Pallet Wrap Calculator
Estimate stretch film consumption per pallet from loaded dimensions, film width, overlap, passes, reinforcement, and stretch.
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Pitch = applied film width × (1 − overlap). Dashed horizontal lines show extra reinforcement loops. Consumption divides the applied length by (1 + elongation); the drawing does not establish load containment.
How this result was calculated
- Perimeter = 2 × (1.2 + 1) = 4.4 m. Pitch = 0.5 × (1 − 50%) = 0.25 m.
- Turns per pass = 1 + ceil(max(0, 1.5 − 0.5) ÷ 0.25) = 5. The first turn covers one film width.
- One pass = perimeter + (turns − 1) × √(perimeter² + pitch²) = 22.0284 m. Applied total = 2 passes + 4 reinforcement loops = 61.6568 m.
- Roll length consumed = applied length ÷ (1 + 100%) = 30.8284 m per pallet. Total for 10 pallets = 308.2839 m.
Detailed breakdown
| Wrapping assumption | Value |
|---|---|
| Loaded perimeter (m) | 4.4 |
| Vertical pitch per turn (m) | 0.25 |
| Turns per full-height pass | 5 |
| Extra top + bottom wraps | 4 |
| Applied film per pallet (m) | 61.6568 |
| Unstretched roll film per pallet (m) | 30.8284 |
| Whole pallets from one uninterrupted roll | 48 |
This is a rectangular-load spiral model, with one level first turn per pass and conservative full-pitch helical turns above it. Reinforcement wraps are full horizontal loops; no top-cover sheet is included.
Elongation is the increase over original film length. Film recovery, tails, tearing, machine setup waste and stretch variation are excluded. Enter the effective applied film width to account for neck-down.
Purchase rolls are based on total film length and assume a roll can be replaced during a pallet. The table separately reports whole pallets from an uninterrupted roll.
Estimated film consumption does not establish containment force, load stability, safe securement or machine settings. Validate those independently for the load and film.
How to use this tool
Pitch = film width × (1 − overlap fraction). Turns per pass = 1 + ceil(max(0, loaded height − film width) ÷ pitch). Applied length per pass = perimeter + (turns − 1) × √(perimeter² + pitch²). Add full reinforcement turns, then divide the applied length by (1 + stretch fraction) to estimate roll consumption.
A worked example
A 120 × 80 cm pallet has a 4 m perimeter. If the model calls for 12 complete equivalent turns, the perimeter-only applied length is 48 m before diagonal travel and stretch adjustments. At 100% elongation, 1 m of unstretched film supplies 2 m of applied film.
Put the result to work
Stretch means elongation relative to the original film length: 100% stretch gives twice the original length. Actual yield depends on tension, neck-down, equipment, corners, tails, and handling. Material consumption does not validate containment force or load securement.
Read the complete guideCommon questions
What does 50% overlap mean?
Each successive band overlaps half of the previous band's width. The vertical advance is half of the film width.
Is stretch percentage a guaranteed saving?
No. It is an editable assumption. Real film performance and machine settings should be measured; excessive stretch can tear film or reduce useful width.
Can this tell me whether a pallet is safe to transport?
No. It estimates film use. Load containment, distribution, restraint, and transport suitability need an independent assessment.