Quick answer: A pallet top sheet, also called a top cover or cap sheet, is a sheet of polythene laid over the top of a loaded pallet before it’s wrapped. Stretch wrap goes round the sides of a load, so it doesn’t seal the top very well. A top sheet keeps rain, dust and dirt off the top layer, and the stretch wrap then holds the sheet in place. It’s worth using on any pallet that will stand outside, travel on an open or curtain-sided vehicle, or sit in a dusty warehouse.

Most pallets are wrapped round the sides and left open on top. For a load going straight into a clean, dry warehouse, that’s fine. For anything else, the top is the weak spot. Here’s what top sheets are, when they’re worth using, and how to fit one so it stays put.

Why stretch wrap alone leaves the top exposed

Hand pallet wrap is wound round the load in a spiral. You can fold the top edge of the film over the corners, but it won’t cover the middle of the top layer. Rain runs off the sides but sits on top, and dust settles there in storage. With cartons, that can mean soggy boxes, stained print or goods that can’t be sold.

When a top sheet is worth using

pallets stored outside, even for a few hours in a yard
loads travelling on curtain-sided or open vehicles, or through pallet networks where they may wait at a hub
goods in cardboard that mustn’t get damp, such as paper, printed cartons or flat-pack furniture
stock that will sit in a warehouse for weeks or months and needs to stay clean
export pallets, which may be handled and stored several times on the way

How to fit a top sheet

Stack and square the load first.
Lay the sheet over the top so it hangs down evenly on all four sides. A sheet that overhangs by about 10 to 15cm on each side is easier to hold in place than one cut exactly to size.
Fold the corners down neatly, like wrapping a parcel.
Wrap the pallet as normal, starting at the base. When you reach the top, take two or three turns over the overhanging edge of the sheet so the film traps it against the sides.
If the pallet will be outside in wind, add an extra turn at the top and check the sheet can’t lift at the corners.

Our guide to wrapping a pallet properly covers the rest of the wrap pattern.

Clear or black top sheets

Clear sheets let you see labels and goods without unwrapping. Black sheets hide the contents and cut out light, which helps with light-sensitive goods and loads that would tempt a thief. It makes sense to match the sheet to the stretch film you use. Our clear vs black guide explains the difference.

Other ways to cover the top

If you only need light protection, you can cover the top with stretch film itself. Pull a length of film across the top from one side to the other, then wrap round so the turns hold it down. Do it twice, at right angles. It isn’t waterproof like a proper sheet, but it keeps off dust and light rain.

For long outdoor storage, some businesses use a fitted cover or hood over the whole pallet. And for loads that need air to reach them, such as fresh produce, a solid top sheet can trap moisture. Our guide to breathable stretch film covers those loads.

Common mistakes

Putting the sheet on after wrapping. It will blow off. The wrap needs to hold it.
Using a sheet that’s too small. If it doesn’t reach down the sides, the wrap can’t trap it.
Leaving loose corners. Wind gets under them and tears the sheet away.
Relying on a top sheet for long outdoor storage without checking it. Sunlight breaks down ordinary polythene over time.

Our guide on stretch film for outdoor and cold storage has more on keeping loads in good shape outside.

Do we sell top sheets?

Not at the moment. We make stretch film in 17 and 23 micron, clear and black, on standard and extended cores, which is what holds the top sheet in place. If you’re not sure what your loads need, tell us what you’re wrapping.

FAQs

What is a pallet top sheet?

A sheet of polythene laid over the top of a pallet before wrapping, to keep rain, dust and dirt off the top layer.

Does stretch wrap keep rain out?

From the sides, mostly. From the top, not reliably, because the film is wound round the load rather than across it. A top sheet solves that.

Should the top sheet go on before or after wrapping?

Before. The stretch wrap is what holds the sheet down, so wrap over the overhanging edges.

What size top sheet do I need?

Big enough to hang down 10 to 15cm on every side of the load. Measure the length and width of the stacked load, then add the overhang on each side.

Pallet Top Sheets: How to Keep Rain and Dust Off Wrapped Pallets