Stretch Film vs Paper Wrapping
Wrapping pallets with paper works differently than traditional wrapping with stretch film, because paper has different physical properties, such as lower elasticity and increased rigidity.
As a result, the wrapping technique and packaging machine solution required are also different in order to ensure the stability and protection of the pallet. Note: this is not comparable to stretch film.
- How paper wrapping works
Paper wrapping machines typically use a combination of mechanical fastening and often an adhesive system to securely attach and connect the wrapping paper, as paper does not have the “cling” layer like stretch film that adheres to the underlying film layer. Additionally, it does not have the high stretchability and memory recovery of stretch film. Wrapping a pallet with paper (like stretch film) is done in layers and requires multiple wraps to create a stable and secure enclosure.
- Specific wrapping machines for paper
Paper wrapping requires specially designed pallet wrappers, as traditional film wrapping machines are not suitable for this purpose:
Paper wrapping machines have an advanced system to regulate roll tension, ensuring the paper does not tear during wrapping.
The wrappers used for this purpose feature a heated adhesive applicator or a mechanical clamp to secure the paper at the start and end of the wrap.
Fully automatic pallet wrappers are equipped with automated cutting and sealing mechanisms, which require more maintenance and adjustments due to their finer setup.
- Type and thickness of paper
Type of paper: For pallet wrapping, KraftLiner or recycled testliner paper is used. Kraft paper is particularly suitable due to its strength, tear resistance, and relative durability.
Paper thickness: The thickness typically ranges from 80 to 120 grams per square meter (g/m²). Thicker paper may be necessary for heavy loads, while lighter loads can use thinner paper. The amount of paper used depends on the load and the intended pallet stability.
- Use of adhesive
Adhesive application: When wrapping with paper, adhesive can be used to bond the layers together and stabilize the load, preventing the paper from coming loose during transport. A biodegradable adhesive is often used, which is environmentally safe and easily breaks down without leaving residue.
Adhesive is applied at the beginning, during, and at the end of the wrap to secure the paper and prevent movement.
- How much paper for a Euro pallet
To wrap an average pallet measuring 1200 mm long, 800 mm wide, and 1500 mm high, the paper usage depends on the number of wraps, the thickness of the paper, and the type of product being wrapped. Below is a calculation:
Number of wraps: At least 3-5 wraps of paper are needed for stable wrapping, depending on the desired stability of the product on the pallet.
Paper weight per wrap: For a paper thickness of 100 g/m² and a circumference of 4 meters, approximately 400 grams is needed per layer.
Total paper usage: For 3-5 (or more) layers, the total paper weight per pallet is approximately 1.8 to 3 kg.
Total paper surface per wrap:
For a single wrap around the entire height (1500 mm), we use approximately 4 meters × 1.5 meters = 6 m² of paper.
Paper weight per wrap:
At a paper thickness of 100 g/m², a single wrap uses 600 grams of paper (6 m² × 100 g/m²).
Total paper weight per pallet:
With 3 to 5 wraps to ensure sufficient strength, the total weight of paper per pallet is approximately:
3 layers: 3 × 600 grams = 1.8 kg
5 layers: 5 × 600 grams = 3 kg
Summary
For a pallet of 1200 x 800 x 1500 mm, wrapping with paper requires:
Between 1.8 and 3 kg of paper, depending on the number of layers.
For heavy and bulky loads, 5 layers are generally recommended, while lighter loads may achieve sufficient stability with 3 layers.
These calculations give you an idea of the amount of material needed to securely and firmly wrap a larger pallet with paper.
Conclusion
Is paper wrapping really sustainable?
Wrapping with paper requires specialized equipment and depends on the paper’s thickness and type, as well as the use of adhesive to ensure stability. The paper usage typically ranges from 1.8 to 3 kg per pallet, depending on the required strength and number of layers.
The claim that paper wrapping has a 62% lower environmental footprint compared to stretch film is based on a life cycle analysis (LCA) – this type of analysis examines the environmental impact of both materials over their entire life cycle, from raw material extraction to production, use, and final disposal. It assumes that twice as much paper is used as stretch film, significantly changing the environmental impact.
Material use:
A considerable amount of wrapping paper is required to match the effectiveness of stretch film—5-10 times more—negating the environmental benefits of the claimed lower ecological footprint.
Durability and performance:
Wrapping paper lacks the durability and recovery capability of stretch film, making it less effective at holding goods together on pallets. This can lead to more damage during handling, storage, and transport, resulting in additional costs and increasing the environmental impact—a factor often overlooked in LCAs.
Environmental considerations:
While using double the amount of wrapping paper reduces the ecological footprint by 62%, using 5-10 times more paper can result in a CO2 footprint 88% to 338% higher than that of stretch film.
Although paper wrapping may initially seem more environmentally friendly, the need for much larger quantities and the increased risk of damage often make it less sustainable and more expensive than stretch film.
