# Stretch Wrap Film Usage and Cost per Pallet Calculator

> Source: https://netray.co/tools/stretch-wrap-film-usage-and-cost-per-pallet-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Estimates film weight and cost per wrapped pallet from pallet size, film width and thickness, pre-stretch and wrap pattern.

## Category

supply-chain

## Industry

Packaging and Printing

## Audience

- Packaging engineer
- Warehouse manager
- Buyer

## Tool

**Kind:** calculator

**Currency:** $

**Inputs:**

#### Pallet load length

**Key:** pal_l

**Type:** number

**Default:** 1.2

**Min:** 0.1

**Step:** 0.05

**Unit:** m

#### Pallet load width

**Key:** pal_w

**Type:** number

**Default:** 1

**Min:** 0.1

**Step:** 0.05

**Unit:** m

#### Load height

**Key:** load_h

**Type:** number

**Default:** 1.6

**Min:** 0.1

**Step:** 0.05

**Unit:** m

#### Film roll width

**Key:** film_w

**Type:** number

**Default:** 0.5

**Min:** 0.1

**Step:** 0.05

**Unit:** m

#### Film thickness (unstretched)

**Key:** thick

**Type:** number

**Default:** 17

**Min:** 5

**Step:** 1

**Unit:** microns

#### Pre-stretch

**Key:** stretch

**Type:** number

**Default:** 200

**Min:** 0

**Step:** 10

**Unit:** %

**Help:** 0 means no pre-stretch. 200 means film is stretched to three times its original length.

#### Overlap between spiral layers

**Key:** overlap

**Type:** slider

**Default:** 50

**Min:** 0

**Max:** 80

**Step:** 5

**Unit:** %

#### Extra revolutions (base plus top)

**Key:** extra

**Type:** number

**Default:** 6

**Min:** 0

**Step:** 1

**Unit:** turns

#### Film price

**Key:** price_kg

**Type:** number

**Default:** 2.6

**Min:** 0

**Step:** 0.1

**Unit:** $/kg

#### Pallets wrapped per year

**Key:** pallets_yr

**Type:** number

**Default:** 30000

**Min:** 0

**Step:** 500

**Unit:** pallets

**Outputs:**

#### Load perimeter

**Key:** perim

**Expr:** 2 * (pal_l + pal_w)

**Format:** decimal

**Description:** Length of film for one revolution, in metres.

#### Spiral revolutions on body

**Key:** spiral

**Expr:** load_h / (film_w * (1 - overlap / 100))

**Format:** decimal

**Description:** Revolutions needed to cover the load height at the chosen overlap.

#### Applied film length (stretched)

**Key:** applied

**Expr:** perim * (spiral + extra)

**Format:** decimal

**Description:** Metres of stretched film on the pallet.

#### Film weight per pallet

**Key:** grams

**Expr:** applied / (1 + stretch / 100) * film_w * thick * 0.92

**Format:** decimal

**Primary:** true

**Description:** Uses film density of about 920 kg/m3 for LLDPE. Result in grams.

#### Film cost per pallet

**Key:** cost_pal

**Expr:** grams / 1000 * price_kg

**Format:** currency

**Primary:** true

#### Film cost per year

**Key:** cost_yr

**Expr:** cost_pal * pallets_yr

**Format:** currency

**Chart:**

#### Film weight per pallet vs pre-stretch

**Type:** line

**X:** stretch

**From:** 0

**To:** 300

**Steps:** 30

**Series:**

- grams

**Disclaimer:** Estimate based on geometry and nominal film thickness. Actual use depends on wrapper settings, film neck-down, containment force and operator technique. Confirm load stability with testing before reducing film.

## Content

**Intro:** Stretch film looks cheap per pallet but adds up over tens of thousands of pallets. This calculator estimates film weight and cost from pallet size, film specification, pre-stretch and wrap pattern, so you can compare options before a trial.

**Sections:**

#### How to use the calculator

**Body:** Enter the pallet load size and height, the film roll width and thickness, the pre-stretch percentage your machine delivers and the overlap used in the spiral. Add extra revolutions for the base and top wraps. Enter the film price per kilogram and annual pallets to see yearly spend. Use the chart to see how pre-stretch changes film weight.

#### The formulas

**Body:** One revolution uses the load perimeter. The body needs load height divided by effective film width, where effective width is film width times one minus overlap. Total applied length is perimeter times all revolutions. Because film is pre-stretched, original film length is applied length divided by one plus pre-stretch. Weight is original length times width times thickness times density.

**Bullets:**

- Higher pre-stretch cuts film weight without changing wrap pattern
- Thinner film at higher pre-stretch can hold similar force
- Extra revolutions at base and top add up quickly

#### Reading and testing

**Body:** Treat the result as a baseline. The saving that matters is the one that keeps the load stable through shipment. Run a trial with a defined wrap pattern, and verify with a load containment test or your carrier's requirements before changing film. Compare the calculated weight with actual roll consumption to calibrate.

**Cta:** If you want pallet packaging materials consumed and costed per shipment inside your ERP, we can review how to capture it without extra data entry.

**Faq:**

#### What is pre-stretch on stretch wrap film?

**Answer:** Pre-stretch is the extension of the film by the wrapper before it touches the load. A value of 200 percent means the film is stretched to three times its original length. It reduces film use but must stay within the film's capability.

#### How much film should a pallet use?

**Answer:** It varies widely with load, film and wrapper, from tens of grams to a few hundred. Use your own measured consumption and this estimate together, then test whether the load stays stable in transit.

#### Does thinner film always save money?

**Answer:** Not always. Thinner film can save weight but may tear on sharp corners or fail to hold the load. Test containment force and puncture resistance on your actual loads before switching.

#### What density is used for the film weight?

**Answer:** The calculator uses about 920 kg per cubic metre, typical for polyethylene stretch film. Film data sheets give exact values. The effect on the result is small compared with thickness and pre-stretch.

## Search terms

stretch wrap calculator, stretch film usage per pallet, pallet wrapping cost calculator, stretch film cost per pallet, pre-stretch film savings, stretch wrap grams per pallet, pallet wrap film consumption, stretch film thickness calculator

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