Why Stretch Film Tears on Sharp Carton Corners

Quick answer

Stretch film tears on sharp carton corners when local puncture stress exceeds film strength at the applied stretch. Raising wrap turns without fixing corners or stretch settings often creates more breaks, not better containment.

Inspect where film fails

Note tears at top corners, strap paths, overhanging cartons, or under the turntable clamp. Photograph the load before re-wrapping hides the cause.

Check stretch and gauge

Excess pre-stretch on thin film thins the web at corners. Confirm actual machine stretch versus the assumed setting and whether the film grade is meant for that stretch window.

Reduce sharp geometry

Add edge boards, rearrange overhang, or use a top frame. Sharp print cartons and rigid-box corners are common tear initiators on export pallets.

Adjust wrap pattern

More film on already-torn corners does not help if the first layer is cut. Use a pattern that builds containment without over-stressing the first contact points.

Validate one change set

Trial protector + stretch window + pattern together, then ship a monitored lot. Avoid changing film brand, stretch, and pallet pattern in one uncontrolled experiment.

RFQ

Tear photos; film grade; machine stretch setting

Load geometry; corner-board proposal

Wrap pattern; containment target

Trial quantity; acceptance photos

Related PackTrades Knowledge

What Is Pre-Stretch in Stretch Film Wrapping?, Export Pallet Stretch-Wrap Spec Checklist, How to Choose Stretch Film Gauge for Pallet Stability, Edge Board Specs for Furniture and Appliance Export.