Stretch film holds palletised loads together during storage and transport. Buying it involves terms like gauge, microns and pre-stretch, which directly affect cost and load safety. This guide explains stretch film gauge and pre-stretch in simple terms, with our free Stretch Film Calculator to estimate usage.
Gauge and microns
Film thickness is quoted in microns (µm) or in gauge (mainly in the US).
1 gauge ≈ 0.254 microns, so 80 gauge ≈ 20 microns.
| Gauge | Microns (approx.) | Typical use |
|---|---|---|
| 60 | 15 | Light loads |
| 70 | 17 to 18 | Light to medium loads |
| 80 | 20 | Standard general use |
| 90 | 23 | Heavier loads |
| 120 | 30 | Heavy or sharp-edged loads |
Cast vs blown film
- Cast film: clear, quiet when unwound, consistent cling.
- Blown film: stronger puncture resistance, often hazier, good for irregular loads.
Pre-stretch
Film is stretched before it is applied, either by hand or by a machine’s pre-stretch rollers. 200% pre-stretch means 1 metre of film becomes 3 metres.
Hand wrapping usually achieves much lower stretch than machines, so machine wrapping uses less film per pallet.
Estimating film per pallet
Example: pallet 1.2 × 1.0 m, load height 1.5 m, film width 0.5 m with 50% overlap, plus 3 extra wraps each at the top and bottom.
- Perimeter: 2 × (1.2 + 1.0) = 4.4 m
- Wraps to climb 1.5 m with 0.25 m effective coverage: 6
- Total wraps: 6 + 3 + 3 = 12
- Stretched film length: 12 × 4.4 = 52.8 m
- With 100% pre-stretch, film used from the roll: 52.8 ÷ 2 = 26.4 m
Weight of film
Film weight = length × width × thickness × density (about 0.92 g/cm³ for polyethylene). 26.4 m × 0.5 m × 20 µm ≈ 0.24 kg per pallet.
Choosing the right film
Use the thinnest film that holds the load safely. Over-wrapping wastes money; under-wrapping risks collapse. Read hand vs machine stretch film and see the Pallet Wrap Calculator.
For load planning, use the Pallet Loading Calculator.
Frequently asked questions
How many microns is 80 gauge stretch film?
About 20 microns.
What does 200% pre-stretch mean?
1 metre of film is stretched to 3 metres.
Is cast or blown film better?
Cast is clearer and quieter; blown is tougher for irregular loads.