If you’ve ever walked through a warehouse and seen a pallet unraveling mid-transit—or worse, watched a stack of goods topple over—you know just how critical proper wrapping can be. Stretch film might look simple, but it plays a huge role in keeping products safe, operations efficient, and costs under control.

Yet, even experienced teams get it wrong. A little too much tension, a mismatched film, or an inefficient wrapping pattern can turn your packaging line into a silent profit drain.

Here are the five most common stretch film mistakes companies make—and how to fix them before they eat into your bottom line.

1. Over-Wrapping: When More Film Means More Waste

At first glance, wrapping a pallet extra tight or adding a few more layers might seem like the safest bet. More film equals more protection, right? Not quite.

Over-wrapping is one of the most common (and most expensive) mistakes in packaging operations. Every extra turn of film adds cost, weight, and time—with diminishing returns on stability. In some cases, over-wrapped pallets even become harder to move or unstack due to excess cling and trapped air.

Why it happens:

• Operators assume “more is better.”
• Lack of clear wrapping standards.
• Inconsistent training across shifts.

How to fix it:

Establish a wrapping standard that defines the exact number of film layers per pallet type. Use pre-stretch film where possible—it maintains strength with less material. And if you’re using automated wrappers, fine-tune the settings to balance film efficiency and load containment.

A good rule of thumb: every unnecessary layer of film costs you twice—once in material and again in labor.

2. Poor Film Tension: Too Tight or Too Loose

Film tension is like seasoning in cooking—too much ruins the dish, too little makes it bland. The same goes for pallet wrapping.

If the film is too tight, it can crush boxes, distort products, or even snap during wrapping. If it’s too loose, the load shifts during transport, making it unstable and unsafe. Either way, poor tension wastes material and increases risk.

Why it happens:

• Manual wrapping relies on operator “feel.”
• Machine tension settings are outdated or miscalibrated.
• Inconsistent film thickness or pre-stretch ratios.

How to fix it:

For hand wrapping, train operators to maintain steady, consistent tension. If possible, introduce tools like tensioning handles or dispensers that help control stretch.

For machine wrapping, schedule routine calibration checks. The goal is firm containment without crushing corners or deforming the load.

A properly tensioned film should stretch uniformly without tearing and “snap back” slightly when released. That elasticity is what keeps the load tight throughout transport.

3. Using the Wrong Film for the Wrong Load

Not all stretch films are created equal. Choosing the wrong one can be just as wasteful as wrapping incorrectly.

Some loads require high puncture resistance (think irregular shapes or sharp edges). Others need cling control to prevent pallets from sticking together. Lightweight loads might benefit from thin, pre-stretched film, while heavy industrial goods demand thicker, stronger films.

Why it happens:

• Procurement teams buy film based on price, not performance.
• Operators don’t match film specs to load type.
• Lack of communication between warehouse and purchasing.

How to fix it:

Start by categorizing your loads:

• Type A: Stable, uniform pallets (standard film).
• Type B: Mixed or uneven pallets (high stretch or hybrid film).
• Type C: Sharp or heavy items (blown film or reinforced wrap).

Once you’ve mapped your needs, test different films for containment, tear resistance, and elasticity. A small switch in film grade can reduce breakage, downtime, and overall film usage by up to 30%.

Remember: the cheapest film per roll is rarely the cheapest in total cost.

4. Ignoring Film Quality and Storage Conditions

Stretch film is sensitive—temperature, dust, and moisture can degrade its performance long before it reaches the wrapping station. A roll stored under direct sunlight or near a heat source can lose elasticity and cling strength.

Poor storage or handling leads to:

• Film that tears too easily.
• Uneven stretch during application.
• Inconsistent load protection.

Why it happens:

• Rolls are stored in high-traffic or unregulated areas.
• Warehouses overlook environmental factors.
• Long-term inventory without rotation.

How to fix it:

Always store film in a cool, dry place away from direct sunlight and temperature swings. Rotate inventory regularly—first in, first out (FIFO) ensures older rolls get used before they degrade.

Inspect rolls before use. If the edges look crushed, the film feels brittle, or it unwinds unevenly, replace it. One faulty roll can slow down your entire wrapping line.

Think of film as you would fresh produce: how you store it affects how it performs.

5. Skipping Equipment Maintenance and Operator Training

Even the best film can’t fix poor equipment or untrained operators. Machines that aren’t serviced regularly can misapply film tension, cause inconsistent wrap patterns, or waste rolls through misfeeds.

Meanwhile, new operators often “learn on the job,” picking up habits that lead to film waste or unstable loads.

Why it happens:

• Fast-paced warehouse environments leave little time for training.
• Machines are treated as “set it and forget it.”
• Lack of preventive maintenance schedules.

How to fix it:

Train every operator—new or experienced—on:

• Correct wrapping techniques.
• Film type selection.
• Safe handling and storage.

For machine operations, create a simple maintenance checklist:

• Inspect pre-stretch rollers weekly.
• Clean sensors and turntables.
• Check for proper film threading and tension settings.

Consistent care not only reduces downtime but extends machine lifespan. A well-tuned wrapper saves more money than any short-term cost cutting ever will.

Bonus: Not Measuring Performance

Here’s a hidden mistake that’s just as costly—not tracking results.

Most warehouses don’t measure how much film they actually use per pallet, or how often wrapped loads fail during shipping. Without data, you can’t see where waste happens—or how much it costs.

The fix:

Track key metrics:

• Film cost per pallet.
• Wrapping time per load.
• Damage rate during transport.

Even a basic spreadsheet can reveal where inefficiencies pile up. And once you see them, you can fix them.

The Ripple Effect of Stretch Film Mistakes

When stretch film is used correctly, it’s invisible—quietly doing its job in the background. But when it’s used wrong, the impact ripples across the entire operation:

• Damaged goods increase claims and customer frustration.
• Extra film adds unnecessary cost and environmental waste.
• Labor inefficiency slows down throughput.

Each small mistake compounds into a larger operational headache. The good news? Every issue on this list can be solved with better training, smarter materials, and a bit of consistency.

The Takeaway: Stretch Film Isn’t Just Plastic—It’s Precision

The difference between a good wrap and a bad one isn’t just film thickness or brand—it’s how you use it. A few adjustments in tension, film type, and process can save thousands in material and hours in labor.

Think of stretch film like a seatbelt for your products. You don’t notice it when it’s working—but you definitely notice when it’s not.

So the next time you load up a pallet, take a moment to check:
Is it wrapped right?
Is it using the right film?
And most importantly—is it doing its job efficiently?

Because in logistics, efficiency isn’t about doing more—it’s about doing better.

Wrap Smarter, Ship Safer

Minimize waste, reduce costs, and keep every pallet secure. Upgrade your pallet stretch film process with expert guidance, quality materials, and tested wrapping solutions.

Visit palletstretchfilm.com to find the right film—and start saving time and money with every wrap.