Quick answer: The six signs are film that feels loose when you press it, cartons that move when the pallet is moved, wrap that doesn’t catch the pallet base, thin patches or gaps, tears that have started to run, and no extra turns at the top and bottom. If you spot any of them, rewrap before the pallet leaves. It takes a few minutes and costs far less than a damaged delivery.

A pallet can look wrapped and still be badly secured. These are the things worth checking before a load leaves your site, not after it arrives damaged. None of them need any equipment, just your hands and eyes.

1. The film feels loose when you press it

Properly stretched film should feel tight against the load, like a drum skin. Press it with your palm at a few points round the pallet. If it gives more than a little anywhere, the tension wasn’t kept up on that turn, and that’s where the load is most likely to start moving.

The fix is to stretch the film as it goes on. You should see it narrow slightly as it comes off the roll. A dispenser with a brake makes this much easier to do consistently.

2. Cartons move when the pallet is moved

Watch the load as a forklift or pallet truck lifts it and sets it down. If cartons shift against each other, lean or slide, the wrap isn’t binding the load into one solid unit. It’s just sitting round the outside of a stack of separate boxes.

This usually means too little tension, too few turns, or a load that was stacked badly to start with. Stack cartons square and tight, with heavy items at the bottom, then wrap with more tension.

3. The wrap doesn’t catch the pallet

If the film only goes round the goods and never wraps the pallet itself, nothing ties the load to its base. On a sharp stop, the whole stack can slide off the pallet in one piece.

Start every wrap with three or four turns low enough to go round the top boards of the pallet as well as the bottom row of cartons. Some people roll the film into a rope for the first turn at the base, which makes a stronger band.

4. There are gaps or thin patches

Uneven tension, or turns that don’t overlap enough, leave patches where the film is stretched very thin or barely covers the layer below. These weak spots are where a wrap usually fails first, especially with the vibration of a long journey.

Overlap each turn by about half the width of the film as you work up the load. Keep your walking pace steady so the tension stays even.

5. The film has torn or started to run

A small tear left alone will spread under tension. Once film starts to run, that whole band stops holding. Tears usually start at sharp corners, strapping or damaged cartons.

If you find a tear before the pallet ships, put an extra turn or two over it. If the same pallets keep tearing, fit edge boards to the corners, check your rolls aren’t damaged at the edges, and think about whether the film is thick enough. Our guide on why pallet wrap keeps tearing covers the common causes.

6. The top and bottom aren’t reinforced

The top and bottom of a load take the most stress from handling, stacking and braking. A wrap that’s even all the way up is weakest exactly where it needs to be strongest.

Add two or three extra turns at the top and three or four at the base. For loads that will be stacked or travel a long way, a cap sheet or top sheet under the film helps hold the top layer down.

A two-minute check before every collection

Press the film at the top, middle and bottom on each side.
Check the film catches the pallet base all the way round.
Look for tears, gaps and thin patches, especially at corners.
Check nothing overhangs the edge of the pallet.
Make sure labels are on the outside and readable.

Our printable pallet load checklist puts all of this on one page you can stick up by the loading bay.

What to do if these keep happening

If the same problems come up again and again, look at three things. First, technique. A written wrapping pattern and a quick demonstration often fix most of it. Second, equipment. A dispenser keeps tension far more even than wrapping by hand. Third, the film. If it keeps running out of stretch or tearing before the job’s done, it may be too thin for the load, or it may not be the film the box says it is. Our guide on checking a roll’s real length and thickness shows how to find out.

FAQs

How tight should pallet wrap be?

Tight enough that it barely gives when you press it, and you can see it has narrowed slightly from being stretched. Not so tight that it tears at the corners.

How many times should I wrap a pallet?

There’s no single number, but a common pattern is three or four turns at the base, overlapping turns by about half up the load, and two or three turns at the top. Heavy or unstable loads need more.

Should the wrap go round the pallet itself?

Yes. Always wrap the top boards of the pallet with the first few turns, so the load is tied to its base.

What thickness should I use for heavy pallets?

For loads over about 500kg, or with sharp edges, use 23 micron. Our guide on stretch film for heavy pallets has more detail.

Our guide on how to wrap a pallet properly covers the technique that avoids most of these problems from the start. Our pallet wrap range covers 17 micron for lighter loads and 23 micron for heavier ones.

Six Signs Your Pallet Wrap Isn’t Holding the Load Properly