A genuinely accurate view of film cost needs to include:

• Annual film consumption — how much film is actually used across the year, not just the unit price.
• Labour costs and time — particularly relevant where film is applied by hand.
• Waste disposal costs — an increasingly significant factor as regulation tightens.

Reviewed this way, a cheaper roll can easily end up costing more per pallet than a higher-performance alternative.

The Regulatory Landscape Is Changing

Two changes make this review more urgent.

The Plastic Packaging Tax (PPT) has increased to £228.82 per tonne for any film that does not contain a minimum of 30% recycled content. Films that meet or exceed that threshold are exempt.

From next year, businesses will also be required to separate plastic films and flexible plastics for waste collection, rather than adding them to general waste. This puts a renewed focus on reducing waste material and excess film usage in the first place — not just managing it after the fact.

Together, these changes mean film choice is no longer just an operational decision. It’s a cost and compliance decision too.

The Hidden Cost of Excess Wrapping

Excess wrapping is a common, and often overlooked, source of waste — particularly where film is applied by hand. Manual wrapping tends to use more material than necessary, and the amount applied can vary significantly from one person to the next, making costs harder to predict and control.

Addressing this doesn’t necessarily mean overhauling the whole packing line. In many cases, it starts with reviewing the film itself and how it’s applied.

Smarter Film Choices

Film technology has moved on considerably, offering ways to reduce material use and cost without compromising load security.

High Performance Films

These provide the same cling, load stability and containment as conventional film, but from less material. Designed to stretch up to 150%, performing above their thickness, they deliver a saving on both cost and waste. Those with 30% or more recycled content are also exempt from the Plastic Packaging Tax.

Pre-Stretch Films

Pre-stretch films have the stretch built in during manufacturing, initiated by the slight tensioning applied as the film goes onto the load. This means less manual effort is required to apply them. Compared to conventional film, they are roughly half the thickness and double the strength, while offering high puncture resistance and reinforced edges for additional protection.

Automated Systems

Applying film by machine means controlled, consistent tension on every pallet, reducing the variation seen with manual wrapping and cutting excess film and waste as a result. The increased elongation achieved through machine application can reduce wastage by up to 50%. A Power Pre-Stretch (PPS) machine film goes further still, using additives that allow it to stretch up to 300% more than conventional film — saving on both wastage and cost.

Perforated Films

A more recent development, perforated films are well suited to industries such as food, horticulture and pharmaceuticals, where products are temperature-sensitive. The perforations improve airflow, allowing items to breathe more easily without trapping condensation. The film’s design also results in an overall reduction in material used.

Why a Packaging Review Matters

Film performance is shaped by more than the material alone — load shape, pallet pattern, product weight, and handling methods all play a part. A packaging review brings all of this together, assessing whether current film is providing the right level of load security, whether more material is being used than necessary, and whether the film in use is aligned with upcoming recyclability and waste requirements.

In some cases, that review reveals room to move to a more efficient or compliant film with no loss of performance. In others, it points to wider improvements in application method or packing line setup.

Conclusion

Stretch film remains essential to secure, efficient distribution. But with the Plastic Packaging Tax rising and new waste separation requirements on the way, the true cost of film now extends well beyond the price per roll.

Looking at cost per pallet — factoring in consumption, labour, waste, and compliance — gives a far more accurate picture, and often reveals straightforward opportunities to reduce both cost and material use without compromising protection.

A packaging review is a practical place to start.