How to Reduce Stretch Film Waste: 13 Pallet Wrapping Tips to Save Costs in Perth

Stretch film waste is a major pain for Perth warehouses. Every extra wrap costs money and pollutes the environment. Rising transport costs and WA’s sustainability push make every meter of film count.

In this guide you’ll learn practical strategies to reduce stretch film waste and boost pallet wrapping efficiency. We’ll cover everything from upgrading film and machines to simple operator fixes, with cost-saving outcomes.

Keep reading to know how to use less stretch film, save money, and leave a lighter environmental footprint.

13 Effective Tips to Reduce Stretch Film Waste and Cut Pallet Wrapping Costs in Perth

Below are 13 practical, field-tested tips for stretch film optimisation and improved pallet wrapping efficiency.

1. Use Pre-Stretch Film to Cut Wrapping Waste

Pre-stretch film is produced and applied in a way that stretches the film before it touches the pallet. This increases linear coverage per roll. That means fewer metres used, better cling and improved load memory; a direct way to reduce stretch film waste while maintaining containment. Pre-stretch is one of the highest-impact changes for cost and plastic reduction.

2. Train Staff for Efficient Pallet Wrapping

Operator habits drive a lot of film waste. Long tails, inconsistent overlaps and loose anchoring all add metres per pallet. Educate the employees to standardise the right technique (short tails, consistent overlap, secure starts/finishes) and reduce variability across shifts.

Run a 10-minute shift-start micro training and post simple SOPs (Standard Operating Procedures) at each station. Track film use by operator for a week to spot improvement opportunities.

3. Start a Stretch Film Recycling Program in Perth

Most pallet wrap is LDPE (Low-Density Polyethylene) and recyclable when clean and uncontaminated. A local recycling program diverts soft plastics from landfill, supports sustainability goals and can lower disposal costs. Hence, it’s a practical step toward eco-friendly pallet wrapping in Perth.

So, set up marked recycling bins, train staff to remove tape/labels, and arrange a local pickup with soft-plastic recyclers Perth.

4. Choose the Right Stretch Film for Your Load Profile

Cast, blown and speciality films behave differently. Cast film is clear and clingy which is great for light, visible loads. Blown film is tougher and puncture resistant which is better for heavy/irregular loads. Matching film type to load is core to stretch film optimisation and prevents over-using material.

Test 2–3 film types on representative SKUs (Stock Keeping Units) and record metres/pallet and containment performance. Compare $/pallet and choose the film that gives the best balance of protection and cost. See our packaging consumables for options.

5. Use Thinner, High-Performance Film

Modern, thin high-performance films out-perform older thicker films because of better stretch and additives. Downgauging (reducing gauge) can cut film usage by 15–30% without losing containment.

Trial a thinner high-performance film with increased pre-stretch. Measure punctures, containment and cost per pallet to validate the net savings before full rollout.

6. Set Correct Film Tension to Avoid Overuse

Containment force; how tight the film is applied, is critical. Too little tension allows shifts; too much wastes film and risks product damage. Proper tension tuning is a simple route to better pallet wrapping efficiency.

So, document tension/torque settings per SKU and use machine presets or torque controls to enforce them. If you need consistent results, consider automation.

7. Optimise Wrapping Technique

A reliable wrapping pattern (anchor base, correct overlap percentage, top seal) secures loads with minimal material.

• Anchor at the pallet base.
• Aim for consistent overlap (a common starting point is 50%).
• Adjust the pattern for tall or irregular loads to avoid unnecessary layers.

Create “wrap recipes” for top SKUs e.g., base wraps, mid wraps, top seal. And post a quick diagram at each station so operators follow the same sequence every time.

8. Use Pallet Bands, Corner Boards & Strapping to Reduce Film

Mechanical supports like pallet bands, corner boards and strapping can replace several film layers on suitable loads. These options are reusable or lower-consumption alternatives that reduce plastic use while maintaining stability.

Trial bands or corner boards on selected SKUs and compare film usage and transit protection. If effective, roll out to similar product groups and update your packaging specs.

9. Optimise Pallet Configuration & Sizing to Minimise Waste

Inconsistent stacking, overhang and voids force extra wrap to stabilise loads. Standardised pallet footprints and strict loading rules reduce wasted film by ensuring repeatable, optimisable wrap recipes.

Enforce pallet-loading specs with warehouse staff and suppliers; reject or reconfigure overhanging loads. Keep a “pallet spec” sheet for common SKUs to speed compliance.

10. Lighten Pallet Loads

Reducing pack weight and empty space lowers the containment force the film must provide.

Switch where practical to lighter pallets (recyclable plastic), corrugated cartons and efficient cushioning (bubble or foam) to reduce film demand and improve sustainable pallet wrapping WA.

Experiment lighter materials for one SKU and compare film metres/pallet and damage rates. If containment stays strong, scale the change across similar product lines.

11. Run a Stretch Film Audit

Data beats guesswork. A simple audit (SKU, pallets/day, metres/pallet, roll length, cost/roll) reveals which products and shifts consume the most film and where optimisation gives the best ROI. Audits are central to reduce pallet wrap waste in warehouses.

Thus, log a week’s data in a spreadsheet, calculate $/pallet and identify outliers. Use results to prioritise trials (pre-stretch, machine settings, training) where savings are largest.

12. Align Packaging Specs with Suppliers & Customers

Supplier alignment is a cost-effective way to minimise film usage pallet wrap.

Double-wrapping and rework stem from mismatched specs across the supply chain. Agreeing on pallet sizes, wrap requirements and labelling reduces rewraps and saves film.

Include packaging specs in POs, run quarterly packaging reviews with key suppliers/customers, and set clear returns policies to avoid reactive rewrapping.

13. Invest in Reliable Wrapping Machines & Automation

When volumes are high (commonly 100+ pallets/day), machines deliver consistent pre-stretch (200–300%), precise tension control and fast cycle times. This leads to predictable stretch film cost saving and reduces labour. Automation is a long-term way to lock in optimisation gains.

So, arrange an onsite demo to see machine performance on your pallets. Browse our pallet wrappers or contact the team to schedule a trial and calculate your payback.

Common Myths About Pallet Wrapping in Perth

Myth: “Hand wrapping is cheaper than machine wrapping.”

Fact: Not usually. Modern machines slash labour and film costs. They often pay for themselves quickly for high-volume users.

Myth: “Thicker film is always better for wrapping.”

Fact: Not necessarily. Thinner, high-performance film (properly stretched) often secures loads as well as thicker film, with much less plastic use.

Myth: “Cheapest rolls save the most money.”

Fact: The lowest upfront cost film can cost more overall if it breaks or shifts. It’s wiser to choose film quality that meets your load needs.

Myth: “If you stretch the film, it will snap in transit.”

Fact: Quite the opposite. Pre-stretching the film increases its strength. Properly stretched film has better “memory” and tear-resistance than loose film.

Myth: “Pallet wrapping machines are too expensive.”

Fact: For fast-moving warehouses, machines save enough on film and labor that ROI is in months, not years.

Myth: “Stretch film costs end up being roughly the same long-term.”

Fact: No – optimising film type, pre-stretch, and usage can cut your stretch film bill by 25–40% or more.

Myth: “One type of stretch film fits all applications.”

Fact: Loads vary. As noted above, a film that’s ideal for one type of load may be wasteful or inadequate on another. Match film (cast vs blown, gauge, additives) to the load for best efficiency.

Conclusion

By tightening up your pallet wrapping processes, Perth businesses see real gains; up to 30–50% less film use, much lower wrapping costs, and stronger, more stable loads. You’ll save money on film and disposal, reduce plastic waste, and improve safety. All these upsides – lower costs, less waste, better load security – come from the practical tips above. Start implementing these best practices now and see how much stretch film you can save.

Ready to reduce stretch film waste and cut pallet wrapping costs in Perth?

Find High-Performance Stretch Film & Pallet Wrappers at Allpack Packaging Technologies

Our reliable, energy-efficient pallet wrapper machines and high-stretch films deliver real stretch film cost savings, improved pallet wrapping efficiency, and more sustainable packaging for WA businesses.

Contact us for expert advice on making your operations more efficient and eco-friendlier. Start shopping now for your ideal equipment.

See our Pallet Wrapping Machines | Shop Packaging Equipment Now

FAQs

Q1. How to reduce packaging waste?

Reduce waste by right-sizing packaging, using reusable or recycled materials, and optimising processes e.g. training staff, recycling programs. In pallet wrapping, use pre-stretch film, optimize load stacking, recycle used wrap, etc., to cut film use and waste at the source.

Q2. How to wrap a pallet correctly?

Securely anchor the film at the pallet base, make 3–4 tight wraps at the bottom, then spiral upward with about 50% overlap. Reinforce the top with 2–3 wraps, and always trim & lock the film tail. Properly centered, overlap wrapping keeps loads tight. (See tip #7 above)

Q3. How much film can I save by switching to pre-stretch film?

Substantial savings. Generally 25–40% less film is used with pre-stretch systems. Some operations see even higher reductions (up to 50%+) depending on their original method. It’s best to run a side-by-side trial to quantify savings on your specific loads.

Q4. Can thinner film really replace thicker film?

Yes – with a high-quality film and proper technique. Modern thin-gauge films (combined with 200–300% pre-stretch) can match the strength of thicker films. Industry tests show downgrading gauge can cut film use by 15–30% per pallet without loss of containment. Always test on a few pallets to ensure containment.

Q5. How many pallets can you wrap with a roll of stretch wrap?

It depends on roll size, stretch, and pallet dimensions. As a rule of thumb, a standard 1500–2000 ft hand-wrap roll (at 50% stretch) covers roughly 10–15 standard pallets. A 5000 ft machine roll (at 250% stretch) could cover dozens.

Q6. Do stretch wrap machines pay for themselves?

For high-volume operations, absolutely. If you wrap 100+ pallets/day, the film and labour savings pay back the machine cost in months. Pallet wrapping machines pay off in film savings alone in under two years. One case calculated $35k film waste saved over 5 years with a machine at 50 pallets/day.

Q7. Is stretch film recyclable?

Yes – most stretch film is made of 100% LDPE plastic, which is recyclable in Australia if kept clean. Soft-plastic programs accept pallet wrap, which is then turned into pellets for new products. Just remove tape and labels before recycling.

Q8. Does stretch film expire?

Stretch film has no fixed “expiration,” but like any plastic, it can degrade in poor conditions. In proper storage (cool, dark, 15–25°C), film can maintain quality for 12–18 months or more. After that, it may become harder to stretch or show brittleness if exposed to heat/UV. Rotate stock and store wraps properly to keep them fresh.