Pallet Wrapper Not Stretching Film Properly? Causes & Servicing Fix
Most businesses don’t realise their pallet wrapping machine is using too much film.
Because nothing has “broken”.
The machine runs. Pallets get wrapped. Dispatch continues.
But behind the scenes, your costs are quietly climbing.
Excess film usage is one of the most common issues we see when carrying out pallet wrapper servicing — and it’s rarely caused by the film itself.
It’s the machine.
The Hidden Cost of Poor Performance
If your pallet wrapping machine is not set up or maintained correctly, it will:
Apply more film than necessary
Fail to stretch film efficiently
Require additional wraps for stability
Increase operator intervention
This leads to a higher cost per pallet, even if your film price stays the same.
In many cases, businesses are using 30–50% more film than they need to without realising it.
The Real Causes of High Film Usage
1. Pre-Stretch System Not Working Properly
Your machine should be stretching film before it’s applied to the pallet.
If it isn’t:
You’re effectively wrapping pallets with “unstretched” film
You use significantly more material per load
Containment force actually drops
This is one of the biggest failures we uncover during pallet wrapping machine servicing.
2. Incorrect Tension Settings
Too low:
Loads are loose
Operators compensate with extra wraps
Too high:
Film snaps or tears
Rewrapping increases usage
Without proper calibration, tension becomes guesswork.
3. Worn Rollers and Mechanical Components
Over time:
Rollers lose grip
Bearings wear
Carriage systems degrade
The machine may still run, but it won’t perform.
This directly impacts how efficiently film is applied.
Worn, damaged pre-stretch rollers identified during pallet wrapper servicing, reducing stretch efficiency and increasing film usage.
4. Operator Adjustments Over Time
This happens on almost every site.
Settings get tweaked:
“Just to make it tighter”
“Just to stop it snapping”
Over time, the machine drifts far from optimal.
5. Poor Wrap Programmes
Too many revolutions.
Inefficient wrap patterns.
No optimisation for load type.
All of this increases film usage unnecessarily.
Why This Isn’t a Film Problem
A lot of businesses try to fix this by switching film.
That’s the wrong move.
If your pallet wrapping machine isn’t applying film correctly, no material will perform properly.
You’ll either:
Use more film
Or suffer from load instability
The machine has to be right first.
How Proper Pallet Wrapper Servicing Fixes This
This is where most providers fall short.
A real pallet wrapper servicing approach doesn’t just “check the machine”.
It restores performance.
At Excelerate, servicing includes:
Measuring actual film usage per pallet
Verifying and correcting pre-stretch performance
Recalibrating tension across the load
Optimising wrap programmes
Identifying mechanical wear affecting performance
The result:
Lower film usage
Stronger, more consistent loads
Reduced operator involvement
Faster, more efficient wrapping
Real Impact: What This Looks Like in Practice
It’s not uncommon for us to see:
Film usage drop from 300g+ per pallet to under 200g
Removal of unnecessary wrap cycles
Elimination of film snapping issues
Improved load containment with less material
This is the difference between a machine that runs… and one that performs.
Clear comparison of pallet wrap usage before and after pallet wrapper servicing, demonstrating significant film reduction through correct machine setup and optimisation.
When Should You Act?
You should be looking at pallet wrapper servicing if:
Your film usage has increased over time
Loads don’t feel as tight as they used to
Film is tearing or snapping
Operators are constantly adjusting settings
You haven’t had a performance-focused service
Or simply:
You don’t actually know how much film you’re using per pallet.
Take Control of Your Film Costs
If your pallet wrapping machine isn’t optimised, you’re losing money every single day.
And you won’t see it on a breakdown report.
You’ll see it in your film spend.
👉 Find out how our pallet wrapper servicing identifies and fixes these issues:
https://www.excelerateltd.com/machinery-servicing
