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Introduction
This article will provide detailed information about plastic pallet covers.
The article will feature topics such as:
What are plastic pallet covers?
How to use plastic pallet covers
Applications of plastic pallet covers
Types of plastic pallet covers
Pallet cover measurements and procedures
Industrial applications of plastic pallet covers
Differences between plastic covers and plastic pallet tarps
Important aspects of plastic pallet covers
And Much More...
Chapter 1: What are Plastic Pallet Covers?
Pallets are covered and protected with plastic pallet covers, commonly known as PPC, which are enormous gusseted poly bags used for storage and shipment. Pallets are found in storage facilities, shipyards, local businesses, warehouses, or even homes. Operations for storing and shipping require plastic pallet covers. Plastic pallet covers ensure that goods transported or stored on pallets are shielded from airborne contaminants, dampness, and other environmental factors. In contrast to bulky, heavy, and expensive pallet cover tarps, plastic pallet covers are designed to do the same job more conveniently and economically. They are a cheap and efficient way to safeguard the merchandise during shipment. Plastic pallet covers vary in size, shape, and form to perform various tasks such as helping businesses store and organize items. Plastic pallet covers protect items from damage due to water, dust, and minor abrasions. Plastic pallet covers can also be used to help brand a company’s items or to help identify items. They are intended to fit snugly over pallets and skids and are made of thin, strong plastic sheets that shield their contents from the outside environment. Pallet covers perform better than pallet cover tarps in terms of price, quality, and durability because they don't include as much material and don't significantly increase a shipment's weight or size. Pallet covers are great for temporary storage or shipment since they are simple to use, come in flat or gusseted forms, and may be personalized to keep products secure and tidy.
It's critical to remember that plastic pallet covers are intended to serve as a short-term solution to cover and protect items but are not intended as long-term substitutes for pallet tarps or other sturdier storage containers. Below, we'll examine how to use plastic pallet covers.
How to Use Plastic Pallet Covers
Pallet covers are easy to use; all users must do is drape them over the boxes placed on a pallet to secure these containers for temporary storage inside or outside. In addition, thermal pallet coverings can keep the pallet warm or cold during storage and delivery, making them ideal for shipments that need to be temperature controlled.
Using plastic pallet covers makes it much simpler to protect a pallet from impurities like dust, moisture, and even spills or leaks. Disposable pallet covers are an alternative, but reusable ones are frequently a better investment because one can use them repeatedly. Pallets that have already been shrink- or stretch-wrapped frequently employ plastic pallet covers for additional protection.
Advantages
Plastic pallet covers have various advantages; however, the following are some of the most widespread ones:
Security: Plastic pallet covers can give an extra layer of protection to shrink-wrapped packages, which is particularly helpful for goods that might be temperature- or weather-sensitive. Perishable items can be kept fresher longer by using thermal pallet coverings or UV-protected covers when storing or transporting them.
Variety: Regardless of the size or contents of the pallet, pallet covers are ideal for all forms of pallet protection because they come in various sizes. The options are further expanded by using custom pallet covers. In addition, fully waterproof pallet covers are offered to protect a pallet that might be exposed to heavy rains.
Reusability: Besides being simple to use, pallet coverings' reusability is one of their biggest advantages. Their reusability ensures they won’t end up in landfills, unlike the shrink wrap plastic also used to keep boxes of items together during storage and transport. Their reusability also leads to reduced costs.
Disadvantages
Despite the aforementioned benefits provided, there are disadvantages to consider when using plastic pallet covers. These drawbacks include:
Lack of Waterproofing: While most pallet coverings can guard against minor leaks or spills, they typically don't offer sufficient defense against larger spills or bad weather, such as torrential rain.
Waste: Despite their reusability, plastic pallet covers may eventually wear from misuse and extreme environmental conditions and need to be replaced. Plastic pallet cover material does not readily decompose which adds to the global waste issue.
Rooftop Use: In certain situations, plastic pallet covers are placed on the roof of a building to protect from weather. The covers may also be weighted down with bricks, pieces of wood or metal, and other heavy objects. However, these objects may become projectiles in more serious weather conditions.
Chapter 2: Applications of Plastic Pallet Covers
Plastic pallet covers protect goods from dust, dirt, moisture, and grease, which can easily happen in a warehouse setting. Their main use is to protect, which means keeping foreign materials out/away from stock or products. Some plastic pallet covers applications are listed below:
Plastic Pallet Covers Can Organize Items
Plastic pallet covers are useful for maintaining order among merchandise. Pallet coverings can help distinguish between various product categories or separate them from one another so that they can be easily discovered when preparing products for storage or transportation. Things can be kept together and shielded with a tough, personalized plastic pallet cover.
Plastic Pallet Covers Protect Products from Damage
Plastic pallet covers are a cheap approach to protect goods from environmental dangers like humidity, UV light, wind, and rain. Additionally, they guard against scratching damage and keep dirt, dust, and debris from getting on them. This additional degree of security is crucial for delicate products.
Plastic Pallet Covers Can Be Used to Brand Items
Plastic pallet covers support custom-branding possibilities. These covers can be printed in various patterns, dimensions, and hues. Pallet coverings can be customized with a company's color and logo to help customers differentiate specific products from competing brands more easily. Furthermore, plastic pallet covers provide branding benefits as they help identify a company as their products are shipped from their business, through various transportation companies, to businesses, and eventually reaching consumers.
Plastic Pallet Covers Can Hold Goods Packed in Gaylord Containers
Gaylord containers are those large cardboard containers you see resting on pallets in factories used to house an entire shipment in a single container. Gusseted poly pallet covers are used as liners for goods packed in Gaylord containers and to cover things on a pallet. Gusseted pallet cover bags provide additional durability and safety for items held within. These plastic pallet covers are ideal for serving the majority of transportation applications involving Gaylord containers.
Leading Manufacturers and Suppliers
Chapter 3: Types of Plastic Pallet Covers
Depending on the product that needs safeguarding, there are many different plastic pallet covers, each of which has advantages for a specific application. However, most plastic pallet covers fall under the categories of tarps, wraps, or covers. We examine many of these coverings in more detail below.
Shrink Wrap Plastic Pallet Coverings
As its name implies, shrink wrap contracts to form an airtight seal around a package. As a result, the commodities held within are shielded from outside contaminants like moisture, dust, and air. In addition, goods can be easily identified and somewhat protected from the elements since shrink wrap is clear and largely waterproof.
As opposed to stretch wrap, or stretch film, which is stretched over the pallet, shrink wrap uses heat to shrink the plastic around the merchandise for a snugger fit. After being heated, shrink wrap starts to contract, encasing containers in an airtight seal. Calculating how much shrink wrap is required to cover a pallet, however, can take time and experience.
A pallet is protected from spills and dirt and metal items are more resistant to rust once shrink-wrapped. In addition, this wrapping secures the goods on the pallet, reducing the possibility of items slipping off or being stolen.
Advantages
Protection: Shrink wrap offers complete 360-degree coverage for all products, preventing contamination and food spoilage.
Multiple Layers of Protection: Manufacturers frequently shrink wrap each box individually to seal products and guard against fouling. Once an entire pallet has been filled with boxes, the entire load may be shrink wrapped as one unit through an additional process for additional protection and to provide more convenient larger shipping units.
Ease: While some training is required to use a shrink wrap machine properly, the procedure is generally straightforward and secure.
Disadvantages
Shrink wrap has a lot of advantages; however, two things can make one rethink using it:
Shrink wrap has limited reusability and generally cannot be used again. After wrapping a pallet, this plastic film must be cut off because it cannot be reused. Additionally, more plastic will probably wind up in landfills as a result.
Shrink wrapping takes time and leads to decreased output. Shrink wrapping must be performed properly to ensure the film is correctly shrunk and to get the maximum protection from the wrapping. This procedure may slow production when utilizing shrink wrap to package individual things.
Blown Stretch Wrap
Stretch wrapping is another category of plastic wrap material used as pallet covering. Stretch wrapping involves a person or machine wrapping a plastic material around the boxes held on a pallet. Stretch wrap may be further classified as blown stretch wrap or cast stretch wrap based on how it is produced. Blown stretch wrap is created by melting plastic, running it through a die where it takes a thin-walled tubular shape, blowing air into the plastic to enlarge this form as it emerges from the die, and subsequently transforming into layers of plastic wrapping.
Blown stretch wrap produces a more resilient film than produced by casting methods. However, this process creates a more opaque film since plastic crystallizes during this process and results in reduced visibility of the items being wrapped. Also, since additional processes are required to transform the plastic into sheets, the thickness is often not as consistent as stretch wrap formed through casting. In addition, blown stretch wrap is more expensive to produce and is, subsequently, used much less than cast stretch wrap.
Cast Stretch Wrap
Cast stretch wrap is produced by rolling a heated resin sheet with cold rollers to form a clear, translucent film. Under this process, plastic is melted as it is fed into a heated screw barrel. The melted material is then run horizontally through a flat die. A slit in the die determines the wrap’s thickness as it emerges from the die. As the wrap continues to emerge from the die, it is subsequently cooled as it is wrapped around a chilled roller.
Plastic Pallet Tarp Covers
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
Clear plastic pallet covers can be utilized for pallets of goods stored inside or outside. Clear plastic pallet covers protect boxes from the outdoors, as well as irritants and contaminants like dust and humidity. In addition clear plastic pallet covers are transparent and offer a clear view of a shipment’s contents.
However, transparent pallet covers might not provide the proper UV protection for perishable objects. Due to their transparency, products are also more susceptible to temperature changes. Clear plastic pallet covers are best suited for short-term shipments when perishable items are involved.
Black Plastic Pallet Covers
Black plastic tarps are great at preventing theft by concealing the contents of specific shipments. Would-be burglars are less inclined to try to steal the contents of a shipment if they can't see what it contains. Additionally, most black pallet coverings feature a UV coating to shield the contents from direct sunlight. Shipments are protected from dirt, dust, and humidity and are resistant to little spills and leaks thanks to the plastic.
Advantages of Black Plastic Pallet Covers
Black poly materials are preferred when shipments need to be concealed or when UVI protection from the sun is required. Black plastic pallet covers can be produced in a huge range of mil thicknesses. In addition, rolls of these bags may be perforated for rapid and simple dispensing.
Thermal Plastic Pallet Covers
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
Pallet top sheets are plastic liners featuring perforated strips for simple dispensing and tearing off rolls. Like other plastic pallet covers, they function to shield products from contaminants like dust, mud, moisture, and grease which are all common in warehouses. Pallet top sheets differ slightly in their specific application than other plastic pallet covers in that they are designed to cover individual layers versus the entire load of a pallet. Pallet top sheets serve to not only protect shipments from exterior substances outside the pallet but, additionally, from leaking cartons found between layers of boxes. Pallet top sheets may perform their function individually or can be used in combination with other plastic pallet covers for extra protection.
Advantages
Rolls of pallet top sheeting have a 3-inch core and are perforated for simple tearing off.
Low-density polyethylene is used to make it.
Pallet top sheets can be recycled.
Pallet-Size Shrink Bags on Rolls
Pallet-size shrink bags are advised for usage with large machinery, heavy irregular loads, and for outside protection, This form of shrink wrap is essentially a gusseted bag dispensed on a perforated roll for simple peel-off. These bags cover an entire pallet of items and are warmed through a heat gun to confine boxes more securely.
Advantages
The UVI additive in these pallet coverings shields items from the sun's rays.
These bags are resilient and strong.
Pallet-size shrink bags help secure items for shipping.
Clear Pallet-Size Shrink Bags on Rolls
Clear pallet-size shrink bags provide transparency and strength when covering large pallet loads. Again, their transparency can serve as a double-edged sword since items housed beneath these bags face increased UV exposure during transport or if stored outside. Clear pallet-size shrink bags are sold in rolls of 25 bags each. Thick 4 mil plastic is used to make shrink bags which help stabilize and secure large loads.
Advantages
Clear pallet-size shrink bags offer good confinement for large or normal-sized loads.
They provide a convenient source of protection for shipments containing multiple pallets.
Clear pallet shrink bags are resistant to environmental factors like moisture or dirt.
This pallet wrap's transparency makes it simple to see the things transported.
Gusseted Black UVI Pallet Covers on Rolls
Gusseted black UVI (ultraviolet-inhibiting) pallet covers on rolls are pre-cut and perforated for quick and simple dispensing. They aid in keeping goods clean, dust-free, and light-free. These covers are frequently used as machinery coverings or to line Gaylord containers and protect objects stored within them from moisture and foreign object contamination. These black plastic pallet covers are ideal for outdoor storage. Their black opaque film aids in preventing theft by concealing the pallet's contents and shields items that might be light-sensitive. Strong polyethylene provides affordable protection, and their pleated sides stretch to the width of most conventional pallets.
Advantages
Gusseted black UVI black pallet covers provide protection from the sun.
They are roll perforated for simple dispensing.
They are both recyclable and reusable.
Vented Pallet Wrap
Vented pallet wrap allows moisture and condensation to escape and is ideal for frozen or cold storage products as a result of this property. In addition, vented pallet wrap rolls are lighter than traditional stretch film rolls which results in reduced shipping costs. The vents also allow for easier handling when using these wraps.
Advantages
Vented pallet wrap is available in both machine-operated and manual hand-wrap rolls.
Vented pallet wrap is made from high-density polyethylene, which leaves little carbon footprint to produce.
They are easier to use and cheaper than traditional strapping used to confine pallet loads.
Pallet Cover Bags
Pallet cover bags guarantee that bin and box contents stay contained and shielded from moisture, dirt, and abrasion. Because they are composed of strong and transparent materials, these bags will survive for a long time and allow easy inspection of the contents. Several sizes and gauge thicknesses are offered to satisfy varied protective needs.
Poly Tarps
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
Poly top sheets are also available to provide enhanced protection for the individual layers of boxes stacked on a pallet. Poly top sheets contribute to the integrity of stored goods by shielding them from mud, dust, moisture, bacteria, and fungus. Poly top sheets conform to FDA guidelines and requirements for covering food goods and come in various sizes to accommodate different boxes. Standard sizes range from 60" by 60" to 75" by 75" and they are also offered in various thicknesses
Chapter 4: Pallet Cover Measurements & Procedures
Pallets are constructed in a variety of sizes and shapes. Selecting pallet wrapping options might be challenging due to this attribute. Care must be taken to choose the proper size of plastic pallet cover so that it can fit over the pallet and its contents tightly. Measuring the shipment itself is the quickest and easiest approach to make sure the correct size pallet cover is chosen. The size of the pallet cover required can be determined using the following formula.
First, measure the pallet's width (W), depth (D) (or length), and height (H). The width should then be increased by around four inches. For pallet measurement purposes one should calculate the height of a pallet by dividing the newly calculated width in half and adding it to the measured height. An example of this measurement formula is featured below.
Depending on how snugly or loosely the cover has to be applied to the boxes on a pallet, those extra (four) inches added to the width might be adjusted. For example, calculate using two inches rather than four for a closer fit.
The dimensions of the pallet cover needed, for instance, are 50 inches x 49 inches x 75 inches if the pallet is 46 inches wide, 49 inches deep, and 50 inches long.
Plastic Wrap Pallet-Covering Procedure
Although there are no set rules for pallet wrapping, the following sequence is typically used:
After wrapping, rip the plastic wrap and attach one end to the pallet to keep it in place.
Use a heat tool to shrink the film used for shrink wrap to form an airtight covering over the pallet.
Then, allow the film to shrink and fit around the pallet.
Check the products' stability to ensure they are all stable and won't fall over during transit.
To add further protection, slide a pallet cover over the top of the loaded object.
Proper Plastic Pallet Cover Usage
When plastic pallet covers are used to protect boxes held on pallets, the following steps are typically followed.
Boxes are stacked and arranged on the pallet. Then, measure the shipment to verify the pallet cover is the appropriate size.
Once measurements have been established, slide the cover over the cargo, so it fits snuggly.
Chapter 5: Industrial Applications of Plastic Pallet Covers
Plastic pallet covers are ideal for various uses and provide excellent ventilation for commodities. Plastic pallet covers also make it possible to economically package and ship pallets of products. The following are some industrial applications for plastic pallet covers:
Covering Appliances
Covering Chemicals, Building and Automotive Supplies, and Materials for Flooring
Covering Furniture
Storing Manufactured Foam
Holding Medical Supplies
Housing Food Service Supplies
Covering Drugs and Pharmaceuticals
The thickness of plastic pallet covers ranges from 1 mil to 4 mils. Pallet cover bags rated 1 mil are frequently used to protect things on a pallet for a short period. In addition to being thicker plastic for improved protection, a 4 mil pallet cover bag is frequently used as a reusable pallet cover that repeatedly covers and uncovers palletized goods. Plastic pallet covers featuring the lightest gauge (1 mil clear pallet covers) are perfect for loads without sharp edges that don't need to be protected from tears and punctures. Plastic pallet coverings featuring 1.5 mils offer excellent dust and moisture protection while saving money. 2 mils plastic is slightly thicker, suitable for most warehouse tasks, and offers protection from moisture, paint, and dust and features tear resistance. Pallet and machinery coverings made of 3 mil polypropylene are excellent for use as container liners. The thickest available pallet coverings are 4 mil; these plastic covers offer excellent tear resistance and are suggested for pallet loads with potentially dangerously sharp edges.
Chapter 6: Plastic Pallet Covers and Plastic Pallet Tarps
Plastic tarps and covers are different grades of plastic that perform the same function. The differences between them include how they are used, the weight of the material from which they are made, their thickness, and lifetime of usage. Tarps are reusable, thick, and heavy weight designed for repeated use, which is unlike shrink wrap plastic that is removed when a shipment reaches its destination.
Lightweight plastic covers are thin and flimsy designed for one and done shipments or in warehouse protection. They provide sufficient protection for short haul deliveries and keep loads secure. Lightweight plastic pallet covers are often used in warehouses to protect loads from dirt, dust, and debris. They are waterproof enough to provide minimal water resistance and can provide protective covering when moving products.
Tarps, known as tarpaulins, have been around for hundreds of years and were originally made of canvas, burlap, and cotton. The construction of tarps shifted with the introduction of plastic fabrics, which are more resilient, reliable, durable, and longer lasting.
In the modern era, canvas or fabric tarps have been replaced by vinyl and plastic tarps due to the expense of canvas tarps, which are still used by the military and heavy industry. Tarps are made of:
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.
Mesh: Mesh tarps are made of a durable polyester mesh fabric that allows air to circulate due to small holes between the fabric threads. They have low wind resistance but provide protection from UV rays.
Biobased Plastics: Biobased plastics are made from biomass such as vegetable oils, corn starch, woodchips, sawdust, and food waste. The plastics made from biomass have the same consistency as regular plastic and are biodegradable. As of the moment, only one per cent of the plastics manufactured in the world are biobased plastics.
Although plastic has been an environmental pollution problem, most of the plastics used to produce plastic pallet covers are recyclable and able to be repurposed at the end of their useful life. They fall into the classifications of post consumer recycled content (PCR) and post industrial recycled content (PIR) each of which is used to make new plastic pallet covers.
The plastic pallet cover industry emphasizes their constant and continuous work to ensure that the products that they produce can be recycled and not thrown into waste disposal dumps.
Chapter 7: Important Aspects of Plastic Pallet Covers
Pallet covers are available in different sizes and thickness combinations. They can be custom-made to size for any required application.
Plastic Pallet Covers Thickness: Pallet Covers range from 1 mil to 4 mil thick. 1 mil pallet cover bags temporarily protect items on a pallet. A 4 mil pallet cover bag is a thicker plastic which provides excellent tear protection, and is reusable to repeatedly cover and uncover palletized items.
Plastic Pallet Covers Can Be Custom Printed: Logos and any other information required by the user can be printed on plastic pallet covers.
The main differences between a pallet cover and a pallet tarp include the materials used, the lifespan of the cover, and the cost.
The Material Used in Covers & Tarps: Less expensive alternative material for pallet covers is made from low-density polyethylene. Pallet cover tarps are made from longer-lasting woven polyester.
Longevity: UVI, moisture, and severe temperatures are just a few variables that might affect the durability of woven poly and low-density polyethylene. Some pallet covers can be reused by adding additives such as a UV blocker to LDPE (low-density polyethylene) to extend the material's lifespan. In a regulated atmosphere, plastic pallet covers typically serve as a dust shield for objects for years.
Cost: Plastic pallet coverings are worth the cost because they can be used repeatedly and, when used properly, practically last as long as woven poly tarps.
How to Know When to Buy Clear Pallet Covers vs. Black UVI Pallet Covers: Black UV-resistant pallet covers may be required for products if they will be left outside for an extended period and require protection from the sun. Otherwise, one may utilize clear or regular black pallet covers.
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 or pallet shrink bags are employed to protect an entire pallet’s contents. Top sheets for pallets can be used alone, in combination with pallet covers, bags, or both. Pallet top cover sheets are frequently employed for a variety of uses. First, they assist in separating stacked layers on a pallet. Suppose, for instance, a pallet is stacked with boxes of ink pens on top and boxes of paper at the bottom. The ink from one of the pen boxes, if it were to be smashed, could flow down and onto the paper. Another use for a top sheet would occur if the pallet's top needs temporary protection from moisture, dust, dirt, and grease when being stored.
Conclusion
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:
Weather Protection
Protection from Puncture Holes
Protection from Theft
Reusability
Recyclability
Branding Opportunities
Availability in Various Gauges and Sizes
Leading Manufacturers and Suppliers
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