Exploring Stretch Wrappers: Your Complete Guide

When your shipping operation starts to grow, manual pallet wrapping can quickly become a bottleneck. That's where stretch wrappers offer a smarter way to protect your loads, boost efficiency, and reduce material waste.

Whether you're just getting started with automation or upgrading your current setup, this guide will help you understand your options, key features to look for, and how to find the right solution for your business.

Stretch wrappers are machines designed to tightly secure pallet loads with stretch film, stabilizing goods for shipment and storage. They're used across industries to cut down on labor costs, improve load consistency, and minimize product damage in transit.

It's not just about wrapping faster it's about wrapping smarter. Ineffective stretch wrapping is a major driver of product damage during shipping. Stretch wrappers deliver consistent containment force that manual wrapping can't match, helping reduce film waste, prevent product shifting, and protect against warehouse and transit damage.

Stretch wrapping systems vary widely from handheld tools for low-volume operations to fully automated machines that integrate with conveyor lines. Understanding the basic categories can help you find the best fit for your production needs.

The most common type of stretch wrapping machine is the turntable stretch wrapper. This style of wrapper has a turntable that rotates a product as the stretch film is wrapped around it. Available in manual, semi-automatic, and fully automatic operation types.

Manual stretch tools assist with hand-wrapping by holding the roll and applying tension. They’re an affordable step up from traditional hand wrapping but can still be time-consuming. Manual turntable tops are also available where the load turns, but the operator still has to do the wrapping.

• Best for: Small operations wrapping fewer than 10 pallets a day.
• Load types: Stable, lightweight loads that don’t require heavy containment force.
• Typical use: Startups, occasional shippers, companies testing new product lines.
• Space needs: Minimal with portable dispensers or at least 8’x8’ space for a manual turntable top. 
• Throughput: Operator-limited; slower and less consistent.

Popular models: Highlight Synergy .5, Encore Dispensers, Highlight Predator Turntable Top

Semi-automatic wrappers automate parts of the process like rotating the pallet, but operators still place and cut the film. They're a popular entry point for small to mid-size businesses.

• Best for: Growing operations needing better consistency without a huge capital investment.
• Load types: Most standard pallet loads under 5,000 lbs.
• Typical use: Warehouses, distribution centers, manufacturers shipping 10–50 pallets per day.
• Space needs: Requires floor space of at least 8'x8'.
• Throughput: 20–30 loads per hour depending on model and operator efficiency.

Popular models: Eagle 1000B, Robopac Ecoplat, Cousins 2100-SRT, Handle It 800, Lantech Q300, Fox FPS 300

Automatic wrappers do it all — attaching film, wrapping, cutting, and sealing — often with minimal or no operator involvement. Ideal for companies shipping high volumes daily.

• Best for: High-volume shippers where speed, labor savings, and consistency are critical.
• Load types: Heavy, light, unstable, or irregular loads.
• Typical use: Large manufacturers, 3PLs, national distribution hubs.
• Space needs: Requires integration with conveyors; larger footprint.
• Throughput: 30+ loads per hour with minimal operator input.

Popular models: Cousins LP-3200, Eagle 2000F, Handle It 1100AA-C, Fox FPS 400, Robopac LT

Robotic stretch wrappers are mobile machines that drive around the pallet to apply film, offering flexible, space-saving wrapping for a wide range of load types.

• Best for: Facilities with limited space, multiple wrapping areas, or oversized loads that can’t be rotated or easily moved.
• Load types: Irregular, heavy, or unstable loads — including extra-wide pallets or products that are difficult to place on a turntable.
• Typical use: Warehouses, manufacturers, and distribution centers, especially those needing flexibility without permanent equipment placement.
• Space needs: Minimal — the machine travels around the load, so there’s no need for a fixed footprint or bolted-down equipment.
• Throughput: Typically 20 - 30 loads per hour, but varies based on operator speed and wrap settings.

Popular models: Robopac S7, Handle It 3000, Cousins Traveler, Combi BeeWrap

The wrapper’s arm rotates around a stationary pallet, perfect for heavy, unstable, or lightweight loads that shouldn't spin.

• Best for: Heavy, unstable, or lightweight loads that shouldn’t spin.
• Applications: Building materials (brick, roofing), fragile goods, lightweight cases.
• Considerations: More expensive than turntables but safer for unstable loads; faster cycle times.

Popular models: Robopac Masterplat HD XL, Cousins 4100T FSR, Handle It 2200, Lantech S300

These specialized machines wrap loads horizontally which is ideal for long products like pipes, lumber, doors, and windows.

• Best for: Long, narrow products that can’t be stacked on a pallet.
• Applications: Lumber, piping, doors, windows, textiles.
• Considerations: Specialized use; not for standard pallet loads.

Popular models: Robopac Compacta, Signode Yellow Jacket, TAB Wrapper Tornado, Handle It FA-200

Instead of wrapping around a load, stretch hooders pull a stretchable hood over the pallet for a tight, waterproof seal.

• Best for: Companies needing UV or moisture protection without excess material use.
• Applications: Fertilizer, building products, outdoor storage items. Loads that require a strong protective film.
• Throughput: High-volume packing of 50+ loads per hour.
• Considerations: Highest upfront cost but offers the tightest seal and best weather protection.

Popular models: Signode Power Flex, Signode Multi Flex, MSK Wraptech, Handle It SH-Core

Understanding the key advantages of implementing a stretch wrapper can help maximize your investment.

Basic Machine Components

• Film Delivery System: Controls how film is stretched and applied. It includes the pre-stretch mechanism, film rollers, and motors.
• Film Carriage: Stretches and dispenses the film with consistent tension. It moves up and down the load during the wrapping process.
• Turntable or Rotary Arm: Rotates the load or moves the film around it.
• Control Panel: Set program wrap cycles, tension, and film usage.
• Load Height Sensor: Automatically detect pallet height and load presence. (A photo-eye uses a beam that bounces off the pallet back to the photo-eye for detection. A laser-eye uses a simple laser beam that does not require refraction.)

Benefits of Using a Stretch Wrapper

• Better load stability
• Reduced film usage and waste
• Lower labor costs
• Faster throughput
• Improved operator safety and ergonomics

Finding the right fit starts with knowing your production needs and future goals.

Main Factors to Consider

• Number of pallets wrapped per day
• Load weight, size, and stability
• Available floor space
• Desired level of automation
• Options and add-ons (cold packaging, scale, load sensor type, roping, etc)

Questions to Answer

When working with a supplier, you will most likely need to answer the following questions to determine which machine is best matched to handle your stretch wrapping needs.

• What type of products or loads are you wrapping?
• What is the length and width of your pallets?
• What is the diagonal length of your loads?
• What is the average height of your loads?
• What is the average weight of your loads? How much do your lightest and heaviest weigh?
• How many loads per hour and per day do you currently wrap?
• How are you wrapping your loads now and how many people does the process require?
• Do you need to be able to weigh your loads for quality or shipping reasons?
• Do your products overhang off the pallet, have partial layers, or have any other additional qualities that must be considered?

Not sure how to calculate your diagonal pallet size? Use our calculator below!

Each industry faces its own unique shipping challenges — and stretch wrapping solutions can be tailored to match. Some machines are purpose-built for specific applications, like windows and doors, round products like tires, or food and beverage. Others can be customized with sensors, conveyors, and wrap settings to meet unique requirements. Read our article in Packaging World to see how we helped a Wisconsin beverage distributor source and install a custom automated pallet wrapping solution.

Stretch wrapping technology keeps evolving making packaging operations smarter and greener. Newer wrappers use energy-saving motors and optimize film usage, helping lower overall operating costs. Robotic arms are being added to fully automated wrappers to reduce the need for an operator. Many machines now come standard or offer an IoT-enabled option for remote monitoring, performance tracking, and predictive maintenance alerts.

Stretch wrappers range from a few thousand dollars to six figures depending on automation, film carriage type, and specialty features. A semi-automatic machine can often pay for itself within a year through film savings and labor reduction.

According to Robopac, if you’re wrapping 50 loads per day, changing from hand wrapping with 10% pre-stretch to using a machine with 250% pre-stretch can save $30,000 or more over five years in just film savings. That’s not even including the savings from labor and damage.

Once you’ve figured out your machine specifications and budget, you’ll need to choose a supplier. Always look for a vendor that provides warranty information, sells quality equipment, and after-sales support such as installation, tech service, and wear parts.

At Rocket Industrial, we work side-by-side with businesses to match the right machine to their needs — whether you’re wrapping 10 pallets a day or scaling up to 500. Our service team records the machine’s serial number in our system to track the manufacturer's warranty, offers additional warranties, keeps parts on hand, and can help with installation or future service needs.

An investment in automation today can mean major savings down the line.

Even if you're only wrapping 10 loads per day, a stretch wrapper can quickly pay for itself. Hand wrapping is not only time-consuming — it leads to inconsistent containment force, more film waste, and a higher risk of product damage.

Most machine stretch wrappers can pre-stretch film by up to 250%, compared to less than 40% with hand wrapping. That means using less material, achieving stronger and more consistent load containment, and reducing the chance of damaged shipments.

Watch a packaging engineer do a time comparison of hand wrapping vs. machine wrapping in our lab in the video below.

Film Savings: Machine-stretched film can reduce film usage by 30–50% compared to manual wrapping. Pre-stretch systems stretch the film 200–300%, getting 2–3 times more pallet wraps out of the same roll.

Labor Reductions: Manual wrapping can take 2–5 minutes per pallet, while a semi-automatic wrapper can cut that to under one minute. Freeing up workers from wrapping allows for reallocation to higher-value tasks.

Damage Reduction: Poorly wrapped pallets are a leading cause of load damage and claims. Studies show proper stretch wrapping could prevent up to 50% of transport damage. Reducing in-transit damage not only cuts direct product loss but also protects brand reputation and reduces claims processing costs.

On average, we see businesses achieve payback on a semi-automatic stretch wrapper within 9 to 18 months, and automatic stretch wrappers within 12 to 24 months. Of course, actual payback timelines vary based on factors like daily pallet volume, labor rates, film usage, and the level of automation.

Looking at demo or used equipment, reviewing leasing options, and taking advantage of payment terms or Section 179 tax deductions can help speed up return on investment even further.

Operator training and machine safety are key to a safe, productive environment, while preventative care will keep your wrapper running smoothly.

Operator and Workplace Safety: Features like soft start/stop turntables and load sensors help prevent injuries. Properly wrapped pallets reduce the risk of collapsed loads and warehouse accidents.

Common Issues: If you’re dealing with film breaks, load shifting, or mechanical hiccups, the culprit is often something simple: incorrect film tension, a misaligned sensor, or a worn-out roller.

Regular Maintenance Practices: Keeping your machine in top shape doesn’t have to be complicated — just consistent. Here’s a recommended schedule:

Daily:

• Perform a visual safety inspection
• Ensure the operating area is clean and free of debris

Monthly:

• Check the operation of safety stops and control devices
• Inspect that the load height sensor is centered and functioning
• Inspect the power cable for wear or damage

Quarterly:

• Grease and lubricate the rack and pinion and the drive chain
• Inspect rollers for wear and replace if needed

Always follow any additional maintenance instructions provided in your machine’s manual. We also recommend keeping common wear parts on hand, such as rollers and belts, so you’re not caught off guard by unplanned downtime.

Stretch wrappers and stretch film go hand in hand — and the right film choice makes a big difference. Achieving the right containment force keeps loads from shifting — too little, and the load can collapse; too much, and you risk crushing products.

Consider the type of goods you are wrapping and the temperature at which they will be stored or transported. Factors include load weight, type, shipping method, and environmental exposure. The film’s thickness also matters as it affects the load's stability and protection levels. 

Always make sure you’re using machine stretch film with your machine. Machine-grade films are stronger and designed to work with pre-stretch systems, delivering more wraps per roll. They are available in various performance styles from standard to ultra performance. The higher performance films are engineered to provide better stretch and puncture resistance.

Specialty stretch films are also available such as UV-protected, color-coded, or vented films which may be required for certain products’ safety.

Pro buyer tip – Always calculate the cost per load when buying stretch wrap, not the cost per roll. Cheaper stretch films may seem like a good deal, but they often require more film per pallet.

Finding the right stretch wrapper means matching machine capabilities to your goals today and setting yourself up for growth tomorrow. From manual turntables to fully automated custom machines, there’s a stretch wrapping solution that fits your production needs, space, and budget.

At Rocket Industrial, we don’t just sell machines — we partner with you to find the smartest, most cost-effective solution. Ready to get started? Contact us today.