This article will provide detailed information about plastic pallet covers.
The article will feature topics such as:
Pallets are shielded with plastic pallet covers, often referred to as PPCs, which are large, gusseted poly bags utilized for both storage and transportation. These covers are commonly used in various settings such as warehouses, storage facilities, shipyards, and even in residential spaces. Plastic pallet covers play a crucial role in protecting items on pallets from dust, moisture, and other environmental factors during handling and shipment. Unlike heavy, costly pallet cover tarps, these plastic covers offer a more cost-effective and practical solution. They come in different sizes and designs to accommodate various storage and organizational needs. These covers also safeguard against minor damage from water, dust, and abrasions and can be used for branding or item identification purposes. Made from durable yet thin plastic sheets, they provide effective protection without significantly adding to the weight or bulk of the shipment. Plastic pallet covers are ideal for temporary storage and shipping due to their ease of use, availability in both flat and gusseted forms, and the option for customization to ensure that products remain secure and orderly.
It's important to recognize that plastic pallet covers are designed for temporary use, providing a protective layer for items but not meant to replace more durable solutions like pallet tarps or other robust storage containers. In the following section, we'll explore the proper way to use plastic pallet covers.
Pallet covers are straightforward to use; simply place them over the boxes on a pallet to secure the items for short-term storage, whether indoors or outdoors. Additionally, thermal pallet covers can regulate the temperature of the pallet, keeping it warm or cool during storage and transportation, which is particularly useful for temperature-sensitive shipments.
Plastic pallet covers provide an effective barrier against contaminants such as dust, moisture, and spills. While disposable covers are available, reusable ones often offer better long-term value due to their durability and multiple uses. They are also commonly used in conjunction with shrink or stretch wrap to offer enhanced protection for the palletized goods.
Plastic pallet covers offer numerous benefits, with some of the most common ones outlined below:
While plastic pallet covers offer several advantages, there are also some drawbacks to keep in mind. These include:
Plastic pallet covers are designed to safeguard goods from dust, dirt, moisture, and grease, common issues in warehouse environments. Their primary function is to shield stock or products from external contaminants. Below are some common applications of plastic pallet covers:
Plastic pallet covers are effective for organizing merchandise. They can be used to differentiate between different product categories or to separate items, making it easier to locate them during storage or preparation for shipment. With a durable and customized plastic pallet cover, products can be kept together and protected.
Plastic pallet covers provide an affordable solution for shielding goods from environmental hazards such as moisture, UV rays, wind, and rain. They also offer protection against scratches and prevent dirt, dust, and debris from accumulating. This extra layer of protection is especially important for sensitive items.
Plastic pallet covers offer opportunities for custom branding. They can be designed in various patterns, sizes, and colors to reflect a company's brand identity. By incorporating a company's colors and logo, these covers help distinguish products from competitors and enhance brand recognition throughout the shipping process. Additionally, custom-branded plastic pallet covers support visibility and identification as products move from the business through different transporters and ultimately to consumers.
Gaylord containers are large cardboard boxes typically placed on pallets, designed to hold entire shipments in a single unit. Gusseted poly pallet covers are used both as liners for goods inside Gaylord containers and as covers for items on pallets. These gusseted covers offer enhanced durability and protection for the contents. They are well-suited for most transportation needs involving Gaylord containers.
There are various types of plastic pallet covers, each tailored to different products and their specific protection needs. Generally, plastic pallet covers are categorized into tarps, wraps, or covers. Below, we will explore these different types in more detail.
Shrink wrap, as the name suggests, shrinks to create a tight, protective seal around a package. This ensures that the items inside are safeguarded from external contaminants such as moisture, dust, and air. Additionally, because shrink wrap is transparent and largely waterproof, it allows for easy identification of goods while offering a degree of protection from environmental elements.
Unlike stretch wrap, which is stretched around the pallet, shrink wrap uses heat to shrink the plastic tightly around the merchandise. When heated, shrink wrap contracts, forming an airtight seal around the containers. However, determining the precise amount of shrink wrap needed to cover a pallet can be time-consuming and requires some experience.
Shrink-wrapping a pallet helps protect it from spills and dirt, and it makes metal items more resistant to rust. Additionally, this wrapping method secures the goods on the pallet, minimizing the risk of items shifting, falling off, or being stolen.
While shrink wrap offers many benefits, there are two key factors that might make you reconsider its use:
Stretch wrapping is a type of plastic wrap used for covering pallets, involving the wrapping of plastic material around boxes on a pallet by either a person or a machine. Stretch wrap can be categorized into blown stretch wrap and cast stretch wrap, depending on the production method. Blown stretch wrap is made by melting plastic, passing it through a die to form a thin-walled tube, then inflating it with air as it exits the die, resulting in layers of plastic wrap.
Blown stretch wrap creates a more durable film compared to cast stretch wrap, but it tends to be more opaque because the plastic crystallizes during the process, reducing the visibility of the wrapped items. Additionally, the thickness of blown stretch wrap can be less uniform due to the extra processing required. It is also more costly to produce, making it less commonly used than cast stretch wrap.
Cast stretch wrap is made by passing a heated resin through cold rollers to create a clear, translucent film. In this process, plastic is melted in a heated screw barrel and then extruded horizontally through a flat die. The thickness of the wrap is controlled by a slit in the die as the material exits. As the wrap emerges from the die, it is cooled by wrapping around a chilled roller to solidify.
A plastic pallet tarp cover is used to safeguard a package. Such pallet coverings can range from clear, throwaway covers to reusable, thermal covers and are often constructed of porous polyethylene. Such coverings are produced in various sizes in order to always protect a pallet’s contents. Most plastic pallet tarp covers also include an ultraviolet (UV) coating to shield perishable items like food from the sun.
Clear plastic pallet covers are suitable for use with pallets of goods stored both indoors and outdoors. They shield boxes from environmental elements such as dust and humidity, as well as other contaminants. Additionally, their transparency provides a clear view of the shipment’s contents, making it easy to identify items without removing the cover.
However, transparent pallet covers may not offer adequate UV protection for perishable items. Their clear nature can also make products more vulnerable to temperature fluctuations. Therefore, clear plastic pallet covers are most appropriate for short-term shipments involving perishable goods.
Black plastic tarps are effective at deterring theft by obscuring the contents of shipments. If the items are not visible, potential thieves are less likely to target the shipment. Moreover, many black pallet covers are treated with a UV coating to protect against direct sunlight. These covers also safeguard shipments from dirt, dust, and humidity, and offer resistance to minor spills and leaks.
Black poly materials are ideal for situations where shipments need to be concealed or require UV protection from the sun. Black plastic pallet covers come in a wide variety of thicknesses, allowing for customization based on specific needs. Additionally, these covers can be provided in rolls with perforations for easy and convenient dispensing.
Thermal plastic pallet covers are helpful for some products that need a controlled temperature. Thermal pallet covers can be useful for both heating and cooling applications, such as keeping a shipment chilly in the summer or warm in the winter. In addition, the items they cover are less likely to be stolen since thermal plastic pallets are opaque.
Pallet top sheets are plastic liners designed with perforated strips for easy dispensing and tearing from rolls. Like other plastic pallet covers, they protect products from contaminants such as dust, dirt, moisture, and grease commonly found in warehouses. However, pallet top sheets are specifically intended to cover individual layers of a pallet rather than the entire load. They not only shield shipments from external contaminants but also prevent leaks from cartons situated between layers. Pallet top sheets can be used on their own or in combination with other plastic pallet covers for added protection.
Pallet-size shrink bags are recommended for use with large machinery, heavy or irregular loads, and for outdoor protection. This type of shrink wrap comes as a gusseted bag on a perforated roll, allowing for easy peel-off. Designed to cover an entire pallet, these bags are heated with a heat gun to tightly secure the contents and provide a more secure enclosure.
Clear pallet-size shrink bags offer both transparency and durability for covering large pallet loads. While their transparency allows for easy visibility of the items, it also increases UV exposure, which can be a drawback if the items are transported or stored outside. These shrink bags are available in rolls of 25 and are made from thick 4 mil plastic, providing strength and stability to secure large loads effectively.
Gusseted black UVI (ultraviolet-inhibiting) pallet covers come on rolls and are pre-cut and perforated for easy dispensing. These covers help keep goods clean, dust-free, and protected from light. They are often used to cover machinery or to line Gaylord containers, safeguarding the contents from moisture and contamination. The black opaque film is particularly effective for outdoor storage, as it conceals the pallet’s contents, which helps deter theft and protects light-sensitive items. Made from durable polyethylene, these covers offer cost-effective protection, with pleated sides that accommodate the width of most standard pallets.
Vented pallet wrap is designed to let moisture and condensation escape, making it ideal for frozen or cold storage applications. This type of wrap is lighter than traditional stretch film, which helps reduce shipping costs. Additionally, the vents facilitate easier handling during use, enhancing overall efficiency.
Pallet cover bags ensure that bin and box contents remain secure and protected from moisture, dirt, and abrasion. Made from durable and transparent materials, these bags are built to last and provide easy visibility for inspecting the contents. They are available in various sizes and gauge thicknesses to meet different protective requirements.
Poly tarps feature loosely-woven polyethylene strips laminated to polyethylene sheets. In addition to protecting items from airborne contaminants, poly tarps are waterproof and offer excellent protection from precipitation. This material also resists stretching which increases its durability. When UV-coated, poly tarps may provide protection from the sun for years. Poly tarps are available in various colors; clear poly tarps are also available. Poly tarps also come in numerous mil thicknesses.
Poly top sheets are designed to offer additional protection for individual layers of boxes stacked on a pallet. They help maintain the integrity of stored goods by shielding them from mud, dust, moisture, bacteria, and fungi. These top sheets comply with FDA guidelines for covering food items and are available in various sizes to fit different box dimensions. Standard sizes range from 60" x 60" to 75" x 75", and they come in a variety of thicknesses to suit different needs.
Pallets come in various sizes and shapes, which can make selecting the right pallet wrapping options challenging. It’s important to choose a plastic pallet cover that fits snugly over the pallet and its contents. To ensure you select the correct size, measure the shipment carefully. Use the following formula to determine the size of the pallet cover required:
Start by measuring the pallet's width (W), depth (D) (or length), and height (H). Then, increase the width by approximately four inches. To calculate the height needed for the pallet cover, divide the adjusted width by two and add it to the measured height. An example of this measurement formula is provided below.
W: 46 inches + 4 inches = 50 inches
D: 49 inches
H: 50 inches + 25 inches (half the width) = 75 inches
The additional four inches added to the width can be adjusted based on how snugly the cover needs to fit. For a tighter fit, you might use a two-inch addition instead of four inches.
For example, if the pallet measures 46 inches wide, 49 inches deep, and 50 inches long, the required dimensions for the pallet cover would be 50 inches x 49 inches x 75 inches.
While there are no strict guidelines for pallet wrapping, the following sequence is commonly used:
When using plastic pallet covers to protect boxes on pallets, the following steps are typically followed:
Plastic pallet covers are versatile and offer excellent ventilation for goods. They are also cost-effective for packaging and shipping pallets of products. Below are some industrial applications for plastic pallet covers:
Plastic pallet covers come in thicknesses ranging from 1 mil to 4 mils. Covers rated at 1 mil are typically used for short-term protection of palletized goods. Thicker covers, such as those rated at 4 mils, provide enhanced protection and are often used as reusable covers for frequent handling of palletized items. For loads without sharp edges that don’t require high resistance to tears and punctures, 1 mil clear pallet covers are ideal. Covers with a thickness of 1.5 mils offer good dust and moisture protection while being cost-effective. A 2 mil thickness is slightly sturdier, suitable for most warehouse tasks, and provides protection against moisture, paint, dust, and is resistant to tearing. For use as container liners or for covering machinery, 3 mil polypropylene covers are highly effective. The thickest option, 4 mil covers, offer excellent tear resistance and are recommended for loads with sharp or potentially hazardous edges.
Plastic tarps and covers, though serving similar functions, differ in several aspects such as their application, material weight, thickness, and durability. Tarps are typically reusable, made from thick, heavy-duty plastic designed for repeated use, unlike shrink wrap, which is intended for single use and removed once a shipment reaches its destination.
Lightweight plastic covers are thin and designed for single-use shipments or minimal warehouse protection. They offer sufficient coverage for short-haul deliveries and help keep loads secure. In warehouses, lightweight plastic pallet covers protect against dirt, dust, and debris, providing minimal water resistance and shielding products during movement.
Historically, tarps, or tarpaulins, were made from materials like canvas, burlap, and cotton. With the advent of plastic fabrics, tarps have become more resilient, reliable, and durable. Canvas tarps have largely been replaced by vinyl and plastic tarps due to the higher cost of canvas, although they are still used in military and heavy industrial applications.
Modern tarps are made from various materials, including:
Polyethylene: Polyethylene tarps are made of a thermoplastic polymer that is resistant to moisture, UV radiation, and mildew. High density (HDPE) or low density (LDPE) polyethylene are used to make them, which can be light duty or heavy duty.
Light duty poly tarps are lighter in weight, have a low poly coating, and lower mesh count. They are not as resilient or strong as heavy poly tarps and are designed for short term use.
High duty poly tarps are heavier, have a thicker poly coating, and high mesh count. They are long lasting and made of high quality materials.
Polyvinyl Chloride (PVC): PVC tarps are made of a vinyl coated polyester fabric that is resistant to tearing, abrasion, and UV radiation and are used for heavy duty applications. They are exceptionally durable, can withstand extreme weather conditions, have high strength, and are used for harsh stressful applications.
When compared to other forms of plastic pallet covers, PVC pallet covers are thicker and resistant to mildew, grease, and acids. They are designed and configured to face the most hazardous and high duty purposes.
While plastic pollution is a significant environmental issue, many plastics used in plastic pallet covers are recyclable and can be repurposed at the end of their useful life. These plastics are categorized as post-consumer recycled content (PCR) and post-industrial recycled content (PIR), both of which are used to manufacture new plastic pallet covers.
The plastic pallet cover industry is committed to minimizing environmental impact by focusing on recycling and ensuring that their products are not disposed of in landfills. Their ongoing efforts are aimed at promoting the sustainability of their products and reducing waste.
Pallet covers come in a variety of sizes and thicknesses and can be custom-made to fit any specific application.
Plastic Pallet Covers Thickness: Available in thicknesses from 1 mil to 4 mil, plastic pallet covers offer varying levels of protection. 1 mil covers are suitable for temporary protection, while 4 mil covers provide excellent tear resistance and can be reused multiple times to cover and uncover palletized items.
Custom Printing on Plastic Pallet Covers: Plastic pallet covers can be custom printed with logos or any other required information to meet user specifications.
The primary differences between pallet covers and pallet tarps are the materials used, the durability, and the cost.
Materials Used in Covers & Tarps: Pallet covers are often made from low-density polyethylene (LDPE), which is a more affordable option. In contrast, pallet tarps are typically made from durable woven polyester, which offers a longer lifespan.
Durability: Factors such as UV exposure, moisture, and extreme temperatures can impact the durability of both woven polyester and LDPE. Adding UV blockers to LDPE can extend its lifespan. Generally, plastic pallet covers can provide effective dust protection for several years when used in controlled environments.
Cost: Plastic pallet covers are cost-effective as they are reusable and can last nearly as long as woven polyester tarps when used correctly.
Choosing Between Clear and Black UVI Pallet Covers: Black UV-resistant pallet covers are ideal for products that will be stored outside for extended periods and need protection from sunlight. For other uses, clear or standard black pallet covers may be sufficient.
Water-Resistance: Like all polyethylene bags, these plastic pallet cover bags are water-resistant but not waterproof. They can protect products during quick transport but should not be used to leave items outside overnight if they can be damaged by water.
Reasons for Using Pallet Top Sheets: Plastic pallet covers and pallet shrink bags are used to protect the contents of an entire pallet. Pallet top sheets can be used alone or in conjunction with pallet covers or bags. They serve several purposes, including separating stacked layers on a pallet. For example, if a pallet is stacked with boxes of ink pens on top of boxes of paper, a top sheet can prevent ink from leaking onto the paper below. Additionally, top sheets provide temporary protection from moisture, dust, dirt, and grease when the pallet is stored.
Plastic pallet covers are ideal for a lot of uses. They are available in a wide selection and variety and can aid in safely storing goods for work or play. Plastic pallet covers require a considerable initial investment, but their ability to protect expensive items from damage and their potential for reuse more than justify this cost. Some of the advantages that plastic covers bring to the table include:
A customized plastic bag, poly bag, or pouch is a container made of thin, flexible plastic film, nonwoven fabric, or plastic textile tailored to meet a product's particular requirements. Chemicals, food, powders, ice, periodicals, and...
A mattress bag is a heavy duty plastic bag designed to protect a mattress from the elements, dirt, dust, moisture, damage, and debris. They come in a variety of sizes and shapes to meet the needs of any size mattress...
A plastic baggie is a type of sack, container, or pouch made of an unwoven material that is exceptionally flexible and pliable made of a polymer. They are used to store food, electronics, pharmaceuticals, shipping, and retail displays for products...
A plastic bag is an unwoven single piece poly fabricated receptacle for storing, carrying, packaging of a wide variety of items and materials. Though they are very thin and easy to carry, plastic bags are strong, waterproof, and hold their shape under normal use...
A poly bag is a common shipping and packaging resource made of polymer material that is exceptionally durable, pliable, and customizable to fit any application. Made of polyethylene or polystyrene materials, poly bags are a precisely...
Evidence bags that cannot be tampered with are essential parts of any crime scene. These evidence bags are made of heavy-duty, leak-proof polyethylene that is tear- and puncture-resistant. They also have a very strong, sticky closing...
Pressure-sensitive adhesive tapes consist of a backing material film coated with an adhesive intended for relatively low-stress applications. Light pressure, usually done by the fingertips, is applied to initiate the binding. In the sticking process, the fluid properties...
A cardboard box is a shipping container made of thick heavy duty paper known as paperboard, which is more than 0.01 inch or 0.25 mm thick. The term cardboard is used as a generic descriptor for various types of solid firm papers used to produce boxes
Carpet tape is a double-sided tape designed for securing carpets or rugs to the floor. It's made of strong, durable, and adhesive material that can hold the carpet in place and prevent it from sliding or wrinkling. Carpet tape is used in
A corrugated box is a disposable container whose sides are made up of layers of material that include an inside layer, outer layer, and middle layer. The middle layer, between the outer and inner layers, is fluted, which are rigid wave shaped arches that provide cushioning...
One kind of pressure-sensitive self-adhesive tape is foam tape. It has one of several different backing materials and is made of foam. It may have adhesive on one or both sides. Foam tapes are, at their most basic level, tapes that are applied to uneven or
A mailing tube is a sturdy, solid, and durable cardboard container designed for shipping long slender devices and products or rolled up maps, banners, and posters. The indestructible exterior of mailing tubes...
Masking tape is pressure sensitive, thin and very adhesive, easy to tear paper that is used in various tasks ranging from masking off areas that are not to be painted or as insulation for electric wires among other...
Paper tubes consist of paper or paperboard sheet layers wound together to form strong, hollow, and usually cylindrical shapes. The paper layers are laminated or bonded together using adhesives. The wall thickness of the tube can vary depending on the number of layers wrapped during manufacturing...
A poster tube is a cylindrical, triangular, or rectangular hollow prism that is commonly used to transport rollable, unframed art, important documents, or long and slender materials. They also carry objects like...
PTFE stands for polytetrafluoroethylene and is a synthetic fluoropolymer used widely in many industries and many other applications. PTFE is also commonly referred to as thread seal tape, teflon tape, and plumber‘s tape...
A shipping tube is a long container used for mailing long items that are rolled or folded to fit in the tube. They are constructed of various types of materials with Kraft paper being the most common and widely...
A Sonotube® is a cardboard concrete forming tube made of waxed paper or lamination that is wound into a tube into which concrete is poured to create supports, columns, and supports for posts. Sonotube® is a registered trademark owned by SPC RESOURCES, INC...
A tape and label core is a thick durable tube that forms the center of a label or tape roll with the same shape as that of a toilet paper or paper towel core but is sturdier and more resilient. Although the shape of tape and...