In U.S. supply chains, pallet stability is not optional — it is a core requirement for safe, efficient, and damage-free logistics. Yet over $5 billion of goods are lost annually due to pallet load failures. The surprising truth is that most failures come from preventable issues such as incorrect stretch film usage, inconsistent wrapping patterns, weak pallets, or simple operator mistakes.

At TP Plastic USA, we supply stretch film to warehouses, fulfillment centers, eCommerce distributors, and exporters across California, Texas, Illinois, Florida, and major logistics hubs. Through thousands of customer interactions, we’ve identified the 7 most common reasons pallets fail — and how to solve each one using better materials, better wrapping technique, and better load containment planning.

This is the complete guide.

1. Cause #1 — Incorrect or Inconsistent Tension When Wrapping

No factor affects pallet stability more than tension, because tension activates the stretch film’s:

• Holding force

• Memory (recovery)

• Containment strength

• Ability to lock the load into place

Why Pallets Fail When Tension Is Too Low

• The film isn’t properly stretched

• Holding force is weak

• Boxes shift during forklift handling

• Pallet leans during truck vibration

• Layers separate due to lack of downward force

Why Pallets Fail When Tension Is Too High

• Stretch film snaps or tears

• Corners puncture the film

• Upper layers collapse due to compression

• Film loses elasticity and can’t recover

Human Factor:

Hand wrapping creates massive inconsistency because every worker pulls with different strength, tone, speed, and angles.

Solution

• Machine wrap → consistent pre-stretch, correct tension

• High-quality LLDPE stretch film → predictable stretch range

• Training for hand-wrap operators → proper angle + pulling technique

• Use power-prestretch films for high-volume warehouses

TP Plastic USA produces both hand-grade and machine-grade films engineered for accurate, repeatable tension performance across different load types.

2. Cause #2 — Choosing Low-Quality or Incorrect Stretch Film Grade

Even if wrapping technique is perfect, film choice can make or break a pallet.

Common Film Quality Failures

• Inconsistent thickness (gauge variation)

• Poor resin blend → weak mechanical properties

• Low puncture resistance → tears on corners

• Poor cling → layers slide apart

• Low recovery force → film relaxes over time

• Film has no memory → pallet shifts after 24–48 hours

These flaws are normal in cheap, generic, or downgraded films that rely on mixed or recycled materials without proper quality control.

Film Must Match the Load Type

• Heavy loads → high puncture, higher gauge

• Light loads → downgauged film is more efficient

• Tall loads → high memory film

• Uneven loads → tough, multi-layer film

TP Plastic USA uses controlled LLDPE/LDPE layer structures for consistent performance across heavy, mixed, and export pallets.

3. Cause #3 — Wrong Wrapping Pattern or Poor Application Technique

A pallet wrapped incorrectly is a collapsing pallet waiting to happen — even with premium film.

7 Common Wrapping Mistakes

1. Not securing film to pallet base

2. Only wrapping the load, not the pallet

3. Too few bottom wraps (no anchor)

4. No reinforcement in the middle “shift zones”

5. Wrapping too tight at top and too loose at bottom

6. Poor overlap between layers

7. No top wrap to lock the upper layers

Each mistake reduces the holding force by as much as 40%.

What a Proper Wrapping Pattern Looks Like

• Start with 2–4 tight bottom wraps

• Apply upward spiral with 50% overlap

• Reinforce middle layers (2–3 extra wraps)

• Add 1–2 secure top wraps

• Ensure consistent film tension throughout

Correct wrapping can dramatically reduce film usage while strengthening the pallet.

4. Cause #4 — Poor Pallet Building and Improper Load Stacking

Even the best stretch film cannot fix a badly built pallet.

Common Pallet Building Errors

• Mixing many box sizes

• Gaps between cartons

• Heavy boxes on top of light boxes

• Weak boxes forming the base

• Overhanging boxes beyond the pallet edge

• Leaning layers or tilted carton rows

Each of these increases the load shift risk significantly.

Proper Pallet Building Principles

• Heaviest items always at the bottom

• Largest, most stable boxes form the foundation

• Align boxes flush with pallet edges (no overhang)

• Minimal gaps

• Maintain a square, column-stacked shape

• Use slip sheets when needed

When the pallet itself is stable, the film only needs to maintain—not fix—the load.

5. Cause #5 — Weak, Broken, or Low-Quality Pallets

The base determines everything.

Pallet Defects That Cause Collapse

• Broken or cracked deck boards

• Loose nails or missing boards

• Rotten wood

• Too much flex in the pallet surface

• Significant gaps

• Unbalanced weight distribution

Impact on Stretch Film Performance

A weak pallet:

• Causes load sway

• Bends under weight

• Makes bottom layers unstable

• Creates uneven film tension

• Leads to faster pallet collapse during vibration

Prevention

• Inspect pallets before use

• Use export-quality pallets for shipping

• Avoid damaged pallets even for domestic shipments

• Replace pallets that flex too much under load

Many companies lose thousands simply because the pallet itself fails — not the film.

6. Cause #6 — Load Not Properly Anchored to the Pallet

If the load is not physically connected to the pallet, it can slide off even if wrapped properly.

How Loads Become “Disconnected”:

• Bottom wraps too weak

• Film not wrapped around pallet deck

• No downward tension to lock the load

• Film starts wrapping too high

As a result:

• Load slides sideways

• Pallet tilts or collapses

• Entire shipment can fall off inside the truck

Prevention

• Wrap the pallet base tightly at least 2–3 times

• For machine wraps → lock the film under the pallet lip

• Maintain downward tension during bottom wraps

• Ensure the first layer is anchored before moving upward

Anchoring is one of the most critical—but most overlooked—steps in load containment.

7. Cause #7 — Environmental Stress: Heat, Cold, Humidity, and Vibration

Stretch film is a performance material, and environmental conditions affect it.

Heat

• Film relaxes

• Memory weakens

• Boxes lose rigidity

Cold

• Film becomes brittle

• Risk of snapping

• Reduced elongation

Humidity

• Cartons lose compression strength

• Entire pallet weakens

• Film stretch behavior changes

Vibration

Long-haul trucking, container shipping, and rail transport introduce:

• Micro-shifting

• “Oscillation stress”

• Lateral movement

• Pressure creep

These all attack the weakest point—whether that’s film, pallet, or carton.

Prevention

• Use temperature-stable LLDPE formulas

• Reinforce top and middle zones

• Avoid over-stretching in cold environments

• Use higher cling in hot climates

TP Plastic USA films are engineered with stable recovery force across temperature ranges common in U.S. trucking, export containers, and warehouse storage.

Bonus Section: The Real Cost of Pallet Load Failure

A single pallet failure can cost:

• $200–$2,500 in damaged goods

• Hours of labor to rewrap

• Customer dissatisfaction or shipment rejection

• OSHA safety incidents

• Delays in the entire warehouse line

This is why investing in high-quality stretch film and proper wrapping technique produces massive long-term savings.

How TP Plastic USA Helps Prevent Pallet Failures

We support distribution centers and warehouses with:

✔ High-performance machine-grade stretch film

• 200–400% stretch

• Multi-layer LLDPE structure

• Superior puncture resistance

✔ Hand-grade stretch film

• Light, strong, comfortable for manual wrapping

• High cling

• Consistent holding force

✔ Technical consultation

We advise on:

• Load type

• Wrapping pattern

• Film grade

• Equipment compatibility

✔ U.S. inventory

Fast delivery from American warehouse stock.

✔ OEM/ODM custom specifications

Micron, width, length, core size, additives, and packaging.

Pallet Failures Are Preventable — With the Right Film and the Right Technique

Pallet load failures are rarely caused by accidents.
They’re caused by:

• Wrong film

• Bad tension

• Poor stacking

• Weak pallets

• Incorrect wrapping patterns

• Environmental stress

• And missed anchoring

With the right stretch film and optimized load containment methods, these failures become extremely rare.

TP Plastic USA stretch films are engineered to protect your warehouse, your products, and your bottom line.