How to Calculate Stretch Film Cost per Accepted Pallet

A lower roll price does not necessarily produce a lower stretch film cost per pallet. Roll quantity, the wrapping recipe, film breaks and rejected wraps all affect how much purchased material becomes an acceptable load. A useful comparison connects the invoice to measured consumption, then separates material cost from the wider cost of operating the wrapping station.

Set the comparison boundary first

Compare like-for-like load groups: the same pallet footprint, approximate height, product arrangement and acceptance requirements. Keep an irregular mixed pallet separate from a uniform carton load. Otherwise, a change in the product mix can look like a change in film performance.

Define an accepted pallet before the trial begins. It should meet your established wrapping and load-security checks. Count each unique accepted pallet once, even if it passes through the wrapper twice. Keep failed or unfinished loads in the trial record so their material consumption does not disappear.

Convert the purchase price to a usable basis

Film price per kilogram = comparable delivered roll cost ÷ verified net film kilograms per roll.

Use the same currency and purchasing basis for both candidates. State whether allocated freight and import charges are included and apply the treatment consistently. Exclude paper cores and outer packaging from the film mass. If roll quantities are unclear, the existing guide to net film weight and core weight explains that separate purchasing issue.

A price per metre can also be useful when the supplied length is verified. Do not mix unstretched supplied length with the longer length after stretching on a wrapper. For different grades, measuring actual consumption often gives a more useful purchasing comparison than estimating yield from a nominal stretch percentage.

Measure consumption across a defined run

1. Identify the film grade, batch, wrapper, operator or shift, load group and approved recipe.
2. Weigh the roll before and after a recorded run using a suitable scale and consistent method.
3. Record roll changes, discarded material, broken-film restarts and rewrapping.
4. Count the unique pallets that pass the agreed checks, and retain the rejected-load count.
5. Repeat enough representative runs to see whether the result is consistent.

The difference between start and finish weights on the same roll measures material removed from that roll. It already includes film later discarded during that run. Do not add that scrap mass again. If you use a different method that weighs only film recovered from completed pallets, account for waste separately.

When several rolls are used, track each roll's consumption rather than subtracting the first starting weight from the final roll's ending weight. Weighing controls and a simple roll log prevent a busy shift from creating a misleading result.

Calculate material cost per accepted pallet

Material cost per accepted pallet = total film kilograms consumed × film price per kilogram ÷ unique accepted pallets.

Keep the mass and price units consistent. Also retain film consumption per accepted pallet as a separate result; it helps distinguish a purchase-price change from a process change. Compare the wrap condition and failure record alongside the cost figure.

Add operating costs without double counting

Film cost is only one part of wrapping cost. Record operator time for roll changes, restarts and rework, then apply your actual labour cost on a consistent basis. Separate that from measured equipment or production losses; avoid charging the same stopped minute twice under different headings.

Do not improve the spreadsheet by weakening the wrapping recipe. Pre-stretch and wrap force have different roles, and a higher pre-stretch setting does not automatically produce a better result. Trials of machine stretch film should preserve the load's acceptance requirements while checking consumption.

Keep a one-page comparison showing the film specification, price basis, measured mass, accepted pallets, rework and approved settings. When requesting a replacement grade, share that wrapping-cost record with your enquiry. A supplier can then respond to the actual operating problem, and purchasing can compare the cost of achieving the same result.

How do I calculate cost per pallet wrapped?
Measure total film consumed during a representative run and divide by the number of unique accepted pallets. Film cost per accepted pallet = total film consumed (kg) × price per kg of net film ÷ unique accepted pallets. Use consistent specifications and purchasing terms when comparing quotations.

How much film does a pallet wrapper use?
Consumption depends on the load, wrapping pattern and machine settings. Weigh each roll before and after a trial, including material consumed by failed wraps. For a spreadsheet-based stretch film consumption calculator, record film weight reduction, net film price and accepted pallet count. Roll weight reduction already includes discarded film from that roll; do not add it twice. This calculates film cost only.