Stretch Wrap Film Usage and Cost per Pallet Calculator
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.
Your numbers
0 means no pre-stretch. 200 means film is stretched to three times its original length.
Your results
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.
Film weight per pallet vs pre-stretch
Sweeps Pre-stretch from 0 to 300, holding your other inputs fixed.
Track packaging consumption in your ERP
Optional: a short review of how to capture packaging material use per shipment.
Optional. The tool and every export work without this. No spam.
How to use the calculator
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
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.
- 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
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.
Frequently Asked Questions
What is pre-stretch on stretch wrap film?
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?
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?
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?
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.
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.
Related Tools
Corrugated RSC Blank Size and Board Yield Calculator
Converts inside box dimensions into the RSC blank size, then shows blanks per sheet, board yield and board cost per box.
Supply Chain & InventoryCorrugated Board Sheet Usage and Trim Waste Worksheet
An editable order list that computes how many blanks fit on each board sheet, trim waste percent and board cost per box.
MES & Shop FloorPackaging Line Downtime and OEE Log Worksheet
A shift-by-shift log that computes availability, performance, quality and OEE for each packaging line.
Supply Chain & InventoryPackaging Supplier Scorecard Worksheet
An editable scorecard that weights quality, on-time delivery, price, responsiveness and compliance into one score per packaging supplier.
More Supply Chain & Inventory tools
See all- Pallet Pattern Cases per Layer and Pallet Calculator
- Carton Stacking Load and Required BCT Safety Factor Calculator
- Carton Cube Utilization, Void Fill and Dim Weight Calculator
- Palletized Unit Load Shipping Readiness Checklist
- Oracle Fusion Inventory Turns and Carrying Cost Calculator
- Distribution ERP Fill Rate Calculator
- Distributor Rebate Tracking Worksheet
- Branch Transfer Planning Worksheet
- Distributor Slow-Moving Inventory Review Worksheet