Guide · 4 min read
Cast vs Blown Pallet Wrap: Which Should You Use?
Every roll of pallet wrap is made one of two ways — cast or blown. They look almost identical on the roll, but they behave very differently on a pallet, and picking the wrong one costs you money. Here's the difference in plain English.
What is cast pallet wrap?
Cast film is made by rapidly cooling the plastic on chilled rollers. The result is a clear, glossy, quiet film that unwinds smoothly and easily off the roll.
Cast wrap is best when clarity matters (you can read labels and barcodes through it), when operators wrap by hand for long shifts (it's low-effort to apply), and when your loads are uniform and stable. It's typically the lower-cost option per roll.
What is blown (sticky) pallet wrap?
Blown film is made by blowing air into the molten plastic, like blowing up a balloon, then cooling it in the air. This gives the film a hazier look but much higher strength, better tear resistance and more cling — which is why it's often called "sticky" film.
Blown wrap is best for heavy, sharp or irregular loads that need maximum holding force, and where a puncture or tear could mean a collapsed pallet. It clings harder, so it holds awkward loads tighter — and because it's stronger, you can often use less film per pallet.
Cast vs blown — the quick comparison
Choose CAST if you want: clearer film, quieter and easier hand-wrapping, lower cost per roll, and you're wrapping stable, uniform loads.
Choose BLOWN (sticky) if you want: maximum strength and cling, better tear and puncture resistance, secure hold on heavy or irregular loads — and better value for money overall, because the extra strength means less film used per pallet.
So which should you buy?
For most everyday warehouse and distribution work, cast film does the job at the lowest cost. If you ship heavy, sharp-edged, or irregular pallets — or you've had loads shift or collapse — blown film is worth the small extra cost because it holds tighter and you use less of it.
Not sure? The cheapest way to decide is to test both on your own loads. We send free samples of cast and blown film so you can feel the difference before you commit to a pallet.
Common questions
Is blown pallet wrap stronger than cast?
Yes. Blown film has higher tear and puncture resistance and more cling, so it holds heavier and more irregular loads more securely. Cast film is clearer and easier to apply but not as strong.
Is cast or blown cheaper?
Cast film is usually cheaper per roll. However, blown film's extra strength often means you use less per pallet, so blown can work out better value for money on heavy loads.
Want a free sample or a quote?
Test our film on your own loads. Free samples, free UK delivery, and same-day quotes — cast or blown, 25 or 35 micron.