Stretch Wrap Gauge Guide: Microns, Mil & Thickness Chart

What Is Stretch Wrap Gauge?

Gauge is a standard unit of thickness for stretch film, where 1 Gauge equals 0.254 microns (μm). In the US, buyers use “gauge” or “mil,” while the UK and Australia typically use microns. A higher number indicates a thicker, often stronger film, but resin quality also impacts performance.

Understanding these units is the first step to ensuring your palletized load survives transit without film failure.

Why Is 80 Gauge the Industry Standard?

80 gauge stretch wrap is the industry benchmark because it supports loads up to 2,400 lbs at the lowest cost per pallet. This thickness offers the optimal balance of puncture resistance and elongation. For most uniform loads wrapped by machine, 80 gauge provides sufficient “load retention” without the unnecessary expense of thicker, heavier films.

Stretch Wrap Gauge Conversion Chart (US/UK/AU)

Use this chart to match your local measurement unit—Gauge (US), Microns (AU/UK), or Mil—to the correct film specification. As a manufacturer, we recommend these parameters for optimal load stability.

Stretch Wrap Gauge (US Std)	Microns (μm) – Global	Mil Thickness (US)	Max Load Weight	Best Application
47 Ga (High-Perf)	12 μm	0.47 Mil	Up to 2,000 lbs	Machine Wrap (Downgauging)
60 Ga	15 μm	0.6 Mil	Up to 1,500 lbs	Light Boxes / Hand Wrap
80 Ga (Standard)	20 μm	0.8 Mil	Up to 2,400 lbs	Standard Pallets / Machine Wrap
90 Ga	23 μm	0.9 Mil	Up to 2,800 lbs	Irregular Loads / Hand Wrap
120 Ga	30 μm	1.2 Mil	Over 3,000 lbs	Sharp Edges / Heavy Machinery

Tip: If you are in the UK or Australia, look for the Micron (μm) rating. In the US, Gauge or Mil is standard.

True Gauge vs. Equivalent Gauge: What’s the Difference?

True gauge measures the film’s actual physical thickness, while equivalent gauge describes its performance relative to standard film. Many manufacturers use advanced resins to create a “True 47 Gauge” film that performs identically to a “Standard 80 Gauge” film. Always verify the “Equivalent Gauge” rating to ensure you are getting the load-bearing strength you paid for.

How to Choose a Gauge for Different Load Types?

Match the gauge to the load’s weight distribution and edge sharpness to prevent breakage. We recommend the following specifications:

Light & Uniform Boxes: Use 60-70 gauge. It is cost-effective for stable loads under 1,500 lbs.
Heavy Machinery or Sharp Edges: Use 90-120 gauge. Thicker film prevents punctures from corners and edges.
Long-Distance Export Shipping: Use high-performance 80 gauge. Its superior “load retention” resists vibration fatigue over long transit times.

Hand vs. Machine Stretch Wrap: Which Gauge?

Machine stretch wrap is typically thinner than hand wrap because machines apply higher pre-stretch percentages (200–300%). A machine can optimize a 47 gauge film to perform like an 80-gauge film. Conversely, hand wrap requires a thicker starting gauge (usually 60-80 gauge) because human force cannot achieve the same level of elongation, requiring more material to maintain integrity.

How Do I Know If My Gauge Is Too Thin?

If your film tears easily at the corners or your load shifts during transit, your gauge is likely too thin. Tearing indicates poor puncture resistance against sharp edges, suggesting a need for 90+ gauge film or the addition of corner boards. Load shifting usually means the film’s “memory” has failed; switch to a higher-performance resin or increase your wrap count rather than just the gauge.

Does Higher Gauge Mean Better Quality?

Not necessarily, a higher gauge does not automatically mean better quality or protection. Modern nanotechnology allows for thinner films (like 47 gauge) to outperform older, thicker films (like 80 gauge) due to superior resin strength and elasticity. Focusing solely on gauge ignores critical factors like cling, tear resistance, and elongation rate. Always prioritize the film’s performance specs over its raw thickness.