The stretch film break can cause significant frustration. The purpose of stretch film is to protect loads of products. If this film breaks, not only there will be an irritating delay in the product delivery, but you will also have to experience a host of larger production problems. However, it doesn’t have to be that way.

In this article, we will discuss the top two reasons why stretch film breaks. We will also discuss how to prevent these instances.

Reasons number 1: Load

Most instances of stretch film break happen due to load profile hazards. Anything that punctures or stresses the film, such as protrusions and sharp edges, can result in it breaking. You will need to check for cuts, nicks, and resin buildups on the contact surfaces to avoid this risk.

One of the best solutions to consider in this regard is to lower the film tension or pre-stretch level. However, finding balance is pivotal here. While setting tension, make sure that it is set at the highest possible level without making the film break or crush the load. Remember, lowering the tension will work only when you add more film layers.

Reason number 2: Wrong Settings

Regardless of the stretch wrap machine or the set-up of your warehouse, taking care of the standard settings can help reduce the risk of in-transit damage. For instance, lack of proper containment force or dragging film tails are the most irritating errors in a stretch wrapping operation. These errors can result in in-transit product damage.

You have to make sure to thread the stretch film properly in the stretch wrapping equipment. Also, make sure that the film you use is ideal for your stretch wrapping applications. Another factor to consider here is the film tension. If you have an automatic stretch wrapping machine in the packaging warehouse, make sure to check the film clamp for nicks or cuts on the contact surfaces. As for the vacuum clamps, be sure to check the air pressure.

Most common film flaws

• A straight line break is the ultimate film break. It usually occurs when you stretch a film beyond its limit.
• The resin imperfection or other manufacturing faults can result in stretch wrap film developing a V-shaped break.
• Some nicks and flaws in the film edge can result in a diagonal tear through the film. It is also one of the most common issues that packaging personnel experience.

How to prevent stretch wrap failure

If you want to determine how to prevent the film from breaking, it is crucial to have a packaging partner on your side. That partner must understand the science related to plastic. That packaging vendor will help you configure the stretch wrapping machinery in the most ideal way. He will also tell you about the film thickness and the amount of tension you need to apply. These tips will help you ensure equal containment forces across all areas of the film to prevent its breakage.