Stretch Wrap & Stretch Film Usage Calculations: A Guide for Canadian Warehouses

For businesses in Canada material handling a high volume of pallet shipments, understanding and managing stretch film usage can lead to significant cost savings. Calculating film usage and achieving optimal stretch rates are crucial for efficient packaging and budgeting. This guide explains step-by-step calculations for estimating stretch film usage and stretch wrap rates, helping warehouses streamline operations and reduce expenses.

How to Determine Stretch Film Usage per Pallet

Understanding how much stretch film you’re using per pallet is the foundation of effective cost management. This stretch wrap calculation will give you a precise estimate of film usage over a given period.

Step-by-Step Calculation for Film Usage:

1. Measure Film Used Per Revolution
   Measure the total length of film required to wrap one complete revolution around the pallet.

   Example Calculation:

   • Pallet Dimensions: 48″ x 48″ x 63″
   • Calculation: 48 inches (per side) × 4 sides = 192 inches per revolution.

2. Convert Inches to Feet
   Convert the measurement from inches to feet for ease in further calculations.
   Formula: $\frac{192 \text{ inches}}{12} = 16 \text{ feet per revolution}$

3. Calculate Total Film per Pallet
   Multiply the number of revolutions needed to secure the pallet by the length of film used per revolution.
   Example Calculation: If it takes 11 revolutions to secure the pallet, then:
   $11 \text{ revolutions} × 16 \text{ ft/revolution} = 176 \text{ ft of film used per pallet}$

4. Calculate Weekly or Monthly Film Usage
   Determine the number of pallets you wrap weekly or monthly, then multiply by the film used per pallet.
   Example: If wrapping 40 pallets weekly, the weekly film usage would be:
   $40 \text{ pallets} × 176 \text{ ft/pallet} = 7,040 \text{ ft of stretch film per week}$

Calculating Stretch Film Stretch Rate

Knowing the stretch wrap rate in canada , or the percentage by which the film can be elongated, helps you gauge the actual length of film available per roll after stretching. This rate affects the overall cost and consumption of film in your warehouse.

Steps to Determine Stretch Rate:

1. Mark the Film for Measurement
   Unroll a portion of the film and mark a 10-inch line. Place this line a few feet away from the film’s end.

2. Stretch the Film on the Pallet
   Begin wrapping the pallet as usual. After a few revolutions, measure the line again to determine the stretched length.

3. Calculate Stretch Percentage
   Use the formula:
   $\frac{\text{Line Length After Stretch - Original Line Length}}{\text{Original Line Length}} \times 100$

   Example: If the line stretches from 10 inches to 22 inches:
   $\frac{22 - 10}{10} × 100 = 120\% \text{ stretch}$

4. Calculate Usable Film Length Post-Stretch
   Use the obtained stretch rate to calculate the effective length of film available per roll.
   Formula:
   $(1 + \text{Stretch Rate}) × \text{Length of Film Roll}$
   Example: For a standard 5000-ft machine roll with a 120% stretch:
   $(1 + 1.20) × 5000 = 11,000 \text{ ft}$

Determining Total Film Rolls Required

To forecast stretch film needs accurately, use the film footage required weekly or monthly and divide it by the effective length of each roll.

Film Usage Formula:

1. Calculate Total Weekly or Monthly Usage
   $\text{Weekly Pallet Count} × \text{Film per Pallet} = \text{Total Film Footage}$
   Example: 40 pallets × 176 ft = 7,040 ft per week.

2. Determine the Number of Rolls
   Divide total footage by the length per roll (considering the stretch rate).
   Example: With a hand roll of 3,300 ft (120% stretch rate), calculate:
   $\frac{7,040 \text{ ft}}{3,300 \text{ ft/roll}} ≈ 2.13 \text{ rolls per week}$

With this data, you can plan your purchasing to match your weekly or monthly requirements, reducing waste and optimizing stock levels.

FAQs: Stretch Wrap Usage and Calculations

Q1: Why is calculating stretch film usage per pallet important?

Calculating film usage per pallet helps manage inventory effectively, reduces excess spending, and ensures enough stock for consistent packaging needs without over-ordering.

Q2: How can we achieve a higher stretch rate?

For hand applications, achieving higher stretch rates depends on technique and film quality. Machines, particularly those with pre-stretch features, can reach up to 250% stretch, maximizing film usage efficiency.

Q3: What is the difference between hand and machine stretch rates?

Hand applications typically achieve a stretch rate of 100% to 150%, while machines with pre-stretch capabilities can reach between 225% and 250%, significantly extending film length per roll.

Q4: How can we reduce our overall stretch film costs?

Using machines for higher stretch rates, optimizing film thickness based on load requirements, and regularly monitoring film usage are effective ways to reduce costs.

Q5: How frequently should we monitor stretch film usage?

Regular monitoring, ideally every quarter, ensures accurate usage data, which helps in adjusting inventory and usage practices to stay cost-effective.

Q6: What are the best practices for hand wrapping pallets to reduce film waste?

Ensure even and tight wraps, avoid excessive revolutions, and practice uniformity in wrapping technique to minimize waste.