What Gauge Stretch Film Do You Need for Your Load?

If you’re ordering stretch film for the first time—or reevaluating what you’re currently using — gauge is the most important specification to get right.

Choose too light, and loads shift, tear, or fail in transit.

Choose too heavy, and you’re overspending on material you don’t actually need.

This guide will help you determine the right gauge based on load weight, shape, and handling conditions—so you can protect your freight without overwrapping.

First: What Does “Gauge” Mean?

Gauge refers to the thickness of stretch film. In North America, stretch film thickness is typically expressed in gauge (ga).

As gauge increases, so does:

  • Film thickness

  • Puncture resistance

  • Load containment strength

  • Cost per roll

For a full breakdown of how pricing is calculated—including gauge, width, and volume — see:

→ How Much Does Stretch Film Cost? (Gauge, Width, & Volume Explained)

Common Stretch Film Gauges

47–60 Gauge (Light-Duty Film)

Best for:

  • Light cartons

  • Uniform boxes

  • Loads under ~800–1,000 lbs

  • Short storage cycles

  • Stable, square pallet builds

If your load is well-stacked and moving only a short distance, lighter film may be sufficient.

However, if cartons have sharp edges or irregular surfaces, you’ll likely need to step up in gauge.


63–70 Gauge (Standard Duty Film)

Best for:

  • Loads 1,000–1,800 lbs

  • Standard 48x40 pallets

  • Moderate warehouse handling

  • General distribution environments

This is the most common range for general-purpose warehouse use.

If you’re shipping standard pallets — especially 48x40 GMA pallets — this is often the starting point.

If you’re unsure whether your pallet type matters, see:

→ 48x40 GMA Pallets: Specifications, Strength, and Typical Use Cases


80 Gauge (Heavy-Duty Standard)

Best for:

  • Loads up to ~2,500 lbs

  • Irregular or mixed-product pallets

  • Longer transit distances

  • Higher stacking environments

80 gauge is widely considered the industry standard for heavier pallet loads.

If you’re seeing:

  • Film tearing during wrapping

  • Corner punctures

  • Load shift in transit

. . . you may need to move up to 80 gauge.

If weight is your main concern, you may also want to review:

→ How Much Weight Can a Pallet Really Handle?


90–120 Gauge (Extra Heavy / High-Risk Loads)

Best for:

  • Heavy machinery

  • Metal components

  • Irregular or sharp-edged products

  • Long-haul or export shipments

These gauges provide significantly more puncture resistance and containment force.

If you’re shipping heavy or oversized freight, you may also need to evaluate your pallet or crating solution.

See:

→ Shipping Oversized or Heavy Loads? When You Need a Custom Pallet or Crate

→ When Do You Need a Crate Instead of a Pallet?

Gauge is Only One Variable

Film performance depends on more than thickness. You should also consider:

  • Pre-stretch capability (especially with machine wrap)

  • Wrap pattern (number of top/bottom revolutions)

  • Load height

  • Corner protection

  • Storage duration

  • Transportation conditions

If you’re evaluating equipment, you may also want to read:

Hand Stretch Film vs. Machine Film: Which Should You Use?

Warning Signs You’re Using the Wrong Gauge

You may be under-spec’d if you see:

  • Film necking excessively

  • Frequent tears during wrapping

  • Loads shifting in trailers

  • Product damage claims

  • Excessive top wrap required to stabilize

You may be over-spec’d if:

  • Film is extremely difficult to stretch

  • Material cost per pallet is unusually high

  • You’re wrapping light loads with 80+ gauge

Proper gauge selection often reduces total film usage—even if the film itself is slightly thicker.

Matching Film to Your Pallet Strategy

Stretch film and pallet selection work together.

If you’re unsure whether a standard pallet is appropriate for your load, review:

→ What Is a Standard Pallet? Sizes, Types, and Common Applications

→ When a Standard Pallet Isn’t Enough — Signs You Should Consider Custom

→ Standard vs. Custom Pallets: Which Is Right for Your Load?

A stable pallet platform reduces the gauge required for containment.

Practical Recommendation

If you’re unsure where to start:

  • Under 1,000 lbs → 60–63 gauge

  • 1,000–1,800 lbs → 70 gauge

  • 1,800–2,500 lbs → 80 gauge

  • Heavy, irregular, or high-risk loads → 90+ gauge

Then test and adjust based on real-world performance.

We can help you determine the correct film based on:

  • Load weight

  • Product type

  • Transit distance

  • Storage conditions

  • Equipment type

Need Help Specifying the Right Film?

Choosing the correct gauge reduces damage claims, improves load stability, and prevents overspending on unnecessary material.

If you’re already working with us on pallets or crates, we can align your stretch film specification with your load design for a fully integrated solution.

Request a Quote

Or give us a call at (630) 765-5476.