What Is Stretch Film? A Complete Guide to Types, Benefits & Cost Effective Applications

Stretch film commonly called stretch wrap has become a core component in today’s packaging and logistics operations. Whether you're running a small warehouse in Melbourne or a high volume distribution centre supplying multiple states, stretch film ensures pallet stability, protects goods from environmental exposure, and reduces the risk of load failure during transport.

What Is Stretch Film (Stretch Wrap) and Its Primary Purpose?

Stretch film is a flexible, elastic LLDPE-based plastic film designed to secure cartons, products, and irregular loads tightly onto a pallet. When stretched and applied around the load, the film contracts slightly, creating what is known as containment force the key factor that prevents pallet movement and product damage.

Its primary purposes include:

• Stabilising loads during transport
• Preventing cartons from shifting or collapsing
• Protecting goods from dust, moisture, and abrasion
• Reducing product damage and warehouse returns
• Increasing handling efficiency

Materials and Composition of Stretch Film

Most stretch films are produced using Linear Low Density Polyethylene (LLDPE), sometimes enhanced with:

• Metallocene additives for extra strength
• Cling agents to improve film to film adhesion
• UVI stabilisers for outdoor exposure
• Pigments for coloured or tinted options

Why It Matters in Packaging and Logistics for Australian Businesses

Australian supply chains involve long distances, uneven road networks, and varying climates from humid Queensland to dry Western Australia. These factors make pallet stability a critical issue.

Using the correct stretch film:

• reduces breakage and returns
• improves warehouse efficiency
• minimises material usage
• lowers operational cost
• enhances safety during manual and forklift handling

Overview of This Guide

This guide explains:

• Types of stretch film
• Key differences between cast, blown, and specialty films
• How to choose the right gauge and film type
• Best practices for hand and machine applications
• Cost saving strategies (CPL/CPP)
• Sustainability and recycling in Australia

Understanding Stretch Film Types and Production Processes

How Stretch Film Works

Stretch film performance depends on:

• Stretchability
• Cling
• Gauge (Thickness)
• Memory
• Tear & puncture resistance

Cast Stretch Film

Produced using slot die extrusion and rapid cooling.

Advantages:

• High clarity
• Quiet unwind
• Consistent thickness
• Ideal for barcode scanning

Limitations:

• Lower puncture resistance

Blown Stretch Film

Produced through a slower air bubble cooling process.

Advantages:

• Superior puncture resistance
• Better tear strength
• Ideal for heavy or irregular loads

Limitations:

• Noisier unwind
• Lower clarity

Pre Stretched, Vented & Specialty Films

• Pre stretched: reduces fatigue and film usage
• Vented: for produce
• Hand grade: for manual application
• Machine grade: for automation
• UVI/coloured/anti static films

When Should You Use Stretch Film?

Use Cases by Volume, Load Type, and Industry

• E commerce → cast film
• FMCG → cast film
• Heavy industries → blown film
• Export loads → blown or UVI

Hand vs. Machine Grade

• Hand film → < 25 pallets/day
• Machine film → high volume operations

When Alternatives May Be Better

• Strapping for extreme loads
• Shrink wrap for full enclosure
• Corner boards for fragile edges

Selecting the Optimal Stretch Film: Gauge, Thickness & Load Profile

Understanding Gauge

• 12–15µm → light loads
• 17–20µm → general warehouse
• 23–30µm → heavy loads

Load Profiles

• A profile: uniform → cast
• B profile: semi irregular → mid gauge
• C profile: irregular/heavy → blown

Climate Considerations

Hot climates may require thicker or blown film.

Application Methods, Equipment & Efficiency

Hand Stretch Film

Tips:

• Maintain consistent tension
• 30–40% overlap
• Secure base and top properly

Machine Stretch Film

Benefits:

• Higher pre stretch ratios
• Lower cost per pallet
• Stronger containment force

Optimising Film Performance

• Proper pre stretch settings
• Correct number of wraps
• Avoid overstretching
• Minimise neck down

Benefits of Using Stretch Film

Load Stability

Creates consistent containment force.

Protection

Shields goods from moisture, dust, and abrasion.

Cost Efficiency

Down gauging and pre stretch improve yield.

Sustainability

LLDPE films are recyclable in Australia.

Economic Analysis: Cost Efficiency & Usage

Cost Per Load (CPL)

Measure cost by pallet, not roll.

Formula

CPP = Roll Price ÷ Pallets Wrapped

Down Gauging

Switching from 23µm → 17µm saves cost & reduces plastic waste.

Stretch Film vs Other Wrapping Methods

Stretch Film vs Shrink Wrap

Shrink = heat required, full enclosure.
Stretch = safer, faster, more economical.

Stretch Film vs Strapping

Strapping = compression
Stretch film = full 360° containment

Sustainability in Australia

Down Gauging

Reduces carbon footprint.

Circular Economy

Soft plastics recycling is increasing nationwide.

Regulations

Compliance needed for exports and major retailers.

McPack’s Role

Guidance, testing, and supply of recyclable stretch films.

Regional Considerations for Australia & APAC

• Long distance transport
• Outdoor storage challenges
• Industry-specific needs (mining, agriculture, FMCG)

FAQs

Difference between hand & machine films?

Machine film is stronger and more consistent.

Best gauge?

Depends on load weight, shape, and wrapping method.

How much film per pallet?

Typically 120–250g depending on load and method.

Is stretch film recyclable?

Yes, LLDPE is recyclable.

Can stretch film be used outdoors?

Yes, use UVI films.

Conclusion

Key Takeaways

  Choose a film based on load profile  

  Cast = clarity, blown = strength  

  Machine wrapping reduces costs  

  Down gauging saves money & material  

Next Steps

  Test films  

  Assess load types  

  Optimise the wrapping process  

Contact McPack

For expert recommendations and high-performance stretch film tailored to Australian warehouse needs.