How to Reduce Film Breakage During Wrapping

Practical Tips to Avoid Stretch Film Tearing and Improve Wrapping Efficiency

Stretch film breakage is one of the most common—and frustrating—issues during pallet wrapping. Whether you’re using hand wrap or a machine wrapper, frequent film tearing slows down operations, increases packaging costs, and reduces load stability.

Fortunately, most film breakage problems can be prevented with the right techniques, equipment settings, and film selection. This guide explains the main causes of stretch film tearing and provides actionable steps to reduce breakage during wrapping.

1. Choose the Right Stretch Film Type

Different wrapping conditions require different types of film. Using the wrong film is the #1 cause of tearing.

✔ Key Factors to Consider

1. Thickness (Gauge)

  • 70–80 gauge: general purpose, most common

  • 90–120 gauge: heavy-duty loads

  • Pre-stretched film: ultra-light weight, easier to use manually

2. Film Material

  • Cast LLDPE: smooth, quiet, high clarity, best for machine wrapping

  • Blown LLDPE: stronger, more puncture-resistant, suitable for sharp-edged loads

3. Load Type

  • Irregular / sharp edges → Choose blown film or higher gauge

  • Uniform pallet load → Standard 80ga cast film is enough

Using a film too thin for the application will almost always result in breakage.

2. Inspect the Load Before Wrapping

Even the strongest industrial film can break when dragged across sharp surfaces.

✔ Look for:

  • Sharp pallet edges or broken wood

  • Pointed product corners (metal, boxes, machinery parts)

  • Stretch film catching on the pallet notch

  • Loose items sticking out of the load

✔ Simple Fixes:

  • Add corner protectors

  • Cover sharp edges with cardboard

  • Repair broken pallets

  • Ensure items are aligned within the pallet footprint

3. Adjust Wrapping Technique (Hand Wrapping)

Incorrect manual wrapping habits often cause unnecessary tearing.

✔ Use Proper Tension

Pulling the film too hard causes excessive stretch and weakens the film.
Pulling too softly reduces load stability.

How to do it right:

  • Keep tension consistent

  • Apply more tension at the bottom layers

  • Reduce tension when wrapping upper layers

✔ Start with a Strong Base Wrap

Begin with 2–3 rotations around the pallet base.
A secure base reduces film drag—one of the biggest breakage triggers.

✔ Avoid Ground Drag

If the film touches the floor for even one second, it may tear instantly.
Always maintain controlled height.

4. Optimize Machine Wrapper Settings

If you’re using a semi-automatic or automatic wrapper:

✔ Check Pre-Stretch Level

Most machines use 200%–300% pre-stretch.
Too much → film becomes thin and weak.
Too little → film has poor holding force.

✔ Reduce Film Tension for Sharp Loads

Many machine breaks happen during the first 10 seconds.
Reduce tension during the first few rotations, then increase gradually.

✔ Adjust Rotational Speed

  • High RPM = more chance of tearing

  • Lower the speed when wrapping lighter loads

✔ Ensure Smooth Roll Feed

Dirt, dust, or sticky residue on rollers can snag film.
Wipe rollers weekly with alcohol.

5. Store Film Correctly

Poor storage conditions weaken film strength.

✔ Ideal Storage Conditions:

  • Temperature: 15–30°C (59–86°F)

  • No exposure to sunlight or UV

  • Keep away from heat sources

  • Avoid stacking rolls horizontally (film deformation)

✔ Moisture & humidity

High humidity can soften cardboard cores and cause the roll to collapse, affecting unwinding smoothness.

6. Upgrade to Better-Quality Film

If you follow all best practices and film still breaks frequently — the issue may be the film itself.

✔ Signs you need a better film:

  • Frequent tearing at the same tension

  • Film has inconsistent thickness

  • Rolls unwind unevenly

  • Edges of the roll are damaged or uneven

  • Your load requires a higher-performance stretch film

High-performance film options:

  • Nano-layer stretch film (50–250 layers)

  • Pre-stretched film (less breakage for manual wrapping)

  • High puncture-resistance blown film

  • Eco-friendly biodegradable stretch film (strong + sustainable)

7. Train Operators Regularly

Even the best film and machines can break if operators lack proper training.

✔ Training should include:

  • Correct tension control

  • How to identify sharp edges

  • Proper threading of machine film

  • Recognizing film defects

  • Safe wrapping speed and lifting technique

Small improvements in technique can reduce breakage by 30–50%.

Conclusion

Reducing film breakage is not just about using a thicker film—it’s about optimizing every step of the wrapping process.

To avoid breakage, focus on:

  • Using the right film type and gauge

  • Inspecting and preparing the load

  • Optimizing tension (manual or machine)

  • Maintaining proper wrapping speed

  • Storing film in appropriate conditions

  • Training staff consistently

With the right strategy, you can significantly reduce downtime, improve load stability, and cut packaging costs.

If you want to explore professional-grade stretch film for your warehouse or logistics operations, visit our store: https://yxx-tech.com

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