5 common mistakes when shrink-wrapping… and how to avoid them

Shrink-wrapping with film is a simple and effective solution to protect pallets, machines, boats or worksites. But like any thermal process, a few bad habits can quickly waste time, damage the film… or even create holes.

Here are 5 very common mistakes we see in the field, and more importantly, how to avoid them.

1. Holding the flame too close to the film

The problem:
When you hold the shrink gun too close to the film, the heat is too concentrated. The result is:

• film that burns through or gets holes,
• overconsumption of film,
• an uneven, unprofessional finish.

How to avoid it:

• Respect the recommended distance (usually around 30 to 40 cm).
• Keep the gun moving continuously, as if you were “sweeping” the surface.
• Always start by heating the thickest areas (corners, folds) instead of insisting on one fixed point.

2. Heating the same area for too long

The problem:
Even at the right distance, staying too long on one spot creates over-thicknesses, burns or holes in the film. You lose quality, strength and time.

How to avoid it:

• Keep moving constantly.
• Work in sections: first the base of the pallet, then the sides, then the top.
• Use a wide back-and-forth motion rather than small, jerky movements.
• Check the overall shrink result before “touching up” details.

3. Using an unsuitable film (too thin, too thick or wrong format)

The problem:
A film that doesn’t match your needs leads to:

• repeated tearing if the film is too thin,
• wasted time shrinking if the film is too thick,
• an unattractive or poorly covered wrap if the size isn’t right.

How to avoid it:

• Define your needs: load weight, storage duration, exposure (indoor / outdoor / sea / UV).
• Adjust the thickness (µm) to the type of application: a light pallet ? a machine exported in a container.
• Choose a cover or sleeve size that matches the real dimensions of the products, to avoid excess material or excessive tension.

4. Not preparing the pallet or the area properly

The problem:
Even with the best shrink gun, a poorly prepared pallet will only give an average result:

• edges sticking out,
• sharp corners piercing the film,
• unstable loads that move during transport.

How to avoid it:

• Check the stability of the load before wrapping (brace if needed).
• Remove or protect sharp edges (corners, metal parts).
• Position the cover or film correctly before starting to shrink, using a pallet riser if necessary.
• Make sure the pallet is accessible all around so the operator can move freely.

In summary

Shrink-wrapping problems are rarely caused by the equipment alone: they usually come from small habits, approximate movements or an unsuitable film. By correcting these 4 points, you improve safety, the final appearance and the overall cost of your operations:

• Flame / film distance
• Heating time on the same spot
• Film selection
• Load preparation

For more information, feel free to contact our team on this page.