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Stretch wrap film is a staple in modern logistics and warehousing, used to secure goods on pallets during storage or transportation. When applied correctly, it ensures load stability, prevents product damage, and enhances safety. However, even the most durable film can fail if misused — leading to costly consequences such as collapsed loads, increased material waste, and shipping delays.

At Dostar Packing Equipment Co., Ltd., a high-tech enterprise focused on the R&D, integration, and production of automated packaging systems, we’ve seen firsthand how the right techniques and technologies make all the difference. In this article, we explore the most common mistakes to avoid when using stretch wrap film — and how automation can help you wrap smarter and more efficiently.

1. Using the Wrong Type of Film

Not all stretch wrap films are created equal. Some are designed for light loads, while others offer high puncture resistance and stretch capacity for heavier or irregularly shaped items.

Mistake: Using a thin or low-quality film for heavy loads.

Solution: Match film type and gauge to your product weight, pallet size, and wrapping method. Dostar helps clients select optimal film specifications through system integration and testing as part of our automated line services.

2. Incorrect Film Tension

Too much tension can crush products, while too little tension can lead to instability. Both issues increase the risk of load failure during transport.

Mistake: Manually wrapping without consistent film stretch or tension control.

Solution: Use semi-automatic or fully automatic pallet wrapping machines with programmable tension settings. Dostar's automated systems provide precise and repeatable tension control to optimize load containment without damaging products.

3. Insufficient Wrapping at the Base

The base of the pallet is the most critical zone for securing the load. If the film isn’t anchored correctly, the load can shift or separate during movement.

Mistake: Starting the wrap too high on the pallet or skipping bottom layers.

Solution: Always start wrapping just below the pallet deck and overlap multiple base layers. Dostar’s automated wrappers are designed to wrap from base to top with configurable bottom wrap settings.

4. Over-Wrapping or Under-Wrapping

Both extremes waste film and compromise load safety. Over-wrapping increases costs and environmental impact, while under-wrapping reduces load integrity.

Mistake: Using a fixed number of revolutions regardless of load type.

Solution: Use equipment that can adapt wrapping patterns based on load size, weight, and shape. Dostar’s smart control systems automatically calculate the optimal number of wraps per pallet.

5. Ignoring Film Breaks or Tails

Loose film tails or broken wraps can cause unraveling in transit — leading to severe load instability.

Mistake: Leaving unsealed tails or ignoring film breaks.

Solution: Ensure proper sealing or film tail treatment. Dostar’s fully automatic systems include tail sealing units and film break detection to prevent these issues.

6. Skipping Equipment Maintenance

Even the best machines need regular maintenance to operate efficiently. Worn-out rollers, misaligned sensors, or broken pre-stretch units can cause inconsistent wrapping.

Mistake: Delaying service until a major failure occurs.

Solution: Establish a preventive maintenance routine. Dostar provides comprehensive after-sales support, including spare parts, software updates, and maintenance services to keep your wrapping line running smoothly.

7. Not Training Operators

Even with automation, human error can occur if operators aren’t properly trained in machine operation and troubleshooting.

Mistake: Relying on untrained personnel for critical tasks.

Solution: Dostar offers on-site training and user-friendly interfaces to reduce errors and improve packaging efficiency across the production floor.

Conclusion

Efficient palletizing isn’t just about using film — it’s about using it correctly. Avoiding these common mistakes can dramatically improve load stability, reduce material waste, and enhance safety throughout your supply chain.

At Dostar Packing Equipment Co., Ltd., we help businesses move beyond trial and error by delivering intelligent semi-automatic and fully automatic packaging solutions tailored to your needs. Whether you’re upgrading a single station or scaling a full production line, our systems are designed to deliver consistent, high-performance pallet wrapping that protects your products and your bottom line.

http://www.dostar-pack.com
Dostar Packing Equipment (Wuxi) Co., Ltd

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