Hand wrap or machine wrap? What you're really buying

Hand wrap and machine wrap are not the same film, and the label doesn't always tell you which one you've got. The only way to know what you're buying is to weigh the roll, weigh the core and measure the film. That takes about ten minutes, and it tells you your real cost per pallet.

What's the difference between hand film and machine film?

Hand film is made to be stretched by a person walking round a pallet. It's usually thicker, so it copes with uneven pulling. Machine film runs on a wrapper that does the stretching at a set force, so it can be much thinner. Machine film is often 6 or 9 micron, and a 5 micron pre-stretched film can be strong.

Pre-stretched film is stretched during manufacture. That makes it thinner, often 7 to 8 micron, and it takes less effort and less film per pallet.

Then there's how it's made. Cast film is cooled on chilled rollers. It's clearer, quieter and cheaper, and most pallet wrap is cast. Blown film is air cooled. It's tougher, more resistant to punctures and hazier, but also noisier and dearer, and suits heavy, irregular loads or long journeys.

Why does micron matter?

Micron is thickness. A micron is a thousandth of a millimetre, so the difference between 17 and 14 is a sliver you'll never see by eye.

But thickness drives how much film is on the roll. A thinner film at the same weight runs longer, and a thicker film runs shorter. So if the label says 17 micron and the film is 14, the numbers on the roll can't all be true at once.

What did we find on a real roll?

One site was buying hand wrap sold as 17 micron and 300 metres. We put a micrometer and scales on it. The film measured 14 micron. The roll weighed 1,746g on a 350g core and was 500mm wide, which leaves about 1,396g of film. Working back from that weight, the roll held about 216 metres, not 300.

At a pallet that takes 50 metres, 300 metres wraps six pallets. 216 metres wraps four. You pay for six and get four.

Here's the cost in illustrative numbers. Say the roll costs £4.50. At 300 metres that's 75p a pallet. At 216 metres it's about £1.04 a pallet. On 500 pallets a week the gap is about £146 a week, or roughly £7,500 a year, from one product that nobody thought was wrong.

Not sure what your film is costing you? We'll weigh and measure a roll with you on site.

Can heavy cores hide how much film you're getting?

Yes, and it's the easiest trick to miss. If a roll is quoted at 2.5kg and nobody says whether that includes the core, you're guessing.

The length formula is simple: net film weight divided by density x width x thickness. Use 0.92 for the density of the polyethylene most stretch film is made from.

Here's an illustrative example. Take a 500mm wide, 20 micron roll with 2.5kg of net film. That's about 272 metres. Now take 2.5kg gross with a 0.6kg core. The film is only 1.9kg, which is about 207 metres. That's roughly 24% less film for the same weight on the label.

So always weigh the empty core. A thick card core or a heavy plastic one can take a good share of the weight you're paying for.

What about rewound machine film sold as hand film?

It happens. Machine film can be rewound onto a small core and sold as hand film. It's made for a wrapper's controlled stretch, not for a person pulling by hand, so it may not behave the way you expect.

The giveaway is a roll that's lighter, thinner or shorter than the label says. Weigh it and measure it, as below.

Ask your supplier whether the film was made as hand film. A good one will tell you straight.

What does it cost when the wrap is wrong?

There are three losses. The first is cost per pallet, as above. The second is loads that fail. A pallet that leans or shifts on a lorry can arrive damaged or be turned away. The third is more film. Operators who don't trust the film add extra layers, and the cost climbs again.

On a wrapper, over-stretching thin film makes it break. Operators then turn the force down and add layers. Lantech, a wrapper manufacturer, gives an illustration of 50 metres a pallet falling to 40, which is 20% less film. Look at what you're using per pallet and ask why.

What about recycled content and Plastic Packaging Tax?

Plastic Packaging Tax applies to plastic packaging with less than 30% recycled plastic. The rate is £228.82 a tonne from 1 April 2026. Manufacturers and importers must register once they reach the 10 tonne registration threshold.

The liability sits with the UK manufacturer or importer. HMRC can, however, make businesses further down the supply chain secondarily or jointly liable, and it takes account of recorded due diligence. So ask your supplier whether the film meets the 30% threshold and keep their answer on file.

We actively source as much recyclable product as we can. If recycled content matters to you, put it in your spec.

How do you check a roll in ten minutes?

You need kitchen scales that read to the gram and a micrometer. Give the job to your QA lead or the shift supervisor, and do it on every new supplier's first delivery and then a roll from each batch.

Weigh the full roll and write it down. Weigh the empty core from a used roll of the same type. Measure the width. Take the film thickness with the micrometer at several points. Then use the length formula to work out the metres on the roll and divide by the metres a pallet takes.

Compare the answer with the label. If it's short, you've found your problem. Ask for the film to be tested again and put what you find in writing.

What should go in the spec?

Write down the film type (hand or machine, cast or blown, pre-stretched or not), the thickness, the width, the net film weight and the minimum length per roll. State the core weight and the type of core. Add recycled content if you need it.

Then say how you'll check it, and how often. A spec that you never test is only a hope.

Frequently asked questions

Is machine film better than hand film?

Not by default. Machine film is made for a wrapper, and it runs thinner because the machine does the stretching. Hand film is built for people and gives more forgiveness. Use the one that suits how you wrap.

How do I work out how long a roll is?

Divide the net film weight by density x width x thickness. Use 0.92 for the density. Weigh the empty core and take it off the gross weight first.

Does Plastic Packaging Tax affect me as a buyer?

The tax falls on the UK manufacturer or importer, but HMRC can make others in the supply chain liable. Keep records showing you asked about recycled content.

How often should I check my wrap?

Check a roll from every new supplier delivery and then a roll from each batch. Check your wrapper settings at least once a shift.

Send us one roll

Send us one roll, or let us weigh and measure one on site. We'll show you the film thickness, the real length and your cost per pallet.

You can also ask for our free site check. We walk the site with your operations team for about 30 minutes and send a written report. There's no contract, and testing is only arranged where it's needed.

Email sales@kptrading.uk or call 020 4576 5500.

Sources

KB Packaging, Blown vs cast stretch wrap film: https://kbpackaging.com/blown-vs-cast-stretch-wrap-film/

Hub Packaging, Pre-stretched film: https://www.hub-packaging.com/?p=230656

Lantech, How much does stretch wrap stretch: https://www.lantech.com/how-much-does-stretch-wrap-stretch-is-more-better/

Lantech, Check your containment force: https://www.lantech.com/check-your-containment-force/

GOV.UK, Plastic Packaging Tax: https://www.gov.uk/government/publications/introduction-of-plastic-packaging-tax/plastic-packaging-tax

GOV.UK, Check if you need to register for Plastic Packaging Tax: https://www.gov.uk/guidance/check-if-you-need-to-register-for-plastic-packaging-tax

GOV.UK, Secondary liability for Plastic Packaging Tax: https://www.gov.uk/guidance/secondary-liability-and-assessment-notices-and-joint-and-several-liability-notices-for-plastic-packaging-tax

Illustrative figures are labelled in the text. Images are illustrative.