In brief
A failed pallet load is rarely explained by film thickness alone. The pallet, product, stacking pattern, wrap programme, handling and route act as one system.
Use evidence from the actual failure to narrow the cause before changing material or adding more wraps.
Start with evidence, not assumptions
Record when and where movement first appeared. Photographs before dispatch and after failure, details of the pallet and load, the wrap pattern, film specification and handling route can help separate causes that otherwise look similar.
Where safety or compliance is involved, follow the site's formal investigation and load-testing procedures. A web guide cannot approve a load for transport.
1. The pallet or load base is unstable
A damaged pallet, poor deck support, overhang or an uneven first layer can create movement that film cannot correct. Check the pallet condition and whether the load transfers weight into the base consistently.
2. The stacking pattern allows internal movement
Gaps, weak cartons, misaligned layers and a high centre of gravity can allow products to move inside an apparently wrapped load. Review the unit load before increasing film use.
3. The film is applied inconsistently
Variation in tension, overlap, wrap pattern, reinforcement or the way the film is anchored can change the result. Manual processes may vary by operator; machine processes may vary through settings, film carriage condition or programme selection.
4. Sharp edges or protrusions damage the film
Corners, metal edges and projecting products can concentrate force and initiate tears. Edge or corner protection, changes to the pallet build or a different wrapping approach may need consideration alongside the film.
5. Handling and transit exceed the assumed route
Forklift impacts, repeated transfers, vibration, braking, double stacking, temperature changes and long storage periods can expose weaknesses that are not visible at the wrapping station.
A practical review sequence
Change one controlled variable at a time where possible. Record the baseline, use representative loads and agree what success means before trialling a new film or programme.
- Inspect pallet condition and load build
- Record film, method, machine and settings
- Observe wrapping at the point of use
- Map handling and transport stages
- Review failure evidence and recurring patterns
- Trial and document the approved corrective action