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5 Signs Your Pallet Wrapping is Failing (And How to Fix It)
Maintaining consistent load containment is the most critical factor in preventing transit damage and ensuring site safety. When a pallet is poorly secured, it doesn’t just risk the product; it risks the safety of everyone in the supply chain. This load containment guide highlights the technical warning signs that your current process is failing and how to implement a stretch film audit to rectify these issues.
1. Visible Pallet Wrap Tension Loss
If the film appears loose or baggy around the corners of the load, you are experiencing significant pallet wrap tension loss. This usually occurs because the film has been over-stretched beyond its elastic limit or the wrong gauge of film is being used for the load weight.
The Fix: Use a high performance film with high memory retention that snaps back to pull the load together.
2. Repeated Shipping Damage and Leaning Loads
A primary indicator of failing load containment is when pallets arrive at their destination leaning to one side or with collapsed corners. This is a clear sign of poor shipping damage prevention.
The Fix: Conduct a stretch film audit to measure the containment force at the top, middle, and bottom of the pallet to ensure uniform stability.
3. Elephant Footing at the Base
When the film is applied too tightly at the bottom without proper distribution, the bottom layers of cartons can crush, a phenomenon known as elephant footing. This compromises the structural integrity of the entire stack.
The Fix: Calibrate your pallet wrapping machines to apply variable tension, ensuring the base is secure without crushing the primary packaging.
4. Excessive Film Usage (Tails and Bunched Film)
If your team is over-wrapping to compensate for poor film quality, you are wasting money and increasing environmental impact. Long tails of film trailing behind pallets are also a major snagging hazard in automated warehouses.
The Fix: Transition to a high performance film that offers higher puncture resistance and better cling at lower gauges, allowing you to use less material while achieving a tighter hold.
5. Inconsistent Wrapping Patterns
Manual wrapping often leads to inconsistent overlaps, leaving weak points in the load containment. If the overlap is less than 50%, the pallet is susceptible to horizontal shearing during transport.
The Fix: Invest in pallet wrapping machines to standardise the wrap pattern and ensure every load meets your documented safety standards.
Reach Out Today!
Don't wait for a costly insurance claim to address your packaging weaknesses. A proactive approach to your wrapping strategy protects your bottom line and your brand's reputation. Contact the team at Hipac Packaging Solutions today!
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