Stretch film, also known as stretch wrap, is a highly stretchable plastic film commonly used to wrap products on pallets and secure them to each other and the pallet. It ensures that products stay tightly bound during transportation and storage, preventing movement and damage.
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Typically made from linear low-density polyethylene (LLDPE). This material is chosen for its excellent elasticity, puncture resistance, and cling properties, which are essential for effective packaging.
Other materials that may be used in stretch films include:
The film can stretch significantly before breaking, allowing it to tightly secure items.
The film has a natural cling property that helps it adhere to itself once wrapped, without the need for adhesives.
Available in various thicknesses, measured in microns or mils, to accommodate different load sizes and weights. There are 3 broad categories
Thin gauge – 10 to 15 microns ( 04. To 0.6 mils)
Medium gauge – 15-20 microns (0.6-0.8 mils)
Thick gauge – 20-30 microns (0.8-1.2 mils)
Stretch film or Stretch wrap is primarily made from linear low-density polyethylene (LLDPE). The manufacturing process involves either the blown film extrusion or the cast film extrusion method. Here’s a detailed look at how each method works:
Pellets of LLDPE are mixed with various additives to enhance properties like strength, elasticity, and cling.
The mixture is fed into an extruder where it is melted and forced through a circular die, forming a tube of molten plastic.
Air is blown into the centre of the tube, causing it to expand like a balloon. This forms a bubble of plastic film.
As the bubble rises, it cools and solidifies. Air rings are used to control the cooling process.
The bubble collapses between rollers, forming a flat film. The film is then wound onto large rolls.
LLDPE pellets are mixed with additives similar to the blown film process.
The mixture is melted in an extruder and forced through a flat die to form a thin sheet of molten plastic.
The thin sheet is immediately cast onto a chilled roller (quench roll), which rapidly cools and solidifies the film.
The solidified film is stretched in both the machine direction (MD) and transverse direction (TD) to enhance its strength and elasticity.
The film is wound onto rolls, and ready for use.
Cast film is usually clearer than blown film.
Blown film typically has higher puncture resistance and load-holding strength.
Cast film is often less expensive due to the faster production process.
Blown film tends to be noisier during application compared to cast film.
Throughout the manufacturing process, stretch film undergoes various quality control tests to ensure it meets specific standards for strength, puncture resistance, cling properties and tear resistance. These tests include:
Measures the force required to stretch the film until it breaks. A sample of the stretch film is clamped between the jaws of the machine. The machine applies a force to the film, stretching it at a controlled rate. The force and elongation are recorded until the film breaks.
Evaluates the film’s ability to withstand punctures from sharp objects. A sharp probe is pressed into the film at a controlled rate. The force required to puncture the film is recorded.
Assesses how well the film adheres to itself. A sample of the stretch film is applied to a flat surface. Weights are placed on top of the film to simulate the pressure it will experience in real-world applications. The film’s ability to cling to the surface and resist slippage is recorded.
The force required to tear the film. A notch is made in the film, and a force is applied to tear it apart which is recorded.
By employing these processes and tests, manufacturers produce high-quality stretch film that effectively secures and protects goods during transport and storage.
Designed for manual application using a handheld dispenser or simply by hand. Ideal for smaller operations.
Applied using a stretch wrap machine, suitable for high-volume operations.
Produced using the blown extrusion process, offering higher puncture resistance and load-holding strength.
Made using the cast extrusion process, known for its clarity and smooth release
When your shipping operation starts to grow, manual pallet wrapping can quickly become a bottleneck. That's where stretch wrappers offer a smarter way to protect your loads, boost efficiency, and reduce material waste.
Whether you're just getting started with automation or upgrading your current setup, this guide will help you understand your options, key features to look for, and how to find the right solution for your business.
Stretch wrappers are machines designed to tightly secure pallet loads with stretch film, stabilizing goods for shipment and storage. They're used across industries to cut down on labor costs, improve load consistency, and minimize product damage in transit.
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It's not just about wrapping faster it's about wrapping smarter. Ineffective stretch wrapping is a major driver of product damage during shipping. Stretch wrappers deliver consistent containment force that manual wrapping can't match, helping reduce film waste, prevent product shifting, and protect against warehouse and transit damage.
Stretch wrapping systems vary widely from handheld tools for low-volume operations to fully automated machines that integrate with conveyor lines. Understanding the basic categories can help you find the best fit for your production needs.
The most common type of stretch wrapping machine is the turntable stretch wrapper. This style of wrapper has a turntable that rotates a product as the stretch film is wrapped around it. Available in manual, semi-automatic, and fully automatic operation types.
Manual stretch tools assist with hand-wrapping by holding the roll and applying tension. They’re an affordable step up from traditional hand wrapping but can still be time-consuming. Manual turntable tops are also available where the load turns, but the operator still has to do the wrapping.
Popular models: Highlight Synergy .5, Encore Dispensers, Highlight Predator Turntable Top
Semi-automatic wrappers automate parts of the process like rotating the pallet, but operators still place and cut the film. They're a popular entry point for small to mid-size businesses.
Popular models: Eagle B, Robopac Ecoplat, Cousins -SRT, Handle It 800, Lantech Q300, Fox FPS 300
Automatic wrappers do it all — attaching film, wrapping, cutting, and sealing — often with minimal or no operator involvement. Ideal for companies shipping high volumes daily.
Popular models: Cousins LP-, Eagle F, Handle It AA-C, Fox FPS 400, Robopac LT
Robotic stretch wrappers are mobile machines that drive around the pallet to apply film, offering flexible, space-saving wrapping for a wide range of load types.
Popular models: Robopac S7, Handle It , Cousins Traveler, Combi BeeWrap
The wrapper’s arm rotates around a stationary pallet, perfect for heavy, unstable, or lightweight loads that shouldn't spin.
Popular models: Robopac Masterplat HD XL, Cousins T FSR, Handle It , Lantech S300
These specialized machines wrap loads horizontally which is ideal for long products like pipes, lumber, doors, and windows.
Popular models: Robopac Compacta, Signode Yellow Jacket, TAB Wrapper Tornado, Handle It FA-200
Instead of wrapping around a load, stretch hooders pull a stretchable hood over the pallet for a tight, waterproof seal.
Popular models: Signode Power Flex, Signode Multi Flex, MSK Wraptech, Handle It SH-Core
Finding the right fit starts with knowing your production needs and future goals.
Questions to Answer
When working with a supplier, you will most likely need to answer the following questions to determine which machine is best matched to handle your stretch wrapping needs.
Not sure how to calculate your diagonal pallet size? Use our calculator below!
Each industry faces its own unique shipping challenges — and stretch wrapping solutions can be tailored to match. Some machines are purpose-built for specific applications, like windows and doors, round products like tires, or food and beverage. Others can be customized with sensors, conveyors, and wrap settings to meet unique requirements. Read our article in Packaging World to see how we helped a Wisconsin beverage distributor source and install a custom automated pallet wrapping solution.
Stretch wrapping technology keeps evolving making packaging operations smarter and greener. Newer wrappers use energy-saving motors and optimize film usage, helping lower overall operating costs. Robotic arms are being added to fully automated wrappers to reduce the need for an operator. Many machines now come standard or offer an IoT-enabled option for remote monitoring, performance tracking, and predictive maintenance alerts.
Stretch wrappers range from a few thousand dollars to six figures depending on automation, film carriage type, and specialty features. A semi-automatic machine can often pay for itself within a year through film savings and labor reduction.
According to Robopac, if you’re wrapping 50 loads per day, changing from hand wrapping with 10% pre-stretch to using a machine with 250% pre-stretch can save $30,000 or more over five years in just film savings. That’s not even including the savings from labor and damage.
Once you’ve figured out your machine specifications and budget, you’ll need to choose a supplier. Always look for a vendor that provides warranty information, sells quality equipment, and after-sales support such as installation, tech service, and wear parts.
At Rocket Industrial, we work side-by-side with businesses to match the right machine to their needs — whether you’re wrapping 10 pallets a day or scaling up to 500. Our service team records the machine’s serial number in our system to track the manufacturer's warranty, offers additional warranties, keeps parts on hand, and can help with installation or future service needs.
An investment in automation today can mean major savings down the line.
Even if you're only wrapping 10 loads per day, a stretch wrapper can quickly pay for itself. Hand wrapping is not only time-consuming — it leads to inconsistent containment force, more film waste, and a higher risk of product damage.
Most machine stretch wrappers can pre-stretch film by up to 250%, compared to less than 40% with hand wrapping. That means using less material, achieving stronger and more consistent load containment, and reducing the chance of damaged shipments.
Watch a packaging engineer do a time comparison of hand wrapping vs. machine wrapping in our lab in the video below.
Film Savings: Machine-stretched film can reduce film usage by 30–50% compared to manual wrapping. Pre-stretch systems stretch the film 200–300%, getting 2–3 times more pallet wraps out of the same roll.
Labor Reductions: Manual wrapping can take 2–5 minutes per pallet, while a semi-automatic wrapper can cut that to under one minute. Freeing up workers from wrapping allows for reallocation to higher-value tasks.
Damage Reduction: Poorly wrapped pallets are a leading cause of load damage and claims. Studies show proper stretch wrapping could prevent up to 50% of transport damage. Reducing in-transit damage not only cuts direct product loss but also protects brand reputation and reduces claims processing costs.
On average, we see businesses achieve payback on a semi-automatic stretch wrapper within 9 to 18 months, and automatic stretch wrappers within 12 to 24 months. Of course, actual payback timelines vary based on factors like daily pallet volume, labor rates, film usage, and the level of automation.
Looking at demo or used equipment, reviewing leasing options, and taking advantage of payment terms or Section 179 tax deductions can help speed up return on investment even further.