Comparative Study of 3-Layer V.s 5-Layer Films.: Improving Load Stability Using Multilayer PE Stretch Films
In warehousing and transportation, palletised loads are exposed to continuous stress in the form of handling shocks, vibration, corner impacts, and gradual loss of stretch recovery over time. Businesses, therefore, do not simply look for stretch films; they require solutions that deliver:
- secure load containment
- Consistent holding force
- Resistance to puncture and tearing
- Optimised material usage without over-wrapping
In many cases, customers assume that increasing the number of layers automatically improves stretch film performance. However, industry research and application-level experience indicate that layer count alone does not guarantee better load stability. What matters more is how each layer is engineered to perform its specific function within the film structure. This case study presents a comparative evaluation of 3-layer and 5-layer PE stretch films to determine which construction delivers reliable performance in real-world pallet wrapping, while maintaining cost efficiency and material optimisation.
Objective
To evaluate 3-layer vs 5-layer PE stretch films and determine how multilayer design influences:
- Load stability and containment force
- Stretchability and recovery
- Puncture and tear resistance
- Overall wrapping efficiency for palletised loads
Understanding Multilayer PE Stretch Films: Why Layer Design Matters in PE Stretch Films
The performance of PE stretch films depends on:
- Raw material selection
- Layer-wise formulation
- Extrusion and processing control
- Application method (manual or machine wrapping)
Industry studies have shown that when thickness and formulation are held constant, increasing layer count alone does not necessarily improve mechanical performance. Instead, functional layer design determines how well a film performs during stretching, wrapping, and end usage.
Technical Insight
In multilayer PE stretch films, separating functional roles across layers allows improved control of elastic recovery, puncture resistance, and holding force. A dedicated core layer can manage load containment energy, while outer layers can be optimized for cling and tear resistance. This engineering approach is more impactful than increasing layer count without functional differentiation.
PE Film Structures Evaluated
3 Layer:
- Balanced core and skin layers
- Suitable for general-purpose pallet wrapping
- Performs well for uniform, stable loads
5 Layer:
- Dedicated core layer for strength and elasticity
- Optimised outer layers for cling and tear resistance
- Better control over stretch recovery and holding force
At Shree Pragya Flexifilm Industries, we focus on engineering each layer to perform a specific role, rather than simply increasing the number of layers.
Application-focused Evaluation Method
The PE stretch films were assessed under typical pallet wrapping conditions, reflecting common warehousing and logistics scenarios.
- Load Type: Palletised cartons and mixed goods
- Wrapping Method: Machine stretch wrapping
- Key evaluation parameters:
-Load containment and stability after wrapping
-Stretch behaviour and film memory
-Resistance to puncture at pallet corners
-Visual integrity after simulated transport handling
The observations presented are based on controlled trials and application-level feedback, reflecting practical pallet wrapping conditions commonly encountered in storage and transportation environments.
Key Findings
Load Stability & Holding Force
- The 5-layer PE stretch film delivered more uniform holding force, keeping palletised loads tightly secured over time.
- The 3-layer film provided adequate containment for lighter or uniform loads but showed limitations under higher stress conditions.
Why It Matters: Improved holding force reduces load shifting, improving transport safety and reducing damage.
Stretchability & Recovery
- Shree Pragya Flexifilm Industries multilayer PE film exhibited controlled stretch and excellent recovery, maintaining tension even after extended storage.
- The 3-layer film demonstrated good elongation but comparatively lower recovery under sustained load.
Why it matters: Better recovery ensures the pallet remains stable during long-distance transport.
Puncture & Tear Resistance
- Shree Pragya Flexifilm Industries multilayer PE stretch film exhibited controlled stretch behaviour and superior elastic recovery, maintaining consistent tension even after extended storage or transport duration.
- The 3-layer film demonstrated good elongation but comparatively lower recovery under sustained load conditions.
Why It Matters: Reduced film breakage means fewer rewraps and lower material wastage.
Wrapping Efficiency
- With higher performance per wrap, the 5-layer film enabled optimised film usage, reducing excessive layering.
- This resulted in reduced material waste without compromising on load security.
| 3-Layer V.s 5-Layer Films: Side-by-Side Comparison | ||
| Load Stability | Moderate | High |
| Holding Force Consistency | Adequate | Excellent |
| Stretch Recovery | Good | Superior |
| Puncture Resistance | Moderate | High |
| Material Efficiency | Standard | Optimized |
| Recommended Use | Light to medium loads | Heavy, unstable |
How Shree Pragya Evaluates Stretch Film Performance
Shree Pragya Flexifilm Industries evaluates PE stretch film performance through controlled application trials, observation of stretch recovery and load containment behaviour, and feedback from typical warehousing and transport handling conditions. This ensures film recommendations are based on practical performance outcomes, not laboratory metrics alone.
Why Shree Pragya Flexifilm Industries PE Stretch Stands Out
With these case study findings, we can conclude that effective pallet wrapping is achieved through intelligent film engineering, not just higher layer count.
By designing multi layer PE stretch films with a purpose-driven layer functionality, Shree Pragya Flexifilm Industries stretch film delivers:
- Superior load stability
- Reliable performance across demanding logistics conditions
- Reduced film consumption through higher efficiency
- Consistent wrapping results for palletised loads
For businesses seeking the ultimate stretch film for pallet wrapping, Shree Pragya’s PE stretch films offer a balanced combination of strength, stretch, and stability, engineered to perform where it matters most. Our technical team can recommend the right PE stretch film based on your load type, wrapping method, and transport conditions.
Disclaimer: Performance may vary depending on load configuration, wrapping technique, and handling conditions.
