In brief
An irregular load should be stabilised at source before wrapping. Stretch film can unitise a suitable build, but it cannot make a damaged pallet or unsupported stack safe.
Classify the risk points, protect vulnerable edges, define a load-specific pattern and validate the complete route.
Stabilise the build first
Use a suitable undamaged pallet, keep weight supported by the deck and remove avoidable overhang or gaps. Review weak cartons, loose items and the centre of gravity before applying film.
Map the irregularities
Mark protrusions, sharp edges, recesses and transitions where film may bridge rather than contact the load. Decide whether corner protection, sheets, banding or another approved restraint is needed alongside film.
Create a load-specific pattern
Connect the load and pallet as one unit, build containment through the height and reinforce defined risk zones. Avoid pulling so hard that soft cartons crush or sharp edges initiate tears.
A mixed-load pattern should be documented separately from the standard uniform-carton pattern.
Validate handling and transport
Check the pallet after forklift movement, staging and representative transport conditions. If the stack settles, film tears or items move within the load, stop and revise the build or securing method under the site's process.
| Risk | Investigate | Possible control to assess |
|---|---|---|
| Overhang | Pallet fit and impact exposure | Rebuild on a suitable footprint |
| Sharp edge | Tear initiation point | Edge protection or build change |
| Gaps | Internal product movement | Re-stack, fill or support |
| High/unstable | Centre of gravity and handling | Reconfigure and formally validate |
Practical checklist
- Reject damaged or unsuitable pallets
- Photograph the unwrapped load
- Identify sharp and unsupported areas
- Document a separate wrapping pattern
- Validate through the real route
Sources and further reading
Sources support the general context. They do not establish a SupplyWrap product specification.