Most stretch film problems have more than one possible cause. The film, wrapping equipment settings, load shape and environmental conditions all play a part. So the first step is to record where and when the problem occurs, rather than changing the film straight away. The checks below are for businesses using both hand stretch film and machine stretch film.
If the film tears during wrapping
First, check where it tears. If the film always tears at the same corner, the cause is usually the load itself: a sharp edge, an item protruding beyond the pallet or a hard end of packing tape can puncture the film, with the tear starting there. Before switching to a thicker film, try using corner protectors and adjusting the load arrangement.
If the film tears as it comes off the roll or on the first wrap, check the tension. If the machine’s pre-stretch ratio or brake setting is higher than the film can withstand, the film thins and tears before it reaches the load. Pulling the film too hard during hand wrapping can have the same result. If the edge of the roll has been crushed by a drop or during transport, tearing will start at that edge; check the damaged roll in a separate trial.
Film stored in a cold warehouse behaves more stiffly and stretches less. In winter, leaving rolls kept outdoors or in a cold store in the working environment before use may help reduce tearing.
If the film does not cling to itself or the tail comes loose
Stretch film holds the load by clinging to the other wraps. If the cling is weak, check the following in order:
- Roll direction: With films made to be more adhesive on one side, fitting the roll the wrong way round leaves the cling side facing out, so the wraps do not hold each other. Ask your supplier about the construction of the film you use.
- Environment: Surface cling weakens in very cold, dusty or damp conditions. Check dusty rolls and wet loads separately.
- Excessive tension: Film that has been stretched too thin has less surface area in contact. Reduce the tension and try again on the same load.
- End of wrapping: Finish by pressing the final wrap against the load. If the tail hangs loose, check the machine’s cutting and pressing mechanism.
If the load loosens after wrapping or slips on the pallet
Loosening usually happens because the film does not hold the load tightly enough or the load is not secured to the pallet. Make sure the first wraps also grip the pallet boards; if the film only covers the cartons, the load may move independently of the pallet. If there are not enough wraps at the top, the cartons may open from above during transit.
The film may loosen slightly a few hours after wrapping. Check the load again before dispatch, not only immediately after wrapping. If the load is stacked narrowly and high like a tower, or the cartons are stacked without interlocking, the film alone cannot keep it stable. Stretch film does not replace the necessary load securing arrangements inside the vehicle.
If the film consumption is higher than expected
The most common causes of excessive consumption are unnecessary wraps, too much overlap between wraps and low pre-stretch. A film that is thicker than necessary also means using more kilograms of film on the same pallet. Compare consumption by measuring it, rather than estimating: divide the roll’s net film weight by the number of pallets wrapped. The calculation is illustrated in the guide to choosing stretch film for pallets.
Symptom, possible cause and initial check
| Symptom | Possible cause | Initial check |
|---|---|---|
| Tears at the same corner | Sharp edge, protruding item | Corner protectors and load arrangement |
| Tears on the first wrap or as it comes off the roll | Excessive pre-stretch or brake setting, damaged roll edge | Tension setting, roll edge |
| Wraps do not cling | Roll fitted the wrong way round, cold or dusty environment | Roll direction, environment, final wrap |
| Loosens before dispatch | Insufficient tension, no connection to the base | Bottom wraps, top wraps, stacking |
| Excessive film consumption | Too many wraps, low tension, thick film | Net consumption per pallet |
| Punctures and tears | Sharp item, thin film | Corner protection, film thickness |
The table shows the order for initial checks; each symptom can have more than one cause. Follow the machine manufacturer’s instructions for equipment settings.
How should you describe the problem when requesting a quote?
Describing the problem as “poor quality film” makes it harder to find a solution. Share the following information together:
- A photo of the affected load and the point where the film tears or loosens.
- The width, thickness and net weight shown on the roll label.
- Whether you wrap by hand or machine; if using a machine, its model and pre-stretch ratio.
- The approximate working temperature and where the roll is stored.
- Pallet dimensions, load height and approximate weight.
- The number of wraps per pallet and the amount of film consumed.
Mertan Ambalaj manufactures stretch film to order at its facility in Merkezefendi, Denizli, in thicknesses of 9–35 microns and widths of 10–50 cm. We assess film strength using a tensile testing device; this measurement does not guarantee that your load will be transported safely under all conditions, so a trial with the actual load is also needed. There is no minimum order quantity, so you can first assess a new film with a small trial order.
Send details of the problem and your photos using the quote form. To review your film choice from the start, browse our stretch film products.