Strapping Vs Stretch Wrap: The Right Way To Secure Pallets Before Peak

Q4 will pressure test your palletising. If loads rock, labels get hidden, or film usage spikes, you feel it in damages, carrier surcharges, and overtime. The fastest win is choosing the right method for each pallet, then settingequipment and training so anyone on shift can get a consistent result. This guide gives you clear criteria to pick strapping or stretch wrapping, real cost-per-pallet pointers, a practical decision tree, and notes on UKcompliance so you can head into peak with confidence.

Strapping, banding, and how they differ from wrapping

Strapping vs banding: In most warehouses, strapping and banding are used interchangeably. Both mean applying a narrow plastic strap around a load to clamp items together or to a pallet.

What strapping does best: It provides high tensile restraint along defined paths, perfect for securing heavy cartons, rigid crates, timber, bricks, white goods, and anything where vertical compression and lateralrestraint matter.

What stretch wrapping does best: It stabilises the full surface of a pallet by applying machine stretch wrap under tension to create containment and dust protection, ideal for mixed-case pallets, irregular shapes,and applications that need full-cover stability and weather protection.

You can also combine both for high-value or tall, top‑heavy loads. Strap for core restraint, then wrap for unitisation and edge hold.

Polypropylene vs PET strapping

Polypropylene strapping: Lighter, more elastic, and cost-effective. Good for medium-duty bundling, carton unitisation, and pallets up to mid weights where some give is acceptable. It is forgiving on corners andsuits semi-auto and automatic strapping machines.

PET (polyester) strapping: Higher tensile strength and better retained tension over time. It is the alternative to steel in many applications, well suited for heavy pallets, bricks, metal components, and loads that settleduring transit. PET resists elongation creep and keeps loads tight.

Rule of thumb: If your loads deform or settle, choose PET. If you need speed with moderate strength at lower cost, polypropylene is usually enough.

What is a pallet wrapper, and when should you use one?

A pallet wrapper is a machine that applies stretch film with controlled pre‑stretch and wrap patterns. Options include turntable, rotary arm, and robotic units. Use a wrapper when you need:

Containment across the whole load surface

Consistent film tension and overlap to reduce tipping or scuffing

Dust and moisture protection

Faster, safer, repeatable wrapping across shifts

If you run varied pallet sizes, a mobile robotic wrapper will give you flexibility without fixed guarding. For consistent pallets at volume, a semi automatic pallet wrapper on a turntable is a reliable workhorse.

If you are comparing on-site solutions, review our stretch wrap machines to see the configurations that fit high throughput operations.

Cost per pallet, waste, and damage rates

Strapping cost: Two polypropylene straps might cost pennies per pallet. PET costs more per metre, but fewer straps may be needed due to higher strength. Labour is low with semi-auto or automatic machines.

Stretch wrap cost: With machine pre‑stretch, film can drop to 50 to 150 grams per pallet depending on pattern and product. Cost per pallet typically ranges from a few tens of pence to just over a pound,influenced by film grade, pre‑stretch ratio, and required wraps.

Damage rates: Wrapping tends to cut scuffs and carton edge crush on mixed loads. Strapping excels at preventing shift in heavy, rigid loads. Many operations see best results by wrapping for containment thenadding one or two PET straps for failsafe restraint on high-value shipments.

Target outcome: Under 1 percent damage and stable film usage. If you are above that, either the containment force is too low or the method does not match the load type.

How to correctly wrap a pallet

Start stable: Use a sound pallet and keep product within the footprint.

Bond to the pallet: Anchor the film to the pallet base and wrap the lower deck area to lock product to timber.

Build containment: Apply 50 percent overlap up the load, then down if needed. Keep even tension and avoid crushing corners.

Top sheet if needed: Add a top cover for dust or light weather resistance.

Label friendly: Leave a clear window for barcodes and routing labels.

Check containment force: The load should not shear more than a few centimetres under a firm push. For daily consistency, store and select a preset on your wrapper for standard loads.

If you need guidance on machine and film selection, explore our stretch wrap section for options that match throughput and sustainability goals.

When to choose what: a simple decision tree

Is the load heavy, rigid, or likely to settle in transit?

Yes: Use PET strapping, optionally add stretch wrap for surface protection.

No: Move on.

Is the load mixed case or irregular, and needs full-surface containment?

Yes: Use machine stretch wrap. Add two straps for tall or top‑heavy pallets.

No: Move on.

Is dust or moisture protection required?

Yes: Use stretch wrap with a top sheet.

No: Move on.

Do labels need to stay visible?

Yes: Use a wrap pattern that leaves a window, or apply straps only if protection is not required.

Do you have recurring corner crush or scuffing?

Yes: Reduce film tension, use corner protectors, or add a wrap with lower pre‑stretch. Consider swapping some straps for wrap to spread load on edges.

Integrating semi‑auto strappers and stretch wrappers

Infeed and outfeed: Place machines where pallets naturally queue. Provide 1.5 to 2 metres of clear space at entry and exit.

Power and floors: Level floor, dedicated power supply, and simple bollard protection reduce downtime.

Controls and presets: Standardise 2 to 4 wrap patterns by pallet type. Name them clearly, train to select before start.

Throughput: Semi automatic turntable wrappers often handle 20 to 40 pallets per hour with trained operators. Semi‑auto strappers can strap a pallet in under 30 seconds depending on strap count.

Data and checks: Add daily checks for film carriage, strap tension, and friction weld quality. Track film and strap usage per shift to catch drift before peak.

Safety and training

Manual handling: Reduce hand wrapping. Use a wrapper to cut back strain and trip risk.

Guarding: Rotary arms and conveyors may require guarding and interlocks. Follow PUWER obligations and keep clear signage.

Knife and corner safety: Train operators to avoid sharp edges and cut‑backs. Use corner protectors where needed.

Fire and film storage: Store films away from heat. Keep strap coils secure to prevent spring‑off.

Clear SOPs: One page, laminated, with photos of good pallets. Include a stop-fault-start checklist.

UK compliance notes

Load security in transit: The Road Traffic Act and DVSA guidance require that loads are secured so they will not move under normal driving. Use methods that maintain restraint for the full journey.

Packaging waste: If you hit producer responsibility thresholds, account for plastic film and strap. Investigate recycled-content films and right‑sizing to reduce tonnage.

Manual handling: Follow HSE guidance to minimise repetitive strain by using mechanical wrapping.

Labelling visibility: Carriers and RDCs may reject pallets with obscured labels. Design wrap patterns that preserve visibility.

What does it cost to wrap a pallet?

As a planning figure, with good pre‑stretch and a standard pattern, many operations sit at 25 to 70 pence per pallet for film. Tall or delicate loads that need extra rotations may reach one pound or a bit more. Costs fall fastwhen patterns are standardised and waste is removed. Aim for the lightest pattern that holds the load without shifting.

Alternatives to plastic strapping

PET and PP are the norm, but you can consider woven polyester strapping for high retained tension and gentle handling.

For full-surface containment without straps, use machine stretch wrap with edge protectors.

Paper-based edge boards plus wrap can replace some straps where customer recycling policies push fibre-only solutions.

For carton-level security, use strong packaging tape to remove redundant straps on case bundles.

Quick reference: choose strapping, wrapping, or both

Choose strapping if the load is heavy, rigid, or likely to settle; if label windows are critical; or if per-pallet cost must be minimal with point restraint.

Choose stretch wrap if the load is mixed case, irregular, requires dust protection, or needs broad containment.

Choose both for tall, high-value, or long-distance loads where failure is not an option.

Summary and next steps

The right method depends on your load, not preference. PET or polypropylene strapping gives high retained tension along defined lines, while a pallet wrapper delivers even containment and protection across the full load.Standardise patterns, train for consistency, and check containment daily, and you will cut damages, film use, and load rejections throughout peak.

If you want an expert view on set‑up and ROI, talk to us about semi‑auto strappers and wrappers that drop straight into existing lines. You can also review our stretch wrap machines to see proven options for Q4readiness.

For more information on Strapping Vs Stretch Wrap: The Right Way To Secure Pallets Before Peak talk to Severn Packaging