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Stretch Film Cost Reduction Without Chasing Cheaper Film

  • Writer: MMP Corporation
    MMP Corporation
  • 7 hours ago
  • 5 min read

Key takeaway


  • Focusing only on price per roll often increases total pallet wrapping costs due to downtime, labor waste, excess film usage, and damage claims.

  • Measuring actual cost per pallet reveals that premium stretch film reduces film consumption, improves productivity, and prevents load damage.

  • High-quality stretch film can lower total pallet wrapping costs by 30–40% when evaluated across labor, downtime, and damage expenses.


The Hidden Costs of Cheap Stretch Film

Most procurement teams fixate on one number when buying stretch film: the price per roll. While understandable, this narrow focus often leads operations in the wrong direction. The cheapest roll on your shelf might be the most expensive film in your warehouse once you factor in the downtime, labor waste, and damage claims that likely follow it through your facility. 


True stretch film cost reduction comes from examining the needs of your entire operation, and once determined, buying quality film in the right amounts can actually  reduce total pallet wrapping costs by 30-40%.


The Hidden Costs of Cheap Stretch Film


The old adage that you get what you pay for has its applications with regard to stretch film. That bargain film purchase looks less appealing when your wrapping line grinds to a halt for the third time in a shift. Film breaks caused by inconsistent thickness, a common pitfall of using low-quality wrap, force operators to stop production, rethread the machine, and restart the cycle. Each interruption costs valuable minutes that compound across hundreds of pallets per day.


Inconsistent tension creates another drain on productivity. Operators spend time adjusting settings, troubleshooting uneven wraps, and fixing loads that don't meet quality standards. These interventions rarely show up on any cost report, but they quietly erode your throughput.


Then there's the film itself. Underweight rolls deliver less material than expected, while poor stretching characteristics force extra wraps to achieve adequate load stability. As a result, you end up using more film per pallet to compensate for inferior performance.


The final hit comes after your pallets leave the facility. Inadequate load containment leads to shifting during transit, resulting in product damage and potential customer claims. Studies show that up to 11% of unit loads arrive at distribution centers with some form of damage, and loose wrapping ranks among the top culprits. When average LTL (less than truck load) damage claims cost around $1,500 per incident, even a small uptick in your damage rate erases any film savings.


How to Reduce Pallet Wrapping Cost Through Better Measurement


Understanding your true wrapping expenses while exploring stretch film cost reduction requires looking beyond the purchase order. Start by calculating your actual cost per pallet wrapped, not just film cost per kilogram.


Track how many pallets each roll completes with your current film, then compare that figure against a quality alternative. Cheaper films often require more material per load due to weaker holding force, which means you're burning through rolls faster than expected.


Monitor operator interventions during each shift. Every film break, tension adjustment, and re-wrap represents hidden labor cost. A single week of tracking often reveals patterns that explain why your wrapping line underperforms despite adequate staffing, giving you ample time to adjust. Document your damage rates and their associated costs, including the time spent processing returns and the customer relationships that suffer when shipments arrive compromised.


Securely wrapped pallets with quality stretch film ready for shipping

Four Ways Premium Film Delivers Stretch Film Cost Reduction


1. Eliminate Downtime Losses


Quality machine stretch wrap maintains consistent thickness throughout the roll, preventing the breaks and stoppages that plague cheaper alternatives. Uniform tension means operators set the machine once and let it run. Calculate the value of your hourly production, multiply it by the downtime hours you currently lose, and you'll see why film reliability matters more than film price.


2. Reduce Labor Waste


True-length rolls eliminate the surprise of running short mid-shift. When operators aren't constantly swapping rolls, fixing breaks, or adjusting settings, the same crew wraps significantly more pallets per day. Operations using quality film consistently report productivity gains of 15-20% from labor efficiency alone.


3. Lower Film Usage Per Pallet


Superior stretching means each meter of film covers more surface area, and better holding force means fewer wraps required to achieve stable loads. Pallet wrapping securely in five passes instead of eight, you've achieved 37.5% material savings, regardless of what you paid per roll. This is where reducing pallet wrapping cost becomes counterintuitive: spending more per kilogram of wrap often means using less per pallet.


4. Prevent Damage Costs


Stable loads travel safely; it’s that simple. When your wrap maintains proper containment force throughout transit, cargo stays put and arrives intact. You eliminate re-wrapping at the dock, reduce claims and returns, and thus protect the profit margin on goods you've already sold.


Measuring Your Real Pallet Wrapping Costs


A simple formula captures your true cost per pallet:


Film cost + Labor cost + Downtime cost + Damage cost = True cost per pallet


Run this calculation for one week with your current film. Note every roll change, every machine stoppage, every re-wrap. Track any damage claims during the period. Then switch to quality film and repeat the exercise. Most operations discover their "expensive" film actually costs 30-40% less when measured honestly.


Partner with MMP Corporation for Quality Stretch Film


MMP Corporation manufactures high-performance stretch film engineered for operational efficiency. Our M Stretch line, available in both machine stretch wrap and hand stretch film configurations, provides consistent thickness, superior stretch characteristics, and reliable load containment that protects your products and your bottom line. Consistent quality with every roll, that’s our promise.


Contact MMP Corporation to discuss your wrapping requirements and discover how premium film can enhance your total cost savings.

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FAQs


Q1: Why is cheap stretch film more expensive in the long run?


Cheap stretch film causes frequent breaks, downtime, higher labor involvement, excess film usage, and increased damage claims, all of which raise total pallet wrapping costs.


Q2: How do you calculate true pallet wrapping cost? 


True cost per pallet includes film cost, labor cost, downtime cost, and damage cost, rather than just the price per roll or per kilogram.


Q3: How does premium stretch film reduce downtime? 


High-quality film maintains consistent thickness and tension, preventing machine stoppages and eliminating frequent rethreading and adjustments.


Q4: Can better stretch film really reduce film usage per pallet? 


Yes, superior stretch and holding force allow fewer wraps per pallet, often reducing material usage by more than 30%.


Q5: How does stretch film quality impact shipping damage? 


Reliable containment force keeps loads stable during transit, reducing product shifting, damage, and costly customer claims.


Q6: What productivity gains come from using premium stretch film? 


Operations often see 15–20% productivity improvements due to fewer roll changes, reduced re-wraps, and less operator intervention.


Q7: What types of stretch film does MMP Corporation offer?


MMP Corporation provides high-performance machine stretch wrap and hand stretch film designed for consistent quality, efficiency, and load stability.

 
 
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