Pallet wrap, also known as stretch wrap or stretch film, is an essential packaging material used to secure and protect products on pallets during storage and transit. The film is wrapped tightly around a pallet creates tension that holds goods firmly in place and reduces the risk of damage.
When choosing pallet wrap, one of the most common questions businesses ask is: should I use cast stretch wrap or blown stretch wrap? While both are designed to stabilise pallet loads, they perform differently depending on your application.
At KB Packaging, we work with customers across multiple industries to help them choose the right stretch film for their specific needs. Below, we explain the key differences between cast and blown stretch wrap to help you make an informed decision.
Cast stretch wrap is a type of pallet wrap manufactured using a cast extrusion process, where molten plastic is rapidly cooled through chilled rollers. This production method allows the film to be made quickly and efficiently, making cast stretch wrap a cost-effective and widely used option.
In fact, cast stretch film accounts for the majority of pallet wrap used across the industry.
Clear and glossy appearance, making pallet labels and barcodes easy to read
Quiet and smooth unwind from the roll
Excellent cling, requiring minimal effort to secure the load
Consistent thickness across the film
Typically more affordable than blown stretch wrap
Cast stretch wrap is often manufactured at high volumes, which helps keep costs competitive. It is ideal for indoor warehouse use, especially where pallets experience minimal movement during handling or transit.
Cast film can continue to stretch after application, which may slightly increase the risk of load movement
Blown stretch wrap is a type of pallet wrap manufactured using a blown extrusion process, where molten plastic is forced through a circular die and cooled slowly with air. This method creates a tougher, more resilient film with enhanced strength and durability.
Blown stretch film is commonly used in more demanding packaging environments where load security is critical.
Blown stretch wrap is particularly well suited to operations where pallets experience movement, uneven loads or longer transit distances. Its strength and resistance help maintain load integrity throughout handling and transportation.
Blown film typically has a hazier appearance and a noisier unwind compared to cast stretch wrap, and it is usually more expensive due to the slower manufacturing process.
The right pallet wrap depends on how and where your products are stored and transported.
Choose cast stretch wrap if you need a cost-effective solution for wrapping pallets stored indoors with minimal movement. It’s an excellent option for general warehouse use and high-volume applications.
Choose blown stretch wrap if your pallets are transported frequently, stored outdoors, or require maximum stability. Its superior strength and elastic recovery help prevent load shifting during transit.
If you’re unsure which stretch film is best for your operation, the team at KB Packaging is always happy to advise.
At KB Packaging, we supply a wide range of cast and blown stretch wrap solutions to suit businesses of all sizes. Our pallet wrap is available in various widths, thicknesses, and roll lengths, along with dispensers and stretch-wrapping accessories to improve efficiency and reduce waste.
For expert advice or to discuss your pallet wrap requirements, get in touch with KB Packaging today and speak to one of our packaging specialists.
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