Pallet Wrapper fault
Pallet Wrapper Film Breaking
Film breaking on a pallet wrapper is nearly always caused by a pre-stretch setting, damaged roller, snag point on the carriage, or a film specification that does not match the machine — not the film itself.
Does this match your fault?
Common symptoms
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Film snaps as soon as wrapping starts
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Film breaks at the same height every cycle
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Breaks during carriage up or down travel
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Film necks down and tears — tension issue
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Only breaks on certain products or load types
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Film wrap looks uneven before it breaks
What causes this
Typical causes
Film not threaded correctly
Film missed a roller or the dancer arm on the carriage. Even a small threading error causes consistent breaks at low tension.
Tension or pre-stretch set too high
Pre-stretch above the film's capability causes it to neck down and snap. Common after a film type change without adjusting machine settings.
Damage or snag point on carriage
A burr, sharp edge, cracked roller or loose guard panel on the carriage catches the film as it travels. Breaks at the same point each cycle.
Load overhang or sharp edges
Unstable loads, excessive pallet overhang, or sharp-cornered products catch the film and snap it. Check the break point relative to the load.
Before calling an engineer
What to check first
These are the practical checks worth trying before calling out an engineer. If none of these resolve the fault, or if the issue keeps returning, it needs a proper diagnosis.
01
Check film threading through the carriage
Rethread the film following the machine's threading diagram exactly. Check every roller is turning freely and none are cracked or rough.
02
Reduce the pre-stretch setting
Lower the pre-stretch percentage in small increments and test. A good starting point for most standard machine film is 150-200%. Do not exceed the film's rated stretch.
03
Inspect the carriage for snag points
Slowly run a cloth along the carriage path looking for anything that catches. Check roller surfaces, guard panels and all fixings for sharp edges or looseness.
04
Check the load profile
Look at where the film breaks relative to the load. If it is always at the same height, check what is at that height on the pallet — overhang, sharp corners or voids.
When to call us
If any of these apply, call now
At this point, continued resets or workarounds are unlikely to resolve the underlying fault. A proper diagnosis is faster and cheaper than repeated call-outs for the same issue.
Film breaks immediately regardless of tension setting
Breaks at the same point every cycle despite load and threading checks
Carriage roller visibly damaged, rough or not turning freely
Related faults
More fault support
Report a Breakdown
Include the machine make and model, the fault you are seeing and any error codes. A photo of the display helps us triage faster.