Stretch Wrap: Cost Per Pallet Explained

For warehouses, manufacturers and distributors, stretch wrap is a daily consumable that can quietly drive up operating costs if not properly understood. While a roll price might look competitive on paper, the true measure of value is stretch wrap cost per pallet. Calculating this figure provides clear visibility into material usage, performance, and where meaningful savings can be made without compromising load security.

What is stretch wrap and why it's used

Stretch wrap, also known as pallet wrap, machine wrap or hand wrap is a highly elastic plastic film used to stabilise, bundle and protect palletised goods during storage and transport. By tightly containing loads, stretch film helps prevent loads shifting, product damage or contamination and product loss.

Stretch film can be applied manually using hand rolls or automatically via wrapping machines, with each method delivering very different outcomes in terms of consistency, efficiency and overall pallet wrapping cost. The right approach depends on throughput, load type and performance requirements.

What factors affect stretch wrap cost per pallet?

Several variables influence how much stretch film is used on each pallet and therefore the total cost.

Film type and thickness

Film thickness, width and roll length all directly affect consumption. Thicker films are denser and use more material by weight, while longer and wider rolls contain more total film. Choosing the wrong specification can quickly inflate the stretch wrap cost per pallet without delivering added performance. 
FROMM offers a complete range of machine stretch film, hand stretch film and hybrid stretch film, each engineered for specific applications and wrapping conditions.

Pallet size and load profile

Taller pallets generally require more wrap revolutions to reach the top of the load and maintain stability. Heavy loads or products with sharp edges and irregular shapes may also require thicker films or additional layers, increasing material usage and cost.

Wrapping method

Manual wrapping is operator dependent and often results in inconsistent film application. Variations in tension, overlap and wrap count typically lead to higher film usage compared to more automated solutions. 

In contrast wrapping machines deliver repeatable results, optimising containment force while minimising excess film. 

Film stretch

Film stretch is one of the most critical factors affecting how much stretch wrap per pallet is actually consumed. Semi Automatic and Automatic wrapping machines can pre-stretch film by 150 - 300% depending on the machine, which effectively turns one metre of film into up to three metres during application. 

Hand wrapping typically achieves an average stretch rate of around 80-150%, with results varying significantly between operators. While FROMM hand films can deliver an ultimate stretch of up to 200% (depending on the film selected), reaching this maximum relies heavily on correct application technique. This variation alone can have a significant impact on how many pallets are wrapped per roll. 

How to calculate stretch wrap cost per pallet

Follow these steps to accurately determine your true cost per pallet:

• Weigh your full roll of hand or machine stretch film
• Weigh the cardboard core from a used roll (the core that the film is wound onto)
• Subtract the core weight from the full roll weight to find the true weight of the film
• Wrap a pallet using your normal process. Sometimes it might be helpful to wrap 2 - 3 pallets to determine the average amount of film used
• Cut the film off the pallet and weigh the used film
• Divide the total film weight by the film used on one pallet to calculate how many pallets you can wrap per roll
• Finally, divide the cost per roll by the number of pallets per roll to determine the stretch film cost per pallet

If you are unsure about any of the steps above, our FROMM sales team can assist you to perform onsite testing to verify any of your film specifications, including using our film micron testing unit to test the thickness of any roll of film.  

Example Scenario:

If a roll costs $80 and wraps 100 pallets, the cost per pallet is $0.80. If you trial a slightly thinner film or optimise your wrapping machine settings to allow you to wrap up to 120 pallets per roll, the cost drops to $0.66 per pallet. This results in significant savings for those wrapping high volumes

The importance of your supplier's technical specifications

Not all stretch film specifications in the market are created equal. Some suppliers are vague in their descriptions and product names rather than providing clear technical data, which can make accurate comparisons difficult.

If two rolls are specified as having the same thickness, width and length, they should weigh the same once the core is removed. A noticeably lighter roll typically indicates a thinner film than stated, which may lead to reduced performance, or alternatively highlight an opportunity to achieve cost savings if the thinner film still meets your load containment requirements. 

 FROMM provides transparent technical specifications and backs every roll with our 'Every Metre Matters' guarantee. What's stated on the data sheet is what you receive. When comparing suppliers, having access to clear and consistent technical information is essential for making informed decisions. 

Tips to reduce stretch wrap costs without compromising load integrity

• Match the film type to your load characteristics and wrapping method
• Review film thickness using a film thickness guide
• Regularly check and optimise machine settings
• Upgrade from hand wrapping to pallet wrapping machines using one of our affordable options such as rental programs or FROMM Stretch
• Schedule routine equipment servicing to maintain consistent performance

These adjustments often deliver immediate reductions in stretch wrap cost per pallet while improving load security. 

Get smarter about wrapping costs with FROMM's Stretch Wrap

Understanding pallet wrapping cost goes beyond the price for a roll of film. Film selection, stretch, load profile and application method all play a role in determining the true cost of film per pallet. 

FROMM Packaging Australia offers a complete range of pallet wrap, advanced wrapping machines and expert technical support to help businesses reduce film usage, improve consistency and protect loads with confidence. 

Want to know more about improving your cost per pallet? To contact us online, visit contact us, or speak with a FROMM expert on 1800 940 356 to optimise your stretch wrapping today.