How to Wrap a Pallet Properly for Transport and Storage

In the logistics industry, a pallet is more than just a wooden platform; it is the fundamental unit of trade. Every day across Australia, thousands of pallets are loaded onto trucks, slid into racking systems, and moved by forklifts. Yet, despite being such a routine task, wrapping a pallet is often done incorrectly.

A poorly wrapped pallet is a liability. It introduces the risk of product damage, workplace injury from falling goods, and rejected deliveries. Conversely, a properly wrapped pallet ensures load stability, protects against dust and moisture, and presents a professional image to your customers.

Whether you are wrapping by hand or using a semi automatic machine, the principles of load containment remain the same. This guide provides a step by step walkthrough on how to wrap a pallet properly to ensure your goods arrive at their destination in perfect condition.

Phase 1: Preparation and Stacking

The quality of the wrap is only as good as the stack underneath it. No amount of stretch film can fix a pallet that has been stacked dangerously. Before you even reach for the plastic, you must ensure the load is stable.

1. Check the Pallet Condition

Start with a solid foundation. Inspect the wooden (or plastic) pallet before loading. Look for broken boards, protruding nails, or missing blocks. A compromised pallet can collapse under the weight of the load or snag the stretch film, causing tears during the wrapping process.

2. Stack for Strength (Interlocking)

Avoid "column stacking" (stacking boxes directly on top of one another in straight columns) if possible. While it offers high compressive strength, it has very low stability. Instead, use an interlocking pattern (like bricklaying), where the boxes overlap. This creates a cohesive unit that is naturally more resistant to toppling.

3. No Overhangs

Ensure that no boxes protrude over the edge of the pallet base. Overhang is a major cause of carton damage because the corners of the boxes which are their strongest points are not supported by the wood. Overhang can reduce the stacking strength of a carton by up to 30%. Furthermore, protruding boxes are easily snagged and crushed by forklifts.

4. Create a Flat Top

Try to create a flat, level surface at the top of the pallet. If you have an irregular load with peaks and valleys, the stretch film cannot apply even downward pressure, which is essential for holding the load in place.

Phase 2: How to Wrap a Pallet by Hand

Manual wrapping is physically demanding and prone to inconsistency, but for many businesses, it is the most practical method. To do it effectively, you must focus on tension and coverage.

Step 1: Secure the Film to the Base

Pull a length of film from the roll and thread it through a corner of the pallet base (the wood itself). Tie a firm knot.

Step 2: The Locking Base Wrap

Begin walking around the pallet. The first 3 to 4 layers should be applied at the very bottom.

The "Roping" Technique: Twist the film into a "rope" for one or two turns. This creates a strong, unbreakable band. Apply this rope around the wooden base and the bottom layer of boxes. This creates a mechanical lock that prevents the load from shifting off the pallet.

Step 3: Spiral Upwards

Once the base is secure, begin working your way up the pallet.

Overlap: You must overlap the previous layer of film by at least 50%. This ensures that every part of the load is covered by at least two layers of plastic.

Tension: This is the hard part. You must pull the film tight as you walk, stretching it as you go around the corners. The film’s "elastic memory" (its desire to snap back) is what holds the load. If you just lay it on loosely, it offers no protection.

Step 4: Secure the Top

When you reach the top of the load, wrap around the top layer 2 to 3 times to create a strong collar.

Top Sheet (Optional): If the pallet needs dust or rain protection, lay a separate plastic "top sheet" over the load now. Then, wrap over the edges of this sheet to seal it in.

Step 5: Spiral Downwards

Do not cut the film at the top. Spiral your way back down to the bottom, maintaining that 50% overlap. This "cross wrapping" pattern (up and down) creates a lattice structure that is significantly stronger than a single upward pass.

Step 6: Finish and Cut

Once you reach the bottom again, do one final wrap around the base. Cut the film and tuck the loose tail into one of the layers. Do not leave a tail hanging loose, as it can get caught in conveyor belts or forklift wheels.

Phase 3: How to Wrap Using a Machine

Using a stretch wrapping machine eliminates the physical strain and guarantees consistency, but it still requires the operator to set it up correctly. It is not just a matter of pressing "Start."

1. Load the Pallet Correctly

Place the pallet in the centre of the turntable. Ensure the load is not sticking out beyond the turntable’s perimeter, as this can be a safety hazard when the machine starts spinning.

2. Attach the Film

Pull a lead of film from the carriage and tie it securely to the base of the pallet (the wood or plastic foot), just like in manual wrapping.

3. Select the Settings

Most modern machines allow you to adjust the wrap cycle. For a standard load, a typical setting profile looks like this:

• Bottom Wraps: Set to 3 or 4. This places extra film at the base to lock the load to the pallet.
• Top Wraps: Set to 2 or 3. This secures the upper layer.
• Carriage Speed: Adjust the speed at which the film moves up and down. A slower carriage speed results in more overlap (and a more secure load).
• Tension: Set the tension knob. Heavier loads (like bricks or beverages) need high tension. Lighter loads (like empty plastic bottles or tissues) need lower tension to prevent crushing the boxes.

4. Monitor the Cycle

Press start and watch the first few rotations. Ensure the film is feeding smoothly and that the "photocell" (the eye that detects the height of the load) is working correctly. The machine should automatically stop when it reaches the top, apply the top wraps, and descend.

Common Mistakes to Avoid

Even experienced warehouse staff can fall into bad habits. Here are the three most common mistakes that lead to load failure.

The "Load to Pallet" Bond Failure

This is the number one reason pallets are rejected by transport companies. If you wrap the boxes tightly together but fail to wrap the film around the wooden pallet base, the entire block of boxes can slide off the wood during a sudden truck brake. Always wrap the wood.

Insufficient Containment Force

"Containment force" is the total pressure the film applies to the load. Simply covering the pallet in plastic isn't enough; the plastic must be tight. If you can easily pull the film away from the boxes with your finger, the tension is too low. The load will vibrate loose on the highway.

"Mushrooming" or Crushing

This happens when the tension is too high for the goods being wrapped. If you wrap soft cartons too tightly, the corners crush in. "Mushrooming" occurs when the top boxes are pulled in tighter than the bottom ones, causing the load to warp. Adjust your tension settings (or manual pull strength) to suit the fragility of the product.

Choosing the Right Film

Finally, a "proper" wrap depends on using the right tool for the job. Not all stretch film is created equal.

Micron (Thickness)

A standard 20 or 23 micron film is suitable for most general freight. However, if you are wrapping extremely heavy items (like concrete or steel), you may need a heavy duty 25+ micron film. Conversely, light loads can be wrapped with thinner 12 15 micron film to save money and reduce waste.

Pre Stretch

If you are using a machine, ensure your film is "machine grade." These rolls are designed to stretch up to 250% or 300%. Putting a hand roll (which is not designed to stretch that much) on a high performance machine will result in constant film snapping.

Conclusion

Proper pallet wrapping is a skill that blends technique with the right materials. It is the final quality control step before your product leaves your care. By ensuring a solid base, locking the load to the pallet, and maintaining consistent tension and overlap, you drastically reduce the chance of damage during transit.

Whether you are wrapping one pallet a day by hand or five hundred a day by machine, the goal is the same: safe, secure, and professional delivery.

At McPack, we specialise in optimising this process. From high performance stretch films to the machinery that applies them, we can help you find the most efficient way to secure your load.