Stretch Film Gauge Chart: Gauge to Mil and Micron, Load Weights and Stocked Rolls
100 gauge is 1 mil and each gauge is 0.254 micron, so the 80 gauge hand film most warehouses buy is 0.8 mil or 20 microns. The chart converts every common gauge, gives the load weight each is planned for, lists every stocked gauge, width and length with case pricing, and works out how much film one pallet uses at hand and machine stretch rates.
Gauge to mil and micron
Gauge is the North American unit for stretch film thickness: 100 gauge equals 1 mil, so 80 gauge is 0.8 mil, and each gauge is 0.254 micron. Most of the rest of the world quotes film in microns, which is why a spec sheet for imported film reads 20 or 23 microns where a US catalog says 80 or 90 gauge. The chart converts each common gauge and pairs it with the load weight suppliers plan around. Load figures assume a square, uniform pallet of cartons; sharp corners, protruding parts and mixed-size loads move a load up one or two gauges.
| Gauge | Mil | Microns | Typical load (uniform pallet) | Use | Stocked widths |
|---|---|---|---|---|---|
| 37 | 0.37 | 9.4 | Light bundling only | Pre-stretched hand film; very light cartons | Not stocked |
| 40 | 0.40 | 10.2 | Light bundling | Pre-stretched hand film; light uniform loads | Not stocked |
| 47 | 0.47 | 11.9 | Up to about 800 lb, uniform | Light hand wrap, cast | Not stocked |
| 50 | 0.50 | 12.7 | Up to about 1,000 lb | Economy hand wrap | Not stocked |
| 57 | 0.57 | 14.5 | Up to about 1,200 lb | Light-duty hand wrap | Not stocked |
| 60 | 0.60 | 15.2 | Up to about 1,500 lb | The standard light hand wrap for uniform cartons | Hand: 12, 15, 18 in (6 rolls); Machine: 20 in (2 rolls) |
| 63 | 0.63 | 16.0 | Up to about 1,600 lb | Equivalent hand film | Not stocked |
| 70 | 0.70 | 17.8 | Up to about 1,800 lb | Medium hand wrap, mixed cartons | Hand: 12, 15, 18, 20, 30 in (10 rolls); Machine: 20 in (2 rolls) |
| 75 | 0.75 | 19.1 | Up to about 2,000 lb | Medium hand or machine wrap | Hand: 18 in (1 roll); Machine: 20 in (3 rolls) |
| 80 | 0.80 | 20.3 | Up to about 2,400 lb | The industry default for hand wrap; most machine film starts here | Hand: 2, 3, 5, 7.5, 10, 12, 15, 17, 18, 20, 30 in (64 rolls); Machine: 20, 30 in (11 rolls) |
| 90 | 0.90 | 22.9 | Up to about 2,600 lb | Heavy hand wrap, edges and corners | Hand: 12, 15, 18, 20, 30 in (9 rolls); Machine: 20 in (2 rolls) |
| 100 | 1.00 | 25.4 | Up to about 3,000 lb | Heavy hand or machine wrap, irregular loads | Hand: 2, 3, 5 in (3 rolls) |
| 120 | 1.20 | 30.5 | Up to about 3,500 lb | Extra heavy hand wrap, sharp edges, drums | Hand: 2, 3, 5, 12, 15, 18, 20 in (14 rolls) |
| 150 | 1.50 | 38.1 | Over 3,500 lb, sharp or irregular loads | Machine wrap for very heavy or hazardous loads | Not stocked |
Equivalent film is the exception to the gauge rule. A resin-engineered 63 gauge 'equivalent to 80' film performs like 80 gauge at lower thickness because it holds more stretch, and pre-stretched 37 and 40 gauge films are applied with almost no further stretch. Compare equivalents on holding force and puncture, not thickness; the mil to micron chart covers the arithmetic for every film type.
Stocked stretch film by gauge, width and length
Every combination in stock, cheapest product per combination. Hand film is 12, 15 and 18 inch; machine film is 20 inch on a 3 inch core. Cast film is clear and quiet with high cling on one side; blown film is tougher and holds better on loads with sharp edges but is louder to apply and less clear. The hand vs machine film page covers the crossover point.
| Type | Gauge | Microns | Width (in) | Length (ft) | Film | Case price |
|---|---|---|---|---|---|---|
| Hand | 38 | 10 | 17.2 | 1,500 | Standard | $72.90 (18.23/roll) |
| Hand | 60 | 15 | 12 | 2,000 | Standard | $93.73 (23.43/roll) |
| Hand | 60 | 15 | 12 | See product | Standard | $98.94 (24.73/roll) |
| Hand | 60 | 15 | 15 | 2,000 | Standard | $102.06 (25.52/roll) |
| Hand | 60 | 15 | 15 | See product | Cast | $109.36 (27.34/roll) |
| Hand | 60 | 15 | 18 | 2,000 | Standard | $102.06 (25.52/roll) |
| Hand | 70 | 18 | 12 | 1,500 | Standard | $88.52 (22.13/roll) |
| Hand | 70 | 18 | 12 | See product | Cast | $107.80 (26.95/roll) |
| Hand | 70 | 18 | 15 | 1,500 | Standard | $98.94 (24.73/roll) |
| Hand | 70 | 18 | 15 | See product | Standard | $104.14 (26.04/roll) |
| Hand | 70 | 18 | 18 | 1,500 | Standard | $98.94 (24.73/roll) |
| Hand | 70 | 18 | 18 | See product | Cast | $104.14 (26.04/roll) |
| Hand | 70 | 18 | 20 | 1,000 | Standard | $44.43 |
| Hand | 70 | 18 | 30 | 1,000 | Cast | $164.70 (41.17/roll) |
| Hand | 75 | 19 | 18 | 1,500 | Blown | $115.34 (28.84/roll) |
| Hand | 80 | 20 | 2 | 1,000 | Standard | $113.26 |
| Hand | 80 | 20 | 3 | 1,000 | Standard | $86.91 |
| Hand | 80 | 20 | 3 | 1,500 | Standard | $113.02 |
| Hand | 80 | 20 | 3 | See product | Standard | $120.04 |
| Hand | 80 | 20 | 5 | 1,000 | Standard | $40.09 (10.02/roll) |
| Hand | 80 | 20 | 5 | 1,500 | Standard | $136.31 |
| Hand | 80 | 20 | 5 | 500 | Standard | $99.61 |
| Hand | 80 | 20 | 5 | See product | Standard | $140.26 |
| Hand | 80 | 20 | 7.5 | See product | Standard | $75.37 (18.84/roll) |
| Hand | 80 | 20 | 10 | 1,000 | Standard | $117.17 (29.29/roll) |
| Hand | 80 | 20 | 12 | 1,500 | Standard | $93.73 (23.43/roll) |
| Hand | 80 | 20 | 12 | See product | Standard | $88.92 (22.23/roll) |
| Hand | 80 | 20 | 15 | 1,000 | Standard | $124.97 (31.24/roll) |
| Hand | 80 | 20 | 15 | 1,500 | Blown | $104.14 (26.04/roll) |
| Hand | 80 | 20 | 15 | See product | Cast | $109.36 (27.34/roll) |
| Hand | 80 | 20 | 17 | 1,500 | Standard | $233.53 (58.38/roll) |
| Hand | 80 | 20 | 18 | 1,500 | Standard | $102.06 (25.52/roll) |
| Hand | 80 | 20 | 18 | 375 | Standard | $78.87 (19.72/roll) |
| Hand | 80 | 20 | 18 | See product | Cast | $109.36 (27.34/roll) |
| Hand | 80 | 20 | 20 | 1,000 | Cast | $107.80 (26.95/roll) |
| Hand | 80 | 20 | 30 | 1,000 | Cast | $181.44 |
| Hand | 90 | 23 | 12 | 1,500 | Standard | $98.94 (24.73/roll) |
| Hand | 90 | 23 | 12 | See product | Standard | $104.14 (26.04/roll) |
| Hand | 90 | 23 | 15 | 1,000 | Standard | $98.90 (24.73/roll) |
| Hand | 90 | 23 | 15 | 1,500 | Blown | $109.36 (27.34/roll) |
| Hand | 90 | 23 | 15 | See product | Cast | $114.56 (28.64/roll) |
| Hand | 90 | 23 | 18 | 1,500 | Blown | $124.34 (31.09/roll) |
| Hand | 90 | 23 | 20 | 1,000 | Cast | $140.72 (35.18/roll) |
| Hand | 90 | 23 | 30 | See product | Cast | $197.61 (49.40/roll) |
| Hand | 100 | 25 | 2 | 650 | Standard | $112.70 |
| Hand | 100 | 25 | 3 | 650 | Standard | $106.67 |
| Hand | 100 | 25 | 5 | 650 | Standard | $119.69 |
| Hand | 120 | 30 | 2 | 600 | Standard | $115.26 |
| Hand | 120 | 30 | 3 | 600 | Standard | $83.59 |
| Hand | 120 | 30 | 3 | 650 | Standard | $126.87 |
| Hand | 120 | 30 | 5 | 600 | Standard | $158.55 |
| Hand | 120 | 30 | 5 | 650 | Standard | $144.08 |
| Hand | 120 | 30 | 12 | 1,000 | Standard | $89.45 (22.36/roll) |
| Hand | 120 | 30 | 12 | See product | Cast | $126.24 (31.56/roll) |
| Hand | 120 | 30 | 15 | 1,000 | Blown | $106.76 (26.69/roll) |
| Hand | 120 | 30 | 15 | See product | Cast | $109.36 (27.34/roll) |
| Hand | 120 | 30 | 18 | See product | Cast | $117.17 (29.29/roll) |
| Hand | 120 | 30 | 20 | 800 | Standard | $184.86 |
| Machine | 60 | 15 | 20 | 7,500 | Standard | $102.84 |
| Machine | 70 | 18 | 20 | 6,000 | Cast | $119.77 |
| Machine | 70 | 18 | 20 | 6,500 | Blown | $110.73 |
| Machine | 75 | 19 | 20 | 5,000 | Standard | $79.68 |
| Machine | 75 | 19 | 20 | See product | Standard | $98.29 |
| Machine | 80 | 20 | 20 | 5,000 | Standard | $103.70 |
| Machine | 80 | 20 | 20 | 6,000 | Blown | $123.62 |
| Machine | 80 | 20 | 30 | See product | Cast | $154.27 |
| Machine | 90 | 23 | 20 | 5,000 | Blown | $117.17 |
| Machine | 90 | 23 | 20 | See product | Cast | $117.17 |
How much film a pallet uses
Film cost per pallet depends more on stretch than on gauge. A hand wrapper who stretches the film 50 percent uses roughly twice the length of a powered pre-stretch carriage at 200 percent, so the higher-gauge film often costs less per pallet on a machine than a lighter film does by hand. The table runs the arithmetic for a standard 48 x 40 pallet wrapped with 3 passes at the base, 2 at the top and a 50 percent overlap up the load.
| Pallet (48 x 40, load height) | Perimeter | Wraps (3 bottom, 2 top, 50% overlap) | Film used at 0% stretch | At 150% stretch | At 250% stretch |
|---|---|---|---|---|---|
| 48 in | 176 in | 9 passes | 132 ft | 53 ft | 38 ft |
| 60 in | 176 in | 10 passes | 147 ft | 59 ft | 42 ft |
| 72 in | 176 in | 11 passes | 161 ft | 65 ft | 46 ft |
For a 1,500 ft hand roll, the 60 inch load at 100 percent stretch uses about 74 ft, or 20 pallets per roll. The same roll on a machine at 250 percent wraps about 35 pallets. Roll counts per pallet are the number to check when comparing a 60 gauge quote against an 80 gauge one: the heavier film costs more per roll and less per pallet when the wrapper is working hard.
Choosing a gauge
- Uniform cartons, under 1,500 lb, hand wrapped: 60 or 63 gauge. Most ecommerce outbound pallets sit here.
- Mixed cartons or anything over 1,500 lb: 70 to 80 gauge. 80 is the default gauge that most hand wrap is sold in for a reason: it tolerates the inconsistent stretch of hand application.
- Sharp corners, drums, pails, metal parts, wire: 90 to 120 gauge blown film, or a lighter film with edge protectors under it.
- Machine wrap: 63 to 80 gauge for most loads at 200 to 250 percent pre-stretch; 100 to 150 gauge only for loads over 3,000 lb or where the receiver specifies it.
- Cold storage and outdoor: step up one gauge; film loses stretch and cling below about 40 F and UV breaks it down over weeks. The pallet cover guide covers weather protection on top of the wrap.
For stacking the load before it is wrapped, the pallet count table gives layers and heights for 60 box sizes.
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Frequently asked questions
How many microns is 80 gauge stretch film?
20.3 microns. Gauge x 0.254 = microns, so 60 gauge is 15.2, 70 gauge is 17.8, 90 gauge is 22.9 and 120 gauge is 30.5 microns.
What does gauge mean in stretch film?
Thickness. 100 gauge equals 1 mil (one thousandth of an inch), so 80 gauge film is 0.8 mil thick. Higher gauge is thicker film with more puncture resistance and holding force.
What gauge stretch film should I use?
60 to 63 gauge for uniform cartons under 1,500 lb by hand, 80 gauge for mixed or heavier loads, 90 to 120 gauge blown film for sharp or irregular loads. Machine wrappers usually run 63 to 80 gauge at 200 to 250 percent pre-stretch.
Is 80 gauge thicker than 60 gauge?
Yes. 80 gauge is 0.8 mil (20.3 microns) and 60 gauge is 0.6 mil (15.2 microns), a third thicker. 80 gauge holds roughly 2,400 lb loads against 1,500 lb for 60 gauge on a uniform pallet.
How much stretch film does one pallet use?
A 48 x 40 pallet loaded 60 inches high takes about 147 ft of 18 inch film at no stretch, 59 ft at 150 percent and 42 ft at 250 percent, assuming 3 bottom wraps, 2 top wraps and 50 percent overlap.