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Buyer guides60-Gauge vs. 80-Gauge vs. 100-Gauge Stretch Film: A Durability Comparison
Gauge is the single biggest lever in how a pallet wrap performs — and the easiest spec to get wrong if you’re ordering by habit instead of by load. Here’s a straightforward comparison to help you land on the right thickness before you commit to a print run.
What gauge actually measures
Gauge refers to film thickness, measured in ten-thousandths of an inch. Lower gauge means thinner, more economical film with more length per pound; higher gauge means thicker film with more puncture resistance and load-holding strength, at a higher material cost per roll.
| Gauge | Best for | Trade-off |
|---|---|---|
| 60-gauge | Light, stable, uniform loads (boxed goods under ~1,500 lbs) | Lower puncture resistance; not for sharp-edged or heavy loads |
| 80-gauge (our standard) | Most general warehouse, manufacturing, and food/beverage loads | Balanced cost and performance for the widest range of uses |
| 100-gauge | Heavy, irregular, or sharp-edged loads (machinery, building materials) | Higher material cost per roll; typically hand-wrap only |
Why we standardize on 80-gauge
Across manufacturers, warehouses, food producers, and logistics companies, 80-gauge blown or cast LLDPE film handles the overwhelming majority of pallet loads without over-spending on material you don’t need. It holds cling and containment on mixed case-good loads, resists the punctures common in warehouse handling, and prints cleanly under both hand and machine tension.
When to go lighter or heavier
If you’re wrapping uniform, lightweight, well-palletized cartons at high volume, a 60-gauge film can reduce material cost without sacrificing containment. If you’re wrapping irregular loads with sharp corners — lumber, metal stock, machinery parts — a 100-gauge film resists tears that would compromise a lighter roll.
Blown vs. cast at any gauge
Independent of gauge, cast film offers a quieter unwind and higher clarity; blown film offers higher tear resistance and better memory (it holds tension better over time). We help you choose both dimensions — gauge and film type — based on your actual load profile.
Not sure what gauge fits your load? Get a custom quote and describe your typical pallet — free mockups in 24–48 hours. Learn more about how we work, or browse more guides.