Last updated: August 1, 2026
Gauge measures stretch film thickness, and higher gauge means thicker, stronger film. The units connect simply: 100 gauge = 1 mil = about 23 microns. As a rough guide, light loads wrap well at 47–63 gauge, medium loads at 70–80 gauge, and heavy or sharp loads at 90–150 gauge. A high-performance film often gives the same containment at a lower gauge, which cuts cost. Not sure what to run? Tell us your loads and get the best price in the market.
Gauge is the American way of describing how thick a stretch film is. The higher the gauge number, the thicker and stronger the film, and generally the more it costs per pallet. Most hand and machine films sold in the Houston market fall between about 37 gauge and 150 gauge. Very light bundling films sit at the low end, while heavy machine films for dense, tall, or sharp-edged loads sit at the top.
Thickness is not the whole story. A modern, well-engineered film can be thinner and still contain a load better than a cheap, thick film, because the resins and manufacturing process control how the film stretches and grips. That is why gauge alone should never be the only thing you compare.
Three units describe the same thing, film thickness. Which one you see depends on where the film was made and sold:
| Unit | Equivalent | Quick conversion |
|---|---|---|
| 100 gauge | 1 mil | Gauge ÷ 100 = mil |
| 1 mil | ~23 microns | Mil × 25.4 ≈ micron (nominal ~23 for film) |
| 100 gauge | ~23 microns | Gauge × 0.23 ≈ micron |
| 1 micron | ~4.3 gauge | Micron ÷ 0.23 ≈ gauge |
Conversions are nominal and rounded for practical use. For example, an 80 gauge film is 0.8 mil, or roughly 18–20 microns.
Use this as a starting point, then confirm with a test wrap. The right gauge depends on load weight, height, stability, and how sharp the edges are.
| Load type | Typical weight | Suggested gauge* | Notes |
|---|---|---|---|
| Light / bundling | Under ~800 lbs | ~37–63 gauge | Uniform, stable, light boxes and bags |
| Medium / general | ~800–1,800 lbs | ~70–80 gauge | Most mixed and palletized freight |
| Heavy | ~1,800–2,600 lbs | ~90–115 gauge | Dense or tall loads needing more hold |
| Very heavy / tall | ~2,600 lbs+ | ~120–150 gauge | High containment force required |
| Sharp / irregular edges | Any weight | Higher gauge or puncture-resistant film | Metal parts, corners, protruding items |
*Illustrative ranges for standard cast machine film. Your ideal gauge depends on the film grade and your wrapper settings. Ask us for a spec match.
Here is where a lot of operations overspend. A premium, high-performance stretch film is engineered to stretch further and grip harder, so it can hold the same load at a noticeably lower gauge than a budget film. Dropping from, say, 80 gauge to a high-performance 60 gauge equivalent means less plastic per pallet at the same containment. Over thousands of pallets, that adds up fast.
The trade-off is the up-front price per roll, which is why it pays to compare films on cost per pallet, not cost per roll or gauge alone. See how to reduce stretch film cost per pallet for the full method.
Send us your load weights and current film, and we'll match a gauge and grade that holds securely for less. Free, same-day, no obligation.
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