stack of pallets
Posted 26 Jul by

Pallet wrapping is a critical step in the packaging and shipping process for numerous industries.

While it may seem like a straightforward task, several challenges can arise during the pallet wrapping process, leading to inefficiencies, damaged goods, and increased costs.

In this article, we will explore the most common problems faced when pallet wrapping and provide practical solutions to overcome them.

The most common pallet wrapping problems

Some pallet wrapping issues you face may be industry specific, however, the below problems can affect anyone who wraps pallets.

1.      Insufficient Load Stability

One of the primary concerns in pallet wrapping is ensuring load stability. Insufficient stability can lead to load shifting, product damage, and safety hazards. To overcome this problem, consider the following steps:

  • Proper Wrapping Technique: Adopt a consistent and effective wrapping technique, such as spiral wrapping or double wrapping, to secure the load evenly. Ensure that the wrap starts from the bottom of the pallet and extends upwards, covering the entire load.
  • Correct Film Tension: Apply the stretch film with the appropriate tension to create a firm grip around the pallet. Avoid excessive tension, which may cause product distortion, or insufficient tension, which may result in load instability. Lots of pallet wrapping machines actually have tension control features that help to maintain consistent tension throughout the wrapping process, which is why we highly recommend working with up-to-date machinery.
  • Use Corner Boards: Utilize corner boards or edge protectors to reinforce the stability of the load and prevent damage to the product’s corners. These boards provide additional support and help distribute the tension evenly across the load.
  • Stabilisation Accessories: Consider using load stabilisation accessories such as strapping, banding, or stretch netting for particularly unstable or irregularly shaped loads. These accessories can provide an extra layer of security and prevent load movement.

2.      Film Breakage:

Film breakage can disrupt the wrapping process, leading to time-consuming rewrapping and potentially compromised load integrity. While it may happen occasionally, there are steps you can take to avoid it, including:

  • Film Quality: Invest in high-quality stretch film that matches the weight and dimensions of your load. Inferior films may be prone to tearing or puncturing. Choose films with sufficient puncture resistance and load-holding capabilities.
  • Film Thickness: Choose the appropriate film thickness for the load. Heavier loads typically require thicker films to provide adequate strength and protection. Consult with your stretch film supplier to determine the optimal film thickness based on the load weight, dimensions, and transportation conditions.
  • Equipment Maintenance: Regularly inspect and maintain your wrapping equipment, including the film carriage, tension control, and cutting mechanisms. Well-maintained equipment reduces the chances of film breakage due to mechanical issues. Lubricate moving parts, replace worn-out components, and ensure proper alignment to minimise film breakage.
  • Operator Training: Train operators on proper handling and loading techniques to minimise the risk of film breakage. Teach them how to identify and address potential causes of film breakage, such as sharp edges, protruding corners, or improper load placement.

3.      Inconsistent Film Coverage:

Inadequate film coverage can leave parts of the load exposed, leading to potential damage during transit. Follow these guidelines to achieve consistent film coverage:

  • Overlap and Layers: Determine the ideal number of film layers required to protect the load adequately. Maintain a consistent overlap between each layer to ensure complete coverage. Typically, a minimum of 50% overlap between film layers is recommended.
  • Wrapping Patterns: Opt for a uniform wrapping pattern that covers the entire pallet surface, including the top, bottom, and sides. Incorporate a sufficient number of revolutions during the wrapping process to ensure proper coverage. Consider alternating the wrapping direction for each layer to enhance load stability.
  • Top Sheet: Consider using a top sheet in addition to the stretch film to provide an extra layer of protection against moisture, dust, or other external elements. The top sheet should cover the entire pallet surface and be securely attached to the load to prevent shifting.
  • Automated Wrapping Systems: Consider upgrading to automated wrapping systems that offer precise control over film application. These systems can ensure consistent coverage and eliminate human error in the wrapping process. You can learn more about automated pallet wrapping systems here.

4.      Inefficient Film Usage:

Excessive film consumption leads to increased costs and waste, while inadequate usage compromises load integrity. To ensure you’re using the right amount of film for your purpose, here are some thing you can do:

  • Film Prestretching: Utilise a prestretch feature on your wrapping machine, which elongates the film before application, reducing the amount of film required while maintaining load stability. Most wrapping machines offer prestretch ratios ranging from 200% to 300%.
  • Film Tension Control: Adjust the film tension according to load specifications. Excessive tension wastes film, while insufficient tension compromises stability. Maintain a balance between achieving a secure load and minimising film consumption.
  • Machine Adjustments: Fine-tune the settings of your wrapping machine to optimise film usage. Consult the manufacturer’s guidelines and conduct periodic audits to identify potential adjustments. Calibrate the film carriage, tension control, and film delivery systems for optimal performance. When you purchase pallet machinery and equipment from us here at Melbourne Packaging Supplies, we’re happy to take the time out to learn about your usage so we can help you use the right products.
  • Training and Awareness: Educate employees on the importance of minimising film waste and encourage them to adopt efficient wrapping practices. Regularly communicate film usage targets and provide feedback to promote accountability. Conduct periodic assessments to identify areas for improvement and reward employees who contribute to efficient film usage.

Don’t fall for pallet wrapping problems

Efficient pallet wrapping is crucial for ensuring load stability, minimising damage, and optimising shipping costs. By addressing common challenges like those we’ve mentioned today, you can improve the overall effectiveness of your pallet wrapping process.

Remember to implement proper techniques, invest in quality materials, conduct regular equipment maintenance, and provide comprehensive training to your employees. And don’t forget to ask us questions.

We’ve been taking care of the packaging needs of businesses all over Australia for more than 40 years so we know a thing or two when it comes to wrapping pallets.