled kept the products from fully separating.
  • The load shift was caused by three main issues: the film failure at the punctured corners, low friction between product layers that caused uneven sliding, and the load being positioned too far in from the pallet edges, which amplified the movement once it began.

Axis Lean 80 GaugeAnti-Slip SheetsStrappingOptimized Wrap Pattern

  

Our team of experts reviewed our lineup of stretch wrap and decided that the best course of action was to switch the customer’s current conventional 80 gauge stretch wrap to our
Axis Lean 80 Gauge high-performance stretch film known for its:

  • High Load Containment
  • High Puncture Resistance
  • Excellent Clarity with High Cling
  • Lowest Cost Per Load / Wrap

We also added to both pallets anti-slip sheets to inhibit movement, strapping to unitize the load, and optimized the wrap patterns for consistency and efficiency.

To start, we needed to know all we could about the load containment so that we could provide a solution. That meant measuring the weight of the pallet overall, and each section of the pallet, as well as the cut & weigh.

A cut & weigh test measures exactly how much film is being used to wrap a load. When a pallet is wrapped, a section of the film is cut off and weighed, which reveals the true film consumption in ounces. These tests are used to identify waste and to set a baseline for improvement.

Pallet 1 – SPECIFICATIONS
Gross Pallet Weight 1436 lbs
Top 4.62 lbs
Middle 14.88 lbs
Bottom 9.25 lbs
Cut & Weigh 25.07 oz

Pallet 2 – SPECIFICATIONS
Gross Pallet Weight 1226 lbs
Turntable Speed 7.25 lbs
Turntable Size N/A
Weight Requirements 5.10 lbs
Maximum Load Size 7.7 oz

The next step was a tilt and vibration test to see how both pallets would currently hold up in transport. The current methods of stretch wrapping proved to be insufficient. Both pallet tests resulted in containment failure. If the load had been exposed to any additional forces, damage to the product was certain, and the potential for injury may have been possible.

Pallet 1
  • The stretch film tore at the pallet corners on the side opposite the tilt.
  • The wrap pulled up one of the pallet boards, exposing nails and a sharp edge.
  • Inside the load, there were gaps and movement, which caused the load to shift.

Pallet 2
  • The film tore at the pallet corners and continued ripping until it fully detached from the pallet.
  • Once the film failed, the load slid off the pallet, and only the sled prevented full separation.
  • The load shift was caused by low friction between layers, the film failure, and the load being set too far in from the pallet edges.

Axis Lean 80 Gauge
Anti-Slip Sheets
Strapping
Optimized Wrap Pattern

Our team of experts reviewed our lineup of stretch wrap and decided that the best course of action was to switch the customer’s current conventional 80 gauge stretch wrap to our
Axis Lean 80 Gauge high-performance stretch film known for its:

  • High Load Containment
  • High Puncture Resistance
  • Excellent Clarity with High Cling
  • Lowest Cost Per Load / Wrap

We also added to both pallets anti-slip sheets to inhibit movement, strapping to unitize the load, and optimized the wrap patterns for consistency and efficiency.

Results: Reduced film used while improving load stability

The final stage of our stretch wrap optimization was to validate the improved setup in real-world conditions.

We rewrapped both pallets using AXIS 80 Gauge high-performance film, added the strapping, and anti-slip sheets to stabilize the loads.

Since the customer used a Wulftec SML-150 Turntable Pallet Wrapper, we replicated their setup in our warehouse. With the same machine on-site, our team performed multiple in-house test wraps to ensure the updated process delivered consistent, failure-free results.

After numerous tests, we visited the customer’s warehouse to have them try out this new stretch wrapping process on their machine, and it performed flawlessly. The results were consistent, stable, and fully aligned with their operational needs.

Pallet Comparison — Collapsible

Pallet 1 Comparison

Gross Weight: 1,436 lbs
Film ↓ ~84% (25.7 oz → 4.1–4.4 oz) Top Containment ↑ >3× (4.62 → 15.5 lbs)
Containment & Film Use
Metric Before After
Top Containment (lbs) 4.62 15.5
Middle Containment (lbs) 14.88 15.6
Bottom Containment (lbs) 9.25 9.00
Cut & Weigh (oz) 25.7 4.1–4.4
Optimized with AXIS 80ga, strapping on both axes, anti‑slip sheet, and a shaped top sheet.

Pallet 2 Comparison

Gross Weight: 1,226 lbs
Film ↓ ~52% (7.7 oz → 3.7–3.9 oz) Top Containment ↑ >2.7× (7.25 → 20.15 lbs)
Containment & Film Use
Metric Before After
Top Containment (lbs) 7.25 20.15
Middle Containment (lbs) — —
Bottom Containment (lbs) 5.10 10.50
Cut & Weigh (oz) 7.7 3.7–3.9
Optimized with AXIS 80ga, strapping on both axes, anti‑slip sheet, and a shaped top sheet.

Reduced Film Usage

Film consumption dropped significantly on both loads, Pallet 1 was reduced by over 84% (from 25.7 oz to just over 4 oz), while Pallet 2 saw a 52% reduction (from 7.7 oz to 3.9 oz). In turn reducing their overall film usage by 68%.

Heightened Load Security

By adding strapping, anti-slip sheets, and custom top sheets, internal shifting and product separation were completely eliminated. As a result, both pallets moved from being classified as unstable (C-load) to fully secure and transport-ready.

Increased Containment Force

Containment strength increased by 247% on Pallet 1 and by 30% on Pallet 2, despite both using dramatically less film than before. Not only were the loads more stable, but the improvements were achieved without added material, labour, or equipment changes.

Improved Safety & Performance

The optimized wrap process eliminated film tearing, corner punctures, and shifting altogether. The loads remained fully intact with no sliding or separation, reducing damage risk, improving safety, and ensuring more reliable pallet transport.

416-299-0960
Contact Us Today!
Looking to Improve your Stretch Wrapping Operations?

Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.

Impak Packaging Gertex Group Logo
Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries

info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

IN Packaging Solutions

What is a Biodegradable Stretch Film?

The Evolution of Packaging: A Need for Sustainability

Traditional plastic stretch films, although recyclable, often end up in landfills. This concern has spurred the development of biodegradable stretch films like Precisionrap DK.

If your business is trying to become more sustainable, the chances are you’ll have discussed how you can make your packaging fit in with this. Among various packaging solutions, biodegradable stretch films have emerged as a promising solution to address environmental concerns associated with conventional plastics. This article delves into Precisionrap DK stretch wrap, a biodegradable alternative that offers both performance and eco-consciousness.

Precisionrap DK Stretch Wrap: A greener choice

Precisionrap DK stretch wrap is a cutting-edge packaging solution designed to cater to the needs of both businesses and the environment. It shares many characteristics with traditional stretch films, such as excellent load stability, protection against moisture and dust, and ease of application. For example, the total film stretches of 285% with a hand application.

However, its key differentiator lies in its biodegradability. It takes a few years to decay, not decades. This can help company’s sustainability goals without a hassle of recycling, while the pricing is same as other Precision product.

Benefits of Precisionrap DK Stretch Wrap

Environmental Sustainability
The primary advantage of Precisionrap DK is its biodegradability. Made from biodegradable materials, this stretch film breaks down naturally over time, reducing its environmental impact compared to traditional plastics.
Reduced Carbon Footprint
Using biodegradable stretch wrap contributes to lower greenhouse gas emissions during production and disposal. This aligns with corporate sustainability goals and reduces carbon footprints in the supply chain.
Cost-Efficiency
Precisionrap DK offers competitive pricing and performance, making it a cost-effective choice for businesses that seek eco-friendly alternatives without compromising on quality.
Versatility
This stretch wrap can be used across various industries, from food and beverage to manufacturing and logistics, ensuring versatility in its applications.
Ease of Use
Precisionrap DK is designed for ease of application, ensuring that businesses can transition seamlessly to this eco-friendly packaging option.

Precisionrap : cost-effective and efficient solution

Precisionrap has a two-part handheld dispenser, which allows ergonomic stretch wrap usage. Aside from less intensity of labour, Precisionrap also offers several key advantages over traditional hand pallet wrapping techniques:

Film Efficiency: Precisionrap consumes less film by weight compared to traditional methods. Based on a cut and weigh test by rewrapping a pallet with Precisionrap and comparing film weights, customers can reduce their film consumption by a minimum of 35%.

Improved Load Containment: According to the force-to-load measurement, Precisionrap significantly enhances load containment, exerting up to 50% more force on the load to maintain its integrity compared to traditional hand-wrapping techniques.

Faster Wrapping: With Precisionrap, you can wrap a typical load 33% faster than with manual hand wrapping. Precisionrap streamlines the process without compromising on wrapping quality.

Consistent Containment: Precisionrap ensures consistency and containment with its snapback test. This test measures the film’s ability to recover to its pre-applied length after being cut vertically. Precisionrap consistently achieves greater and more consistent snapback and load containment compared to traditional hand-wrapped pallets, regardless of the operator.

Biodegrading process of Stretch Films

3 Steps of Assimilation
Precisionrap DK is a plastic based film that has additives included in the manufacturing process. These additives, usually enzymes, enable the plastic to break down.
Step 1.
After 2 years of stable shelf-life, Precisionrap DK starts the chemical reaction begins causing the film to assimilate and attract micro-organisms that consume the carbon.
Step 2.
When the film breaks down by oxidative degradation, it simply turns into smaller pieces of plastic. A low molecular mass oxidation products are established.
Step 3.
With abundance of UV rays, heat, and micro-organisms, the film will be bio-degraded in the ocean or buried landfill. At the end of the process, which takes 6 to 24 months, only a little bit of CO2, H2O and biomass remain.

Get a greener Stretch wrap quote Today!

Have a question about equipment or service?
Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.
Impak Packaging Gertex Group Logo
Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries
info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

IN Packaging Solutions

Stretch wrapping basics

Stretch wrapping is a technique used throughout the packaging industry to secure products to a skid and provide extra protection while in transport. This technique is particularly useful while shipping several boxes or products on a skid. Pallet Wrapping will ensure that your products are safe, stabilized and secure so they reach your customer without being damaged or tampered. This article aims to give you a clear understanding of how stretch wrapping works and how it is implemented. You need to follow certain steps so that you stretch wrap your products properly preventing them from getting damaged during the shipping process.

Stretch Wrapped skids of Bottle Water heavy

stretch film

Stretch Film is a highly stretchable plastic film that is used in the stretch wrapping process. This highly stretchable film is wrapped around the boxes while adjusting the tension, wrapping the skid providing a secondary protection. There are two types of stretch film which are commonly used: Machine stretch film and Hand stretch film.

Stretch Wrapping Equipment

Fox FPS 300 Pallet Wrapper with wrapped palletPallet Wrappers/Stretch Wrappers tightly wrap a loaded skid or a pallet with machine stretch film. A loaded pallet is placed on the turn-table and with the carriage mounted with stretch film, the turntable rotates dispensing film and wrapping the pallet. Pallet Wrappers tightly wrap the pallet making it stable, air-tight and clean. You can also use a hand wrapper to wrap the pallet by hand using hand stretch film.

Different types of pallet wrappers

FOX FPS-400H High Profile Pallet Wrapper
turntable pallet wrappers

The Turntable Pallet Wrapper is like a spinning plate for pallets. Just like the name sounds, this machine has a turntable on the bottom of the structure that spins. You place the pallet on the rotating platform, and a roll of stretch film is dispended high to low as it turns. You can adjust the tightness and number of wraps as needed. It’s an easy and effective way to protect and contain products during transport. 

Wulftec WRT-150 Rotary Arm Pallet Wrapper
rotary arm pallet wrappers

Imagine a big oscillating arm that hugs your pallet with stretch film to ensure containment during transport – that’s the Rotary Arm Pallet Wrapper. The pallet stays still, and the arm moves around the skid, wrapping the film from top to bottom. This method is great for fast and stable wrapping, especially for tricky loads that may wobble.

FOX FPS 3000FT Orbital Wrapper
orbital pallet wrappers

The Orbital Pallet Wrapper is perfect for irregularly shaped loads. Instead of spinning the pallet, it wraps the film around the load horizontally from all sides. This ensures that every part of the load is securely covered, preventing any shifting during shipping. This type of stretch wrapping machine is perfect for long product like furniture and cabinetry.

Handle-IT Model 3000 Mobile Stretch Wrapper
mobile pallet wrappers

The Mobile Pallet Wrapper is like a compact wrapping machine on wheels. You can take it anywhere in your warehouse, no fixed spot needed. Just place the pallet on the floor, attach the film, and let the machine move around the pallet to wrap it up neatly. It’s convenient, safe and saves time!

Handle-It Logo
Wulftec Logo
Berran Industrial Group Logo
Highlight Pallet Wrapper Logo

Key Considerations FOR hand WRAPPING

The following are the steps to be considered before stretch wrapping a skid using a hand film:

1. Select the right size pallet or skid

Make sure you stack your boxes or products using the right size skid.  Using a skid that is too large or too small will result in an insecure and unstable load. The best size is one that is not larger than the products placed on top otherwise the plastic may tear on the sharp pallet corners; yet the pallet has to completely cover the base area of the products you want wrapped or you may have damage to your products in shipping.

2. Stack the base of the skid properly

If you have different size boxes, make sure to place the larger heavier boxes on the pallet first. Make sure not to leave any gaps and occupy as much space as you can to make the base stable and secure.

3. Stack the rest of your boxes on the skid

Properly place the remaining boxes or products on the skid. Make sure that your boxes do not cross the edges of the pallet and placed them as close as possible to each other in order to prevent them from moving after being wrapped. Do not stack your pallet too high as it can destabilize the load by raising the center of gravity. Make sure your skid is in cubical or square shape.

4. Start the Stretch Wrapping Process

Tie the stretch film around the corner of the skid. This will ensure that the film does not come off while wrapping. While holding the hand stretch wrapper, start walking around the skid. Once you reach the corners of the skid, tightly secure and apply tension ensuring it is nice and tight around the load. Always start from the bottom and then go towards the top.  It is recommended that you go around the skid at least 5-6 times to ensure stability. Once the wrapping is finished, check the skid thoroughly for sturdiness. If the load is moving and is not stable, you should consider wrapping it again. Once your pallet is stable and sturdy, tear the stretch wrap from the skid and you are done.

get a free consultation today!

If you have a high volume of skids or pallets to wrap, we recommend using a machine pallet wrapper. If you have any questions about stretch wrapping and wrapping equipment, please call us at (416) 299-0960 and a representative will guide you in selecting the right stretch film and equipment for your packaging needs.

Have a question about equipment or service?
Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.
Impak Packaging Gertex Group Logo
Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries
info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

IN Packaging Solutions

5 Things You Need to Know about Downgauging Stretch Wrap

In recent years, the growing concern for environmental sustainability has led to significant changes in the packaging industry. One such development is the adoption of downgauging stretch film, a process that involves reducing the thickness of the film while maintaining its performance characteristics. In this article, we will explore the concept of film downgauging, its advantages, and address common concerns about the quality and appearance of the packaging.

Sustainable Stretch Film Icon

1. What is film downgauging?

Film downgauging refers to the process of reducing the thickness of stretch films used in packaging without compromising their performance. Traditionally, plastic films were thicker to ensure strength, durability, and barrier properties. However, advancements in technology and material science have allowed manufacturers to create thinner films that meet the same quality standards as their thicker counterparts.

2. Why should you consider downgauging Stretch film

Downgauging stretch film offers several benefits, both for businesses and the environment. By reducing the amount of material used in packaging, companies can significantly decrease their carbon footprint and overall waste generation. Thinner films require fewer raw materials during production, resulting in lower energy consumption and greenhouse gas emissions. Moreover, downgauging can lead to cost savings, as less material is required for packaging without compromising on performance.

3. Will it still meet quality requirements?

One of the most common concerns about downgauging stretch film is whether it will meet the necessary quality requirements. However, manufacturers have made significant strides in developing thin films that maintain the necessary toughness, barrier properties, shelf-life, and resistance to damage during transportation and end use. Advanced materials and technologies allow for the creation of thinner films that possess the required strength and durability, ensuring the packaged products remain intact and protected. 

4. Does the package still maintain its shelf appearance?

Maintaining the visual appeal of packaged products is essential to brand identity and consumer perception. Fortunately, downgauging plastic film does not necessarily compromise the package’s shelf appearance. With advancements in printing and coating technologies, it is possible to enhance the visual aesthetics of thinner films, ensuring that they still look as good as their thicker counterparts on store shelves. Packaging designers can employ various techniques to maintain branding elements and eye-catching designs, ensuring consumer satisfaction.

5. Will consumers notice?

Consumers are increasingly conscious of sustainability issues, and many actively seek out products with environmentally friendly packaging. According to The Dow Chemical Co. study conducted in 2011, consumers may notice a change in packaging thickness if given more than a 10% reduction. However, the quality and functionality of the package, as well as the brand’s commitment to sustainability, are often more important factors for consumers. By effectively communicating the sustainability of downgauging, companies can enhance their brand reputation and appeal to environmentally conscious customers.

In general, the process of downgauging stretch film for packaging offers a range of benefits, such as reducing the environmental impact and saving costs. As you read through this article, you may consider the option of downgauging your stretch film. By planning how downgauged packages feel to customers and promoting sustainability, it is possible to provide a solution that satisfies brand owners, retailers, and consumers.

Whether you decide to pursue downgauging or explore newer and more innovative stretch films, it is advisable to involve a packaging expert who can assess your packaging operation and help determine the most suitable film for your specific application. You can trust our team of highly experienced packaging specialists who possess a deep understanding of stretch film wrapping and can provide valuable guidance.

Book a free audit today

Have a question about equipment or service?
Just give us a call or send us a message with the form below. One of our customer service representatives would be happy to help you with whatever you need.
Impak Packaging Gertex Group Logo
Impak Packaging

110A Iron St.
Etobicoke, Ontario
M9W 5L9
Phone: 416-299-0960
Fax: 416-299-0961
Email: info@impakpackaging.com

Inquiries
info@impakpackaging.com

416-299-0960

Parts and Service

servicing@impakpackaging.com

416-299-0960

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