In brief
A tear is evidence. Its location and timing can separate a sharp load point from roll damage, excessive tension, poor threading or a machine fault.
Do not assume thicker film is the first or only correction. Record the failure, isolate one cause and retest.
First record where the tear begins
Note whether the film fails at the roll edge, on a particular corner, inside the carriage or after the pallet has moved. Photograph the load and retain the roll label or batch reference where practical.
Check the load
Sharp corners, protruding products, splintered pallets, overhang and gaps can concentrate stress. Correct the pallet build or consider suitable protection before changing film specification.
Check the roll and handling
Damaged roll edges, impacts, contamination and poor storage can create a repeatable initiation point. Compare an undamaged roll from a known batch without changing other variables.
Check application and equipment
For hand wrapping, observe tension, angle and sudden pulling. For machine wrapping, check threading, rollers, film carriage condition, settings and maintenance instructions. Stop and isolate equipment where site procedure requires it.
- Does the break repeat at the same load feature?
- Does it follow one roll or batch?
- Does it occur at one programme or operator?
- Did a setting, supplier or storage condition change?
Confirm the correction
Use representative difficult loads and the normal handling route. Record breaks per defined number of pallets, applied material and load condition so that solving tears does not introduce instability or hidden waste.
| Clue | First check | Avoid assuming |
|---|---|---|
| Same corner | Load profile and protection | The whole roll is weak |
| Damaged roll edge | Handling and storage | More tension will help |
| Inside machine | Threading, rollers and settings | Film is the only cause |
| Random after change | Batch, process and environment | One easy pallet proves the fix |
Practical checklist
- Photograph the tear location
- Record roll and process details
- Inspect pallet and load edges
- Change one controlled variable
- Validate both break rate and load stability
Sources and further reading
Sources support the general context. They do not establish a SupplyWrap product specification.