Top 7 Stretch Film Mistakes That Increase Freight Damage Claims

Freight damage claims are costly, time-consuming, and often preventable. While many shippers focus on carrier performance or pallet quality, one critical factor is frequently overlooked: how stretch film is selected and applied.

Improper stretch film usage is a leading contributor to load shifting, product damage, and rejected freight claims. In this article, we break down the top seven stretch film mistakes that increase freight damage risk—and explain how to avoid them.

Mistake #1: Choosing Stretch Film Based on Price Alone

Low-cost stretch film may appear to save money upfront, but it often lacks consistent stretch, cling, and recovery. As a result, operators compensate by applying more layers, increasing material usage without improving load stability.

This creates a false economy: higher freight damage rates, more claims, and increased waste.

For a deeper cost analysis, see: Hidden Costs of Low-Quality Stretch Film in Freight Shipping

Mistake #2: Using the Wrong Gauge for the Load

Gauge selection is critical. Using film that is too thin for heavy or irregular loads can lead to film failure, while using overly thick film for light loads increases cost without adding protection.

Correct gauge selection depends on:

Pallet weight
Load height and stability
Shipping distance and handling frequency

Learn how gauge interacts with other parameters here: Width, Length, Gauge: How These Three Stretch Film Parameters Work Together

Mistake #3: Over-Wrapping Pallets

More film does not equal more protection. Once optimal containment force is achieved, additional wraps provide diminishing returns.

Over-wrapping increases:

Material costs
Labor time
Plastic waste

And in some cases, excessive film restricts proper stretch, reducing load stability.

For a full breakdown, read: How Over-Wrapping Increases Costs Without Improving Load Stability

Mistake #4: Ignoring Stretch Film Yield

Many warehouses compare rolls based solely on length (e.g., 1500ft vs 2000ft), without considering yield, stretch capacity, or pallets wrapped per roll.

A longer roll does not always mean lower cost per pallet—especially if the film requires more layers to perform.

Learn why roll length alone is misleading: Stretch Film Yield Explained: Why Roll Length Alone Is Misleading

Mistake #5: Inconsistent Wrapping Technique

In hand-wrapping operations, tension and wrap patterns often vary from operator to operator. Inconsistent application leads to uneven containment force, increasing the risk of load shifting during transit.

Common issues include:

Loose top wraps
Insufficient bottom anchoring
Uneven overlap

Standardizing wrap patterns and training operators significantly reduces freight damage claims.

For operational comparisons, see: Machine Film vs Hand Wrap: Cost and Efficiency Comparison

Mistake #6: Using the Wrong Film Width

Film width affects coverage and containment. Using film that is too narrow increases the number of wraps required, while film that is too wide may reduce control on smaller pallets.

Incorrect width selection often leads to inefficient wrapping and unstable loads.

For guidance on optimizing dimensions, reference: Stretch Film Length Matters: 1000ft vs 1500ft vs 2000ft

Mistake #7: Focusing on Appearance Instead of Performance

A tightly wrapped pallet may look secure, but visual appearance does not guarantee load stability. True performance is measured by how the load behaves during:

Forklift handling
Braking and cornering
Long-distance freight transport

Evaluating containment force and real-world handling performance is far more effective than adding extra film layers for visual reassurance.

For ROI-focused evaluation, see: Stretch Film ROI Explained: Price vs Performance

How to Reduce Freight Damage Claims with Better Stretch Film Practices

Reducing freight damage claims starts with eliminating these common mistakes. Best practices include:

Selecting industrial-grade stretch film with consistent performance
Matching gauge and width to load requirements
Standardizing wrap patterns and tension
Evaluating cost per pallet—not cost per roll

These steps improve load stability while lowering overall packaging costs.

Conclusion

Freight damage claims are rarely caused by a single factor. In most cases, they result from small, compounding mistakes in stretch film selection and application.

By addressing the seven mistakes outlined above, warehouses and shippers can reduce claims, improve shipping performance, and achieve better ROI from stretch film.