Choosing the wrong stretch wrap gauge is one of the most common — and costly — packaging mistakes in warehouse operations. Too light a gauge and loads shift or fail in transit. Too heavy and you're paying for film you don't need on every pallet, every day.
This guide covers every gauge available, matched to load weight, application type, and wrapping method so your procurement team can spec the right film the first time.
What Is Stretch Wrap Gauge?
Gauge measures the thickness of stretch wrap film. One gauge unit equals 0.01 mil (0.000254 mm). An 80-gauge film is 0.80 mil (0.0203 mm) thick. Higher gauge = thicker film = greater puncture resistance and load containment force.
Gauge alone does not determine performance. Pre-stretch ratio — how much the film is elongated before it contacts the load — has an equal or greater effect on yield, cost per pallet, and holding force. A 60-gauge film pre-stretched at 250% delivers more holding force than an 80-gauge film applied with no pre-stretch.
Stretch Wrap Gauge Comparison Table
| Gauge | Thickness | Type | Max Pre-Stretch | Load Weight | Best For |
|---|---|---|---|---|---|
| 37 ga | 0.37 mil | Hand | None | Up to 250 lbs | Bundling light items, securing loose products on shelves |
| 47 ga | 0.47 mil | Hand | None | 250–500 lbs | Light pallet loads, unitizing cartons, retail bundling |
| 60 ga | 0.60 mil | Machine | 150–200% | 500–900 lbs | Light-duty automated wrapping, high-volume low-weight loads |
| 63 ga | 0.63 mil | Hand | None | 500–900 lbs | General hand wrapping, mixed-weight warehouse pallets |
| 70 ga | 0.70 mil | Machine | 200–250% | 900–1,500 lbs | Medium-duty machine wrapping, stable uniform loads |
| 80 ga | 0.80 mil | Hand / Machine | Up to 300% (machine) | 800–2,000 lbs | Most common warehouse gauge; suitable for the majority of standard pallet loads |
| 90 ga | 0.90 mil | Machine | 250–300% | 2,000–2,500 lbs | Heavy loads, loads with sharp or protruding corners |
| 100 ga | 1.00 mil | Machine | 250–300% | 2,000–3,000 lbs | Heavy-duty machine applications, dense loads, cold storage |
| 115 ga | 1.15 mil | Machine | 200–300% | 2,500–4,000 lbs | Extra-heavy loads, irregular shapes, mixed unstable pallets |
| 120 ga | 1.20 mil | Machine | 200–300% | 3,000–4,500 lbs | Maximum-duty: steel coils, heavy machinery, construction materials |
Load weight ranges are approximate and assume standard pallet configurations. Sharp edges, irregular shapes, or long transport distances warrant upgrading one gauge tier regardless of weight.
Selection Guide by Load Weight
| Load Weight | Hand Gauge | Machine Gauge | Notes |
|---|---|---|---|
| Under 250 lbs | 37 ga | — | Bundling only; not a full pallet wrap application |
| 250–500 lbs | 47 ga | 60 ga | Light cartons, retail goods, assembly components |
| 500–900 lbs | 63 ga | 60–70 ga | Standard mixed-SKU pallets, e-commerce fulfillment |
| 900–1,500 lbs | 80 ga | 70 ga | Food and beverage cases, bagged goods, boxed parts |
| 1,500–2,000 lbs | 80 ga | 80 ga | Most industrial pallets fall in this range; 80 ga is the industry standard |
| 2,000–2,500 lbs | Not recommended | 90 ga | Loads above 2,000 lbs should use machine wrap for consistent tension |
| 2,500–3,000 lbs | Not recommended | 100 ga | Dense industrial loads; ensure wrapping equipment supports this gauge |
| 3,000–4,000 lbs | Not recommended | 115 ga | Heavy manufacturing, steel, lumber, construction materials |
| Over 4,000 lbs | Not recommended | 120 ga | Consult your equipment manufacturer for maximum film compatibility |
Selection Guide by Application
| Application | Gauge | Width | Film | Method |
|---|---|---|---|---|
| Standard warehouse pallet — mixed cartons | 80 ga | 18" | Clear | Hand |
| High-volume distribution — uniform loads | 70–80 ga | 20" | Clear | Machine |
| High-value goods (cargo privacy required) | 80 ga | 18–20" | Black | Hand or Machine |
| Food and beverage — cold storage | 80–100 ga | 20" | Clear | Machine |
| Automotive parts — sharp edges | 90–115 ga | 20" | Clear | Machine |
| Building materials — lumber, pipe | 80–115 ga | 18–20" | Clear | Hand or Machine |
| Outdoor or long-term storage | 80–100 ga UV | 18–20" | Clear UV | Hand or Machine |
| Light bundling — loose parts | 37–47 ga | 12–14" | Clear | Hand |
| E-commerce — high cycle, low weight | 47–63 ga | 18" | Clear | Hand |
| Steel coils, heavy machinery | 115–120 ga | 20–23" | Clear | Machine |
Width Selection Guide
Width is often overlooked but directly affects wrapping efficiency. A wider film covers more surface per revolution, reducing wrap cycles and labour time per pallet.
| Width | Type | Best Application |
|---|---|---|
| 12" | Hand | Bundling small items, narrow loads, securing loose parts |
| 14" | Hand | Compact pallets, moderate loads, tight spaces requiring precision |
| 18" | Hand | Most common hand wrap width — standard warehouse pallets, order staging |
| 20" | Machine | Standard machine wrap width — high-volume distribution, uniform loads |
| 23" | Machine | Wide or oversized loads, reducing wrap cycles on large pallets |
Hand Wrap vs. Machine Wrap
| Factor | Hand Wrap | Machine Wrap |
|---|---|---|
| Daily pallet volume | Under 20 pallets/day | 20+ pallets/day |
| Film consistency | Varies by operator | Consistent tension every wrap |
| Film cost per pallet | Higher (less pre-stretch) | Lower (250–300% pre-stretch maximizes yield) |
| Labour time per pallet | 2–4 minutes | 45–90 seconds |
| Operator fatigue | Significant at high volume | Minimal |
| Capital cost | Low (dispenser only) | Higher (turntable or rotary arm) |
| Best gauge range | 37–80 ga | 60–120 ga |
| Break-even volume | — | Typically 25–40 pallets/day |
Clear vs. Black Stretch Wrap
| Property | Clear Film | Black (Opaque) Film |
|---|---|---|
| Cargo visibility | Full — contents visible through wrap | None — contents fully concealed |
| Theft deterrence | Low | High |
| UV protection | Standard (UV grade available) | Carbon black provides inherent UV blocking |
| Receiving audit | Contents scannable without unwrapping | Must unwrap to audit contents |
| Cost | Standard | Typically 10–20% higher |
| Best use | Standard warehouse, distribution, food & beverage | High-value goods, electronics, pharmaceuticals, outdoor storage |
Film Yield: Estimated Pallets per Roll
Pre-stretch dramatically increases film yield. The figures below assume a standard 48"×40" GMA pallet at 60" load height with 3 base wraps and 4 top wraps.
| Film | Roll Length | Pre-Stretch | Effective Length | Est. Pallets/Roll |
|---|---|---|---|---|
| 80 ga hand, 18" | 1,500 ft | 0% | 1,500 ft | 4–6 pallets |
| 80 ga machine, 20" | 5,000 ft | 200% | 15,000 ft | 40–60 pallets |
| 60 ga machine, 20" | 5,000 ft | 250% | 17,500 ft | 50–70 pallets |
| 115 ga machine, 20" | 5,000 ft | 200% | 15,000 ft | 25–35 pallets |
Quick-Reference Decision Tree
- Load under 500 lbs, hand wrapping → 47 ga, 18" clear
- Load 500–2,000 lbs, hand wrapping → 80 ga, 18" clear (the warehouse standard)
- Load 500–2,000 lbs, machine wrapping → 80 ga, 20" clear
- Load over 2,000 lbs → machine wrap required; start at 90 ga
- Sharp edges or protrusions → upgrade one gauge tier regardless of weight
- Cargo privacy required → black film, same gauge as above
- Outdoor or long-term storage → UV-stabilized film, same gauge as above
- High volume (>25 pallets/day) → machine wrap; 60–80 ga at 250% pre-stretch
Frequently Asked Questions
Is higher gauge always better?
No. Over-specifying gauge increases cost per pallet with no functional benefit. For loads under 2,000 lbs on standard pallets with no sharp edges, 80-gauge hand wrap is optimal. Use the tables above to match gauge to actual requirements.
Can I use machine wrap film on a hand dispenser?
Not effectively. Machine rolls use larger core sizes (typically 3") and are designed for powered pre-stretch. Hand dispensers cannot pre-stretch film — you will apply machine film at 0% pre-stretch, wasting material and applying uneven tension. Use hand-grade film on hand dispensers.
What happens if I under-gauge a load?
Film puncture and load failure. Under-gauged film tears at corners and protrusions, allowing the load to shift or collapse during transport. The cost of one load failure typically exceeds the annual savings from using a lighter film.
How do I switch from hand to machine wrap economically?
Calculate your current hand wrap cost per pallet (roll cost ÷ pallets per roll). A semi-automated turntable wrapper typically pays for itself in 6–18 months at 20+ pallets per day through reduced film cost and labour time. Contact us for a volume-based cost analysis.
Does film colour affect holding strength?
No. Clear and black films of the same gauge and formulation have identical mechanical properties. The carbon black pigment in opaque film does not affect stretch or holding force.
For volume pricing, technical specifications on specific rolls, or help matching film to your wrapping equipment, contact Harix Industries at sales@harix.ca or (905) 975-9000.