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.
A real-world example
A machinery parts exporter kept experiencing torn film at one specific corner of pallets carrying angled steel brackets, despite already using 23 micron blown film — the heaviest common gauge. The fix wasn't a heavier film (none is available beyond that range as a practical option); it was adding a corner board specifically at that pressure point before wrapping. The film held fine everywhere else on the pallet — the problem was concentrated stress at a single sharp point that film alone, at any reasonable gauge, wasn't going to solve indefinitely.
FAQ
At what point should I stop trying to solve tearing with a heavier film and add physical protection instead? If you're already using 23 micron blown film (the practical maximum for most standard use) and still seeing tears at the same specific point repeatedly, that's the signal — the issue is concentrated stress, not general film capacity.
Are corner boards expensive relative to the film they protect? Corner boards are a relatively low-cost addition compared to the cost of a torn pallet, damaged goods, or a failed shipment — this isn't usually a meaningful trade-off once framed against the failure cost.
Can I reuse corner boards, or are they single-use? Depends on the material and condition after use — cardboard corner boards are typically treated as low-cost consumables rather than something to recover and reuse, given their low individual cost.
Does the same "extra passes at pressure points" technique apply to hand-wrap and machine wrap equally? The principle applies to both, but it's easier to control precisely with hand-wrap, where an operator can deliberately add wraps at a specific point; machine wrap typically needs either a program adjustment or manual intervention to concentrate extra wraps at one spot.
Working with a specific irregular load and want a concrete recommendation? Talk to PackGPT and describe the load.