Short answer: 100 gauge = 1 mil ≈ 25 microns, so 80 gauge ≈ 20 microns. Thicker isn't automatically better. The cheapest film is the thinnest one that holds your loads securely, measured as cost per pallet.
Gauge, mil and micron
| Gauge | Mil | Approx. microns | Typical use |
|---|---|---|---|
| 47–60 | 0.47–0.6 | 12–15 | Pre-stretched hand film, light uniform loads |
| 70 | 0.7 | 18 | Light to medium loads |
| 80 | 0.8 | 20 | The general-purpose hand film standard |
| 90–100 | 0.9–1.0 | 23–25 | Heavier loads |
| 120+ | 1.2+ | 30+ | Heavy, sharp or irregular loads |
True gauge vs. equivalent gauge
True gauge film is actually as thick as its label. Equivalent (performance) gauge film is thinner, but its resin is engineered to perform like a thicker film. Equivalent films can cut cost and plastic use, but quality varies. Judge them on your loads, not the label.
Cast vs. blown film
- Cast: clear, quiet, smooth unwind. A common default for hand and machine wrapping.
- Blown: typically tougher and more puncture-resistant, with better cling. Often used for loads with sharp edges.
How to cut stretch film costs
- Measure cost per pallet. Weigh a roll before and after wrapping a typical load. That tells you the real cost.
- Try pre-stretched film for hand wrapping. It's lighter, easier on workers, and usually uses less material per pallet.
- Check machine pre-stretch settings. Powered pre-stretch wrappers can stretch film several times its length. Settings left too low waste film.
- Downgauge carefully. Test a thinner or high-performance film on real loads before switching.
- Fix the wrap pattern. Consistent top and bottom wraps and proper overlap matter more than film thickness.
Want a cost-per-pallet comparison for your loads? Request a free packaging audit, or see our stretch film options.