Stretch Film Gauge Chart: Complete Guide to Thickness, Mil and Micron

Choosing the right stretch film thickness is essential for effective pallet wrapping, load stability, and packaging cost control.

However, stretch film thickness is measured differently across international markets. In the United States, buyers commonly use Gauge and Mil, while manufacturers and packaging professionals in many other markets generally use Micron (μm).

Understanding these measurements helps businesses compare product specifications, evaluate different manufacturers, and select the right stretch film for their packaging applications.

In this guide, VISENPACK explains stretch film thickness measurements, provides a practical gauge conversion chart, and discusses how to choose the appropriate film thickness for different packaging requirements.

1. What Is Stretch Film Gauge?

Gauge is a traditional unit used to describe the thickness of plastic film, including stretch film.

It is particularly common in the United States packaging industry.

A higher gauge number indicates a thicker film.

• 60 Gauge is thinner than 80 Gauge.
• 80 Gauge is thinner than 100 Gauge.
• 100 Gauge is thinner than 120 Gauge.

For example, 80 Gauge stretch film is approximately 20.32 microns thick.

Although gauge is widely used in the United States, it is important to understand how it converts into microns when comparing international product specifications.

2. Stretch Film Gauge to Micron Conversion Chart

One of the most useful conversions for stretch film buyers is:

1 Gauge = 0.254 Microns

The following chart shows commonly referenced stretch film thickness conversions.

These figures are mathematical conversions based on standard unit relationships. Actual stretch film thickness should be confirmed through product specifications and appropriate measurement methods.

3. What Is the Difference Between Gauge, Mil and Micron?

Gauge, Mil and Micron all describe film thickness, but they use different measurement scales.

Gauge

Gauge is commonly used in the United States packaging market. A higher gauge number represents a thicker film.

For example, 80 Gauge stretch film corresponds to 20.32 microns.

Mil

Mil is another thickness measurement used in the United States. One Mil equals one-thousandth of an inch.

• 0.8 Mil = 20.32 μm
• 1.0 Mil = 25.4 μm
• 1.2 Mil = 30.48 μm

Micron

A micron, also known as a micrometer, is one-millionth of a meter.

Microns are widely used in international packaging specifications and are convenient for communicating exact stretch film thickness requirements.

4. How to Calculate Stretch Film Thickness

You can use the following formulas to convert between different thickness units.

Gauge to Micron:

Micron = Gauge × 0.254

Micron to Gauge:

Gauge = Micron ÷ 0.254

Mil to Micron:

Micron = Mil × 25.4

Micron to Mil:

Mil = Micron ÷ 25.4

For example, if a buyer requires 23-micron stretch film:

23 ÷ 0.254 = 90.55 Gauge

Therefore, 23-micron stretch film is approximately 90.55 Gauge, commonly rounded to 91 Gauge.

This conversion is useful when comparing specifications from American distributors and international manufacturers.

5. What Stretch Film Thickness Is Commonly Used?

The appropriate stretch film thickness depends on the application, load characteristics, wrapping equipment and required packaging performance.

The following ranges are indicative examples rather than universal industry standards.

Actual requirements vary according to film formulation, pre-stretch capability, load weight, pallet geometry and wrapping conditions.

A thicker film is not automatically better. A properly engineered thinner film may provide sufficient load containment while reducing material consumption.

6. Does Thicker Stretch Film Always Mean Better Performance?

Not necessarily. Film thickness is only one factor affecting stretch film performance.

Other important properties should also be considered when evaluating stretch film quality.

Tensile Strength

Tensile strength describes the film's resistance to pulling forces during stretching and application.

Puncture Resistance

Puncture resistance determines how well the film withstands sharp edges, corners and protruding products.

Elongation

Elongation describes how much the film can stretch before breaking. It is an important property for both hand and machine stretch film.

Holding Force

Holding force helps maintain tension around a pallet load during transportation and storage.

Cling Performance

Cling helps adjacent layers of stretch film adhere to each other and maintain a secure wrap.

For this reason, buyers should evaluate overall film performance rather than selecting products based on thickness alone.

7. How to Choose the Right Stretch Film Gauge

Choosing the right stretch film thickness requires more than comparing micron values. Buyers should consider the actual packaging conditions.

1. Load Weight

Heavier pallet loads may require stronger film performance and appropriate wrapping tension.

2. Product Shape

Products with sharp corners, irregular shapes or protruding edges may require better puncture resistance.

3. Wrapping Method

Hand stretch film and machine stretch film have different application requirements. Machine wrapping also depends on equipment settings and pre-stretch capability.

4. Transportation Conditions

Long-distance transportation, frequent handling, warehouse storage and environmental conditions can influence packaging requirements.

5. Cost Per Pallet

Instead of comparing only the price per roll, calculate how much film is consumed per pallet. This provides a more meaningful comparison of total packaging costs.

6. Film Performance Testing

When changing film thickness or specifications, test the product under actual wrapping conditions.

Evaluate load stability, film breaks, wrapping consistency and material consumption before making a final decision.

8. How Can Buyers Compare Stretch Film Specifications?

When requesting quotations from different stretch film manufacturers, buyers should provide consistent product specifications.

Important details include:

• Film width
• Film thickness in microns
• Film length
• Net film weight
• Core weight, if applicable
• Film type
• Application method
• Required color
• Packaging requirements

For example, a buyer may specify the following requirements:

Providing these details makes it easier to compare quotations and avoid misunderstandings between buyers and manufacturers.

For manual pallet-wrapping applications, explore our Hand Stretch Film page for product details and customizable width, thickness, and roll-length options.

9. Frequently Asked Questions

What is 80 Gauge stretch film in microns?

80 Gauge stretch film is approximately 20.32 microns thick.

What is 100 Gauge stretch film in microns?

100 Gauge stretch film equals 25.4 microns, or 1 Mil.

Is 90 Gauge stretch film the same as 23 microns?

Not exactly. 90 Gauge equals 22.86 microns, while 23 microns is approximately 90.55 Gauge.

Is 80 Gauge stretch film thicker than 100 Gauge?

No. 100 Gauge is thicker than 80 Gauge.

Which is better, thicker or thinner stretch film?

Neither is automatically better. The right choice depends on load characteristics, wrapping conditions, film performance and total packaging cost.

Should buyers use Gauge or Micron when ordering stretch film?

Both can be used, but specifying thickness in microns is generally convenient for international purchasing. US buyers may also specify gauge.

10. Work with a Stretch Film Manufacturer

Understanding stretch film thickness is an important step in selecting the right packaging material.

However, the best specification is not necessarily the thickest film. It is the film that provides the required load stability, wrapping performance and cost efficiency for your application.

VISENPACK focuses on stretch film manufacturing and offers different film formats for industrial packaging requirements.

Our product range includes:

• Hand Stretch Film
• Machine Stretch Film
• Mini Stretch Film
• Pre-Stretched Film
• Colored Stretch Film
• Coreless Stretch Film
• Stretch Film Jumbo Rolls

We offer customizable film specifications to meet different packaging applications.

If you are evaluating stretch film specifications or looking for an additional manufacturing partner, contact VISENPACK to discuss your requirements.

VISENPACK | Your Stretch Film Solutions Partner

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