Uniform, boxed pallets are the easy case for stretch film. Irregular loads — mixed SKU sizes, sharp edges, protruding parts — need a different approach.
What makes a load "irregular"
- Mixed SKU sizes on the same pallet, creating gaps, overhangs, and uneven surfaces
- Sharp or protruding edges — metal brackets, machined parts, angular packaging (see the Auto-Parts & Industrial Export guide)
- Inconsistent stacking height across the pallet footprint
- Soft or crushable items mixed with rigid ones, where uniform wrap tension risks damaging the softer items
Film selection for irregular loads
Prioritize puncture resistance over cling force — see the full trade-off explanation in Cling Force vs Puncture Resistance. In practice, this usually means:
- Blown film over cast film, for its higher tear resistance
- 20–23 micron gauge rather than the lighter 15–17 micron range — see the Micron Guide
Wrapping technique matters as much as film choice
- Extra wraps at pressure points — sharp corners and protrusions benefit from additional passes specifically at that point, not just uniform overall wrapping.
- Corner boards or edge protectors for genuinely sharp metal or angular edges, used alongside film rather than relying on film alone to survive repeated contact with a sharp point.
- Bottom-up wrapping with adequate base wraps — irregular loads are more prone to shifting, so a solid base anchor matters more here than on uniform pallets.
When film alone isn't enough
For loads with genuinely sharp metal edges or protruding hardware, no stretch film gauge will indefinitely resist repeated abrasion at a single contact point. In these cases, combining film with physical edge protection (corner boards, foam padding at contact points) is the more reliable approach than trying to solve it purely through film selection.
Working with a specific irregular load and want a concrete recommendation? Talk to PackGPT and describe the load.