Why Condensation is Costing Food Manufacturers Millions
Condensation issues on jarred sauces, resolved by ExcelAir perforated pallet wrap
The Hidden Cost of Pallet Condensation
Condensation might seem like a minor issue on wrapped pallets, but for food manufacturers it can be a silent profit killer. Trapped moisture during storage or transport causes:
Damaged packaging and illegible labels
Spoiled stock due to mould and bacteria growth
Product returns and customer complaints
Higher energy costs from extended cooling times
Each of these problems eats into margins, disrupts supply chains, and damages brand reputation.
Why Condensation Happens in Food Logistics
Condensation builds up when traditional pallet wrap traps heat, gases, and moisture inside the load. This is especially common in:
Chilled and frozen food supply chains
Products leaving blast chillers or cold stores
Hot-fill food and beverage products
High-humidity environments during summer months
Exports where goods experience temperature fluctuations during cross-climate movement
If your pallets leave the warehouse hot and sealed in non-breathable film, condensation is inevitable.
The Financial Impact on Food Manufacturers
The costs add up quickly:
Damaged goods → unusable products that must be written off
Retailer chargebacks → penalties for failed delivery standards
Increased cooling costs → pallets take longer to reach safe core temperatures
Lost contracts → repeated failures can jeopardise supply agreements
Industry studies show condensation-related losses can cost large food manufacturers millions annually, with waste, inefficiency, and rewrap labour all contributing.
How Perforated Pallet Wrap Solves the Problem
Perforated or ventilated pallet wrap is engineered to allow airflow through the load while still maintaining high load stability. This innovation delivers:
Faster cooling → pallets can chill up to 50% quicker
No trapped condensation → packaging, labels, and product remain dry, and pallets stay secure and stable
Reduced spoilage → less waste and fewer rejected deliveries
Lower energy costs → improved airflow reduces chiller run times in your facility and on temperature-controlled trailers
Our ExcelAir perforated pallet wrap is trusted across the UK food industry to eliminate condensation issues, cut plastic use, and improve supply chain efficiency.
Ready meal manufacturer packed their products warm, leading to condensation, which can now escape with our perforated pallet wrap
Case Example: Food Producer Savings
A UK chilled foods manufacturer cut heat-related delays by over 40% after switching to ExcelAir. At the same time, they reduced stretch film usage by 30%, saving on both packaging tax and material costs.
The Sustainable Bonus
By reducing wasted product and using less film per pallet, perforated wrap not only saves money but also helps food manufacturers meet sustainability targets — reducing CO₂ emissions, plastic waste, and energy consumption.
Final Thoughts: Stop Letting Condensation Drain Profits
Condensation may not always be visible until goods arrive at the retailer — but by then, the damage is done. With the right pallet wrap, food manufacturers can protect product quality, cut costs, and strengthen their supply chain resilience.
