Choosing the right pallet wrap is essential for ensuring load stability, reducing waste and keeping transport costs in check. Two of the most common options used in warehouses and distribution centres are conventional stretch film and pre-stretched film. This article will focuses on pre-stretched vs conventional pallet wrap.

While both serve the same basic purpose,  to secure goods during storage or transit,  they perform very differently. Here’s a breakdown of how they work, and the key advantages of pre-stretched wrap in particular. Take a look at the video with Boyd, one of our packaging experts, where sums up the comparison and shows the difference between the two films.

What is Conventional Stretch Film?

Conventional stretch film is typically made from polyethylene and is designed to stretch during application. It requires physical force or a stretch wrapping machine to elongate the film and create the tension needed to hold pallets together.

This type of wrap can be highly effective, especially when applied using the right techniques and machinery. However, it can also be more difficult to apply consistently and efficiently, particularly in manual wrapping situations. The amount of force required can lead to operator fatigue and inconsistent results from pallet to pallet.

What is Pre-Stretched Pallet Wrap?

Pre-stretched wrap, as the name suggests, has already been stretched during the manufacturing process. This means that when it comes off the roll, it doesn’t require as much tension or effort to apply.

The film is thinner, lighter and more rigid, yet still strong enough to secure loads effectively. It clings tightly with minimal user input, making it easier and faster to use, particularly for manual applications.

Key Differences

1. Application Effort
Pre-stretched film requires much less effort to apply. Since it has already been stretched, workers don’t need to pull tightly to activate the tension. This makes wrapping less physically demanding and reduces the risk of repetitive strain injuries.

2. Film Memory
Once applied, pre-stretched film wants to return to its original shape. This gives it excellent “memory” and helps it maintain a tight hold on the load, even as items settle or shift slightly during transport.

3. Film Thickness
Although pre-stretched film is thinner than conventional wrap, its performance is often comparable or better. The reduced thickness translates into using less material overall, which supports sustainability goals and reduces plastic waste.

4. Cost Efficiency
By using less film and applying it more quickly, businesses can see cost savings over time. There’s also less film waste from over-application or poor technique, which is more common with traditional stretch film.

5. Consistency
With pre-stretched wrap, it’s easier to achieve uniform wrapping, especially in hand-wrap situations. The wrap behaves more predictably, leading to consistent containment force across multiple pallets.

6. Load Stability
Because of its memory and ability to contract around a load, pre-stretched film offers excellent load stability. It keeps products secure without the need for excessive layers or overtightening.

When to Use Pre-Stretched Wrap

Pre-stretched film is ideal for businesses looking to improve sustainability, reduce operator fatigue and increase wrapping efficiency. It’s particularly suited to:

• Manual pallet wrapping

• Low to medium-volume operations

• Businesses aiming to cut plastic waste

• Warehouses with a focus on ergonomics and safety

When Conventional Wrap Might Still Be Useful

Conventional stretch film still has its place, especially in high-volume settings using automatic machines capable of applying consistent stretch. It may also be more suitable for irregularly shaped loads or very heavy pallets that require additional containment force.

Final Thoughts

Understanding the difference between pre-stretched and conventional pallet wrap can help you make better choices in terms of efficiency, sustainability and safety. Pre-stretched film offers a smart alternative for many operations, delivering consistent results with less material and effort, all while supporting broader environmental and operational goals.

If you’re looking to reduce waste, save time and improve efficiency, then get in touch with our expert Pallet Wrap team to arrange free on-site demonstration.