How to Reduce Stretch Film or Plastic Wrap Waste by 50%

For many warehouses, stretch film waste is a hidden cost that quietly erodes profits. Over-wrapping, hand application and inefficient machines drive up material usage, labour time and disposal costs. As pressure grows to improve both sustainability and operational efficiency, reducing plastic wrap waste has become a key priority. With the right approach, businesses can dramatically cut film usage without compromising pallet stability. 

At FROMM Packaging Australia, sustainability and performance go hand in hand. With Swiss-engineered innovation and local technical support, FROMM continues to lead the industry in high performance pallet wrapping solutions designed to dramatically reduce stretch film usage while improving load stability and protection. 

The true cost of stretch film waste

Stretch film waste carries both a financial and environmental price tag. Excess film usage increases consumable costs, contributes directly to landfill volumes and drives up labour time during wrapping operations. The Australian Packaging Covenant Organisation reports that soft plastic packaging remains one of the largest contributors to commercial plastic waste streams, with only a fraction recovered through stretch film recycling programs. 

In warehousing and logistics, inefficient wrapping can result in:

• Overuse of machine pallet wrap and hand film
• Increased film costs
• Greater risk of product damage from inconsistent containment

When multiplied across thousands of pallets per month, even small inefficiencies in stretch film application can equate to tens of thousands of dollars in preventable waste each year.

How to achieve stretch film waste reduction

Reducing stretch film waste by up to 50% is not achieved through a single change. It is the result of optimising machinery, materials and wrapping techniques together. The following strategies form the foundation of more sustainable pallet wrapping.

Invest in a high performance Pallet Wrapping Machine

Hand wrapping remains one of the largest sources of stretch film overuse, inconsistency and operator fatigue. Machine wrapping, by contrast, delivers controlled tension, optimal pre-stretch and repeatable wrap patterns for every load.

FROMM's range of semi-automatic pallet wrapping machines and automatic stretch wrappers are designed to optimise film output while improving throughput and load security. If you invest in a machine with powered pre-stretch technology, it can dramatically reduce the amount of film required per pallet and eliminate guesswork in the wrapping process. 

Optimise your machine settings

Even the most advanced pallet wrapping machine must be correctly configured to achieve maximum film efficiency. Incorrect pre-stretch settings for the type of film, wrapping patterns or carriage speed can easily double film usage without improving load security. 

FROMM's locally based service technicians work directly with our customers to fine tune:

• Film tension and force-to-load
• Wrap patterns and film overlaps
• Pre-stretch and carriage or turntable speed

Proper optimisation ensures consistent containment while minimising stretch film waste across every wrapped pallet.

Employ the right wrapping techniques 

Wrapping technique is just as important as machinery and film selection. Poor application or excessive overlapping leads to unnecessary film consumption with little improvement to stability. 

Best practice wrapping includes:

• Applying film from the base of the load upward
• Overlapping each wrap by approximately 30 - 50 percent
• Wrapping tightly around load corners for load integrity
• Avoiding excessive top wraps unless required for weather protection

These simple technique adjustments can significantly reduce plastic wrap waste while improving transport safety. 

Choose the right stretch film for the job

Not all stretch films perform the same. Selecting a thinner film made with quality materials, allows operators to use less plastic without sacrificing load containment.

FROMM's advanced 12-micron range FORZA can deliver measurable sustainability and cost benefits including: 

• Up to 250% stretch for maximum yield
• Up to 40% reduction in plastic consumption
• More than 20% reduction in overall wrapping costs
• Wraps more pallets per roll than traditional 20-micron films
• 100% recyclable

Advanced resin technology and multi-layer manufacturing mean performance is driven by film structure rather than thickness alone. As outlined in FROMM's stretch film thickness guide, high performance films frequently outperform older, thicker alternatives.

Explore sustainable alternatives and recycling

Innovation in sustainable materials continues to advance, including films with recycled content and biodegradable options. While these technologies evolve, recycling remains one of the most effective ways to reduce environmental impact immediately.

FROMM actively supports sustainability initiatives through:

• Industry guidance on pallet wrap recycling
• Ongoing investment in recyclable stretch films
• A national strap recycling program as part of our broader sustainability commitment. 

By combining superior film with responsible recycling practices, businesses can achieve meaningful environmental gains without compromising operational efficiency.

Ready to reduce your stretch film waste?

Ready to employ smarter, more sustainable packaging practices? Contact FROMM Packaging Australia today or call 1800 940 356 to explore high performance pallet wrapping solutions, advanced stretch films and recycling initiatives designed to reduce costs and environmental impact.

Contact us or talk to an expert on 1800 940 356