How to estimate pallet wrap consumption
Calculate spiral film use from load perimeter, overlap, reinforcement, and stretch, while keeping material yield separate from load containment.
Have your measurements ready? Put the method to work.
Pallet Wrap CalculatorMeasure the loaded footprint and wrapped height
Use the outside footprint of the loaded pallet, including bulges. Its perimeter is twice the sum of length and width. Enter the height that the film must cover and the usable film width. This estimator does not include a top sheet or guarantee that the pallet base is anchored adequately.
A pass means one modeled traverse of the wrapped height. Reinforcement turns add complete loops around the perimeter at the top or bottom. The actual machine program or hand-wrapping method may use a different path, so record those assumptions.
Overlap determines vertical advance
The pitch, or vertical advance per turn, is film width × (1 − overlap fraction). A 50 cm film with 50% overlap advances 25 cm each turn. The first turn covers one film width; subsequent turns cover the remaining height at that pitch.
Turns per pass are 1 + ceiling(max(0, height − film width) ÷ pitch). For the rising turns, the model uses the diagonal travel length √(perimeter² + pitch²), rather than assuming each turn is perfectly horizontal.
Worked example: one pass and four reinforcement turns
A 120 × 80 cm load has a 400 cm perimeter. Wrapped height is 150 cm, film width is 50 cm, and overlap is 50%. Pitch is 25 cm and turns per pass are 1 + ceiling((150 − 50) ÷ 25) = 5.
Applied length for the pass is 400 + 4 × √(400² + 25²) = approximately 2,003.12 cm. Four additional complete reinforcement turns add 1,600 cm. Total applied film is about 36.03 m before adjusting for stretch. This is a geometric scenario, not a recommended wrap recipe.
Stretch changes roll consumption
Stretch is elongation relative to the original film length. At 100% stretch, 1 m from the roll becomes 2 m of applied film, so the example consumes about 18.02 m of unstretched roll length. At zero stretch, it consumes the full 36.03 m.
A nominal 300 m roll would supply sixteen complete 18.02 m scenarios before additional real-world loss. Tails, tearing, unusable roll ends, width reduction under stretch, and actual tension can reduce that count. Confirm that your roll-length specification and stretch convention match the inputs.
Consumption is not containment
More film does not by itself prove that a load is safe. Film properties, puncture resistance, corner geometry, containment force, load integrity, anchoring, and transport conditions matter. The calculator does not simulate any of those performance characteristics.
Measure actual roll use across representative pallets, then update the stretch and wrapping inputs. Use the result for purchasing and packaging-cost comparisons; obtain a separate load-containment assessment where required for the shipment.
Technical references
Service rules and equipment can change. Verify the specifications for your shipment.