Pallet Wrapper fault
Inconsistent Wrap Pattern
An inconsistent wrap pattern — uneven overlap, missed sections, variable tension or poor load containment — is usually caused by pre-stretch drift, sensor issues, film spec mismatch or carriage timing problems.
Does this match your fault?
Common symptoms
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Wrap overlap varies across the load height
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Some sections of the load are over-wrapped, others under-wrapped
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Film tension changes between wraps
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Loads look different after every wrap cycle
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Top or bottom of load not being covered properly
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Wrap pattern changes between products or operators
What causes this
Typical causes
Pre-stretch roller wear or slip
Worn pre-stretch rollers lose grip over time, causing the stretch ratio to vary. This directly affects how much film is applied per revolution and creates inconsistent overlap.
Film tension setting drift
Tension potentiometers or digital settings drift over time, particularly on older machines. Small changes in tension setting create large differences in wrap pattern.
Carriage speed or overlap program issue
The overlap percentage, top/bottom wrap counts or carriage speed settings have been changed — often by an operator — causing the pattern to change unexpectedly.
Film specification mismatch
A film change without adjusting machine settings causes different stretch and cling behaviour. What worked with one film may not work with another.
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 and note the current machine settings
Access the machine parameters and note the pre-stretch percentage, overlap setting, top and bottom wrap counts and film tension. Compare to any recorded baseline settings.
02
Inspect pre-stretch rollers for wear
With the machine isolated, check the pre-stretch roller surfaces. They should have a consistent texture and grip. Smooth, glazed or uneven rollers need replacing.
03
Run a test wrap and observe the pattern
Run a wrap cycle on a standard load and watch the carriage travel. Note where the pattern changes — this tells you whether it is a carriage speed, tension or top/bottom setting issue.
04
Check if a film change has been made recently
Ask operators if the film type, micron or supplier has changed. A film change without machine adjustment is one of the most common causes of sudden pattern inconsistency.
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.
Pre-stretch rollers visibly worn, glazed or uneven
Wrap pattern inconsistency has developed suddenly with no settings change — sensor or mechanical issue likely
Load security is being compromised — product shifting in transit
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.