In load containment, puncture resistance is one of the most important mechanical properties of stretch film — yet it’s also one of the least understood. Many warehouses assume film breaks because it’s “too thin,” but in reality, most failures come from weak resin structure, poor film layering, or incorrect tension, not thickness alone.

A pallet does not fail because of one isolated puncture event.
It fails because of puncture → tear → propagation → full film break.

At TP Plastic USA, we engineer multi-layer LLDPE stretch films designed to maximize puncture resistance, control tear direction, and maintain film integrity even under the toughest warehouse conditions.

This is your complete guide to how puncture resistance works — and why it matters.

1. What Is Puncture Resistance?

Puncture resistance is a film’s ability to absorb force without tearing, especially when encountering:

• Sharp carton edges

• Broken pallet boards

• Straps, buckles, and metal corners

• Irregular loads

• Sudden vibration or impact during transport

A film with high puncture resistance does two things well:

(A) Absorbs the impact

It stretches around the object rather than snapping.

(B) Controls tear propagation

If the film is punctured, the tear does not quickly spread.

Both are critical for pallet stability.

2. Why Puncture Resistance Matters More Than Thickness

Many operators assume:
“Thicker film = stronger film.”
But this is outdated and incorrect.

Modern films are engineered with:

• C6/C8 LLDPE resin

• Multi-layer blown or cast structures

• High elongation formulas

• Advanced tear propagation controls

A 17-micron high-performance film can outperform a 23-micron commodity film simply because the resin and layering are more advanced.

Thickness ≠ Strength

Formula + Structure + Resin = Strength

This is why premium downgauged films (12–17 micron) often resist puncture better than old 20–23 micron films.

3. Two Types of Puncture Failures: Dart Impact vs Tear Propagation

(1) Dart Impact Failure

This measures how much force a film can take before breaking when struck with a rounded object.

Used for:

• Some machine-wrapped pallets

• Uniform loads

• Smooth carton surfaces

It’s important, but it doesn’t tell the whole story.

(2) Tear Propagation Failure

This is the real enemy in warehouses.

Once a puncture starts, does the film:

• Hold the tear in place?

• Slow it down?

• Spread the tear rapidly across the film?

A film with poor tear control will fail catastrophically.

Why tear propagation matters:

• Forklift movement causes vibration

• Trucks cause lateral motion

• Export containers add long-duration stress

• Sharp objects keep pressing into the punctured area

In other words:
The initial hole is not what destroys the pallet.
The spreading tear is.

4. What Causes Stretch Film to Tear? (Real Warehouse Examples)

Sharp Corners

Soft cartons, heavy-duty boxes, or stacked edges create pressure points.

Uneven Pallet Surfaces

Broken boards or rough wood pierce the film.

Metal or Plastic Strapping

Straps can cut into film during movement.

Protruding Objects

Tools, rods, barriers, machine parts, etc.

Corner Crumpling

If boxes shift or collapse inward, they create new sharp edges.

High Tension + Poor Film Structure

Overstretching weakens puncture resistance dramatically.

80% of tears we see come from tension misuse + bad pallet building.

5. Resin Quality Is Everything: C4 vs C6 vs C8 LLDPE

C4 LLDPE (lowest performance)

• Basic resin

• Low puncture resistance

• Used in cheap, commodity stretch films

C6 LLDPE (mid-tier performance)

• Better tear resistance

• Suitable for standard machine wrap

• Good for consistent loads

C8 LLDPE (high performance)

• Superior puncture strength

• High elongation & memory

• Best tear control

• Ideal for downgauged high-performance films

TP Plastic USA uses C6 and C8 LLDPE in multi-layer structures for optimized puncture performance.

6. Multi-Layer Film Engineering: Why More Layers = Better Strength

Modern films aren’t one solid sheet — they are multiple engineered layers, each providing different properties:

Typical roles:

• Outer layer: gloss, cling, scratch resistance

• Middle layer: main load-bearing strength

• Core layer(s): tear resistance & puncture strength

• Inner layer: controlled cling for wrapping grip

The number of layers matters less than the resin distribution inside the layers.

This is why two 17-micron films can perform completely differently depending on the engineering.

7. How Stretch Film Actually Fails — The Tear Propagation Sequence

1. Puncture point forms
   (from corner, pallet, impact)

2. Film elongates around the point
   Good film can survive this stage.

3. Molecular bonds at the puncture weaken
   Poor film begins to split.

4. Tear “runs” upward or downward
   This is the dangerous stage.

5. Film snaps under tension
   Load containment is lost.

6. Pallet destabilizes or collapses
   Especially during forklift movement.

A good stretch film stops or slows propagation.

8. How TP Plastic USA Designs Film to Resist Puncture

✔ C6/C8 LLDPE Core Structure

High-performance resins provide superior tear resistance.

✔ Multi-Layer Engineering

Core layers contain tear-resistant blends.

✔ Corner-Resistant Formulation

Designed to handle sharp or inconsistent loads.

✔ Balanced Cling

Prevents sticking that leads to tearing during rotation.

✔ Optimized Puncture Strength for Machine Wrap

Consistent tension = less accidental film break.

✔ High Recovery Force

Allows film to return to position instead of splitting.

✔ Low-Gauge, High-Strength Options

12–17 micron downgauged films outperform older 23 micron products.

TP Plastic USA films are engineered for real warehouse environments — not just lab tests.

9. Real-World Use Cases Where Puncture Resistance Is Critical

1. Beverage pallets

• Heavy

• Sharp corners

• High vibration

• Liquid weight shifts

2. Export pallets

• Long container journeys

• Humidity + heat → carton weakening

• Vibration cycles over weeks

3. Mixed cartons (eCommerce pallets)

• Unpredictable shapes

• Uneven surfaces

4. Building materials

• Sharp edges

• High-density loads

5. Cold storage applications

• Film stiffness increases at low temps

• Puncture strength is harder to maintain

6. Heavy industrial products

• Metal components

• High tension wraps

• Risk of edge impact

10. Puncture Resistance + Proper Wrapping Technique = Maximum Stability

Even the strongest film will struggle if the wrapping technique is wrong.

To maximize puncture resistance:

• Use correct bottom wrap

• Add reinforced mid-zone wraps

• Avoid overstretching (common machine issue)

• Use cross-wrap on unstable loads

• Don’t stretch thin films past their engineered limit

• Choose the right gauge for the right load type

The best performance comes from combining:

☑ High-quality film
☑ Proper film tension
☑ Correct wrapping pattern
☑ Good pallet building

Puncture Resistance Determines Whether a Pallet Survives the Real World

Pallets don’t fail because they’re wrapped poorly once —
they fail because the film cannot handle:

• Sharp edges

• Vibration

• Impact

• Stress cycles

• Temperature shifts

• Uneven tension

Puncture resistance is the ability to absorb the hit and stay intact, and it is one of the defining qualities of true high-performance stretch film.

TP Plastic USA engineers its films with the resin quality, multi-layer structure, and mechanical strength required to keep pallets stable under real-world warehouse conditions — not just on paper.

Better film → fewer breaks → safer loads → stronger logistics.