Quick answer: The safest ways to spend less on pallet wrap are to match the film thickness to the load, stretch the film properly, wrap to a set pattern instead of adding turns by guesswork, and check you’re getting full-weight rolls. Don’t save money by cutting turns off heavy loads or using thin film where it isn’t strong enough. A damaged delivery costs far more than the film you saved.

When packaging costs creep up, the first instinct is to buy thinner film or use less of it. Both can backfire. There are better places to look first, and most of them save money without making loads any less secure.

1. Check you’re getting full rolls

Two rolls sold at the same length and thickness can hold different amounts of film. Weight is the easiest way to tell. A 400mm x 250m roll of 23 micron film should weigh about 2.43kg including the core, and a 17 micron roll about 1.87kg. If your rolls come in noticeably lighter, you’re paying for film you’re not getting. Our guide on checking a roll’s real length and thickness shows how to test this in a few minutes.

2. Match the film to the load

This is usually the biggest saving. Plenty of warehouses use 23 micron on every pallet because it’s what’s on the shelf. For light, square, even loads that stay indoors, 17 micron holds just as well, uses less plastic and costs less per roll.

It works the other way too. Using 17 micron on heavy or sharp-edged loads to save money often means adding extra turns to stop it tearing, which wipes out the saving and takes longer. Keep 23 micron for pallets over about 500kg, sharp corners, loads that can shift, long journeys and outdoor storage. Our 17 vs 23 micron guide helps you decide.

3. Stretch the film properly

Stretch film is meant to be pulled tight as it goes on. Every bit of stretch means fewer metres come off the roll for the same coverage, and the film grips the load harder as it tries to pull back. If your team wraps with the film going on at full width and no tension, they’re using more film for a weaker hold. Our guide on what “up to 500% stretch” means explains how much difference this makes.

4. Wrap to a set pattern

Without a pattern, people tend to keep going round until the pallet “looks done”. That usually means too much film in the middle and not enough where it matters. A simple pattern works better for most hand-wrapped pallets:

three or four turns at the base, catching the pallet itself
work up with each turn overlapping the one below by about half
two or three turns at the top
then back down if the load needs it

Write the pattern down and put it next to the wrapping area. Everyone then uses about the same amount of film per pallet, and you can see how many pallets a roll really does.

5. Use a dispenser if you wrap a lot

A hand dispenser with a brake keeps the tension even, so the film stretches consistently and you need fewer turns. It also means fewer torn and wasted starts. If you wrap several pallets a day from one spot, it’s one of the cheapest ways to cut film use. See do you need a hand dispenser?

6. Stop film being wasted before it’s used

Store rolls somewhere dry and not too cold, in their boxes, standing on their ends. Cold film is stiffer and tears more easily. Dropped rolls get damaged edges that tear every time you use them. Our guide on storing stretch film rolls has the details.

Protect sharp corners with edge boards. They cost little and let you keep the film tight without it tearing.

7. Fewer roll changes add up

Every roll change takes a few minutes. On a busy site, that adds up over a week. Full-weight rolls with the right amount of film on them last longer, so you change them less often. It doesn’t show up on the invoice, but it shows up in how many pallets go out each shift.

Where not to cut

Don’t take turns off heavy or unstable loads, and don’t drop to thinner film on loads that need the strength. A load that shifts in transit can mean damaged stock, a refused delivery, a return and an unhappy customer. Any of those costs more than a year’s saving on film. The aim is the right amount of the right film, not simply less of it. Our pallet load security checklist is a quick check before each pallet leaves.

FAQs

What’s the quickest way to cut pallet wrap costs?

Switch light, even loads from 23 micron to 17 micron, and make sure the film is being stretched as it goes on. Those two changes alone usually make a noticeable difference.

Is thinner film always cheaper?

Per roll, yes. Per pallet, not if you have to add extra turns to stop it tearing. Match the thickness to the load.

How much film should a pallet use?

It depends on the pallet size, load height and your pattern. Our pallet wrap calculator gives you an estimate for your own loads.

Is it cheaper to buy more at once?

Usually. Our trade pricing improves with volume, so larger orders cost less per box, and delivery to mainland Great Britain is free on every order.

Our pallet wrap calculator gives you an estimate of rolls and cost for your usual pallet size. When you’re ready, our pallet wrap rolls list the real weight of every roll next to the price, so the comparison is easy to make.

How to Cut Pallet Wrap Costs Without Cutting Load Safety