In brief
Roll price does not reveal cost per pallet. You also need net film content, the applied mass for representative loads and evidence of process losses.
Keep direct material cost separate from wider operating cost so assumptions remain visible and comparisons stay useful.
Calculate direct film cost first
Use the price and verified net film mass to calculate cost per kilogram of film. Then measure the film applied to a representative pallet by roll-weight difference or another controlled method. Direct film cost per pallet is applied film mass multiplied by film cost per unit mass.
Use consistent units and exclude core and packaging weight. If the supplier provides length and thickness but not net mass, request verified product data rather than building a purchasing decision on an unconfirmed estimate.
Segment the pallet population
A single average can hide meaningful variation. Calculate normal repeat loads, mixed loads and difficult exceptions separately. Weight the results by actual pallet mix only when the activity data is reliable.
Add visible process losses
Film breaks, discarded partial rolls and rewraps consume material without creating an additional successful pallet. Include them in a period-level measure. For machine processes, roll changes and film-related stoppages may also have an operating effect that belongs in a separate cost view.
Compare outcomes, not isolated inputs
A lower roll price can produce a higher applied cost. A lighter film can need more revolutions or create more breaks. A higher-priced film can still be uneconomic if it does not improve the relevant process result. Compare candidates under controlled settings and record load condition after representative handling.
| Layer | Include | Keep visible |
|---|---|---|
| Direct film | Applied mass × cost per unit mass | Net film content and test method |
| Process loss | Breaks, waste and rewrap material | Period and wrapping point |
| Operating effect | Time, changes and film-related stops | Labour and downtime assumptions |
| Outcome | Damage or failed-load evidence | Do not claim causation without investigation |
Practical checklist
- Confirm net film mass and purchase basis
- Measure applied mass on representative load families
- Record breaks, discarded film and rewraps
- Separate material cost from operating assumptions
- Retain the trial and calculation record