Calculator inputs
The page stays in a single-column flow, while the calculator fields use a responsive 3-column, 2-column, and 1-column layout.
Formula used
1. Load perimeter: Perimeter = 2 × (Length + Width)
2. Vertical advance per revolution: Vertical advance = Film width × (1 − Overlap %)
3. Turns along height: Turns along height = Ceiling(Height ÷ Vertical advance)
4. Turns per layer: Turns per layer = Turns along height + Top wraps + Bottom wraps
5. Total revolutions: Total revolutions = Turns per layer × Layers
6. Applied film length: Applied length = (Perimeter × Total revolutions) + Tail allowance
7. Roll film consumed: Roll consumed = Applied length ÷ Stretch factor × (1 + Waste %)
8. Film mass: Mass = Consumed length × Width × Thickness × Density
9. Cost per pallet: Cost per pallet = Roll consumed × (Roll cost ÷ Roll length)
How to use this calculator
- Enter the wrapped load length, width, and required wrap height.
- Provide the film width, thickness, and material density.
- Set overlap, layers, prestretch, and the extra top and bottom wraps.
- Add tail allowance, waste allowance, roll length, and roll cost.
- Enter the pallet count for batch planning.
- Press the calculate button to show results above the form.
- Review film length, mass, pallets per roll, and cost outputs.
- Use the CSV and PDF buttons to export the current result set.
Example data table
| Length (mm) | Width (mm) | Height (mm) | Film Width (mm) | Overlap (%) | Layers | Prestretch (%) | Roll Length (m) | Roll Cost | Applied Length/Pallet (m) | Consumed/Pallet (m) | Cost/Pallet |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1,200 | 1,000 | 1,500 | 500 | 50 | 2 | 200 | 1,500 | 85.00 | 89.20 | 30.92 | 1.75 |
Frequently asked questions
1. What does this calculator estimate?
It estimates applied film length, roll consumption, film area, material mass, pallets per roll, rolls needed for a batch, and cost per pallet.
2. Why is prestretch important?
Prestretch changes how much roll material is actually consumed. Higher prestretch usually lowers roll draw while still producing the applied film length on the load.
3. What overlap value is common?
Many operations begin around 30% to 60% overlap. The right value depends on containment requirements, film grade, machine setup, and product stability.
4. Why add top and bottom extra wraps?
Extra top and bottom wraps help lock the film at the start and finish points. They also improve containment near the pallet base and load top.
5. Should the height include the pallet?
Use the actual height that needs coverage. If the wrap must capture the pallet deck or runners, include that section in the entered wrap height.
6. Does film thickness affect film length?
Thickness does not change the applied wrap path. It changes mass and can influence performance, containment, puncture resistance, and realistic cost evaluation.
7. Can this be used for hand wrap and machine wrap?
Yes. For hand wrapping, use a lower prestretch value. For powered wrappers, enter the machine’s effective prestretch setting and expected waste allowance.
8. Why show both applied length and consumed roll length?
Applied length describes the film placed around the load. Consumed roll length shows how much material leaves the roll after prestretch and waste are considered.