Stretch Film Reduction: How Can You Drastically Reduce Plastic in Logistics Packaging?
- Karine Morel
- [wpcode id="48710"]
Table of content
In a context where environmental, economic, and regulatory pressures continue to increase, logistics companies must reinvent their packaging practices. Reducing plastic packaging particularly stretch film is no longer simply a CSR initiative: it has become a logistical, economic, and operational necessity.
For warehouse and Supply Chain managers, one question now dominates: how can plastic usage be reduced while maintaining pallet stability, productivity, and safety?
The good news is that solutions already exist. They are efficient, proven, and designed to replace a large portion of stretch film applications.
Among them, the COMBO Solution developed by CGP Coating Innovation stands out:
STABULON®, the anti-slip palletizing sheet for vertical stability,
STABUSTRAP®, the reusable elastic band for peripheral load containment,
STABUSTOP®, the anti-slip pallet feet designed to secure the pallet base.
Together, these three technologies significantly reduce—and in some cases eliminate—the need for stretch film while improving logistics safety.
1- Why Reduce Stretch Film in Logistics?
1.1. Environmental and Regulatory Pressure
Reducing plastic usage is becoming imperative for businesses. Across Europe, regulations are becoming increasingly stringent: recyclability targets, penalties on non-recyclable plastic packaging, tonnage reporting requirements, plastic taxes, and more.
Although stretch film is highly effective, it remains a plastic material that is difficult to recycle. As a result, warehouses generate tons of waste every year.
Reducing its use immediately helps to:
- reduce carbon footprint,
- reduce waste,
- anticipate future regulatory requirements.
1.2. Operational and Economic Pressure
Beyond sustainability, reducing stretch film also helps to :
- lower purchasing costs,
- reduce wrapping time,
- accelerate logistics flows,
- improve safety by avoiding cutter-related injuries.
Less plastic = greater logistics efficiency.
2- The CGP COMBO Solution: A High-Performance Alternative to Stretch Film
CGP Coating Innovation has developed an integrated approach that replaces a large portion of stretch film with 100% recyclable paper-based solutions and reusable systems.
This combination provides a credible, sustainable, and industrially scalable alternative.
2.1. STABULON®: The Anti-Slip Sheet That Stabilizes Loads
Stretch film is often used to prevent load layers from sliding.
However, stretch film actually provides no friction between products.
By contrast, STABULON®, the anti-slip palletizing sheet, offers:
- a high coefficient of friction,
- excellent vertical stability,
- reduced lateral movement,
- improved cross-docking operations.
Depending on the application, STABULON® can reduce stretch film consumption by a factor of 2 to 4.
2.2. STABUSTRAP®: The Reusable Elastic Band for Peripheral Load Containment
Peripheral wrapping is one of the main causes of stretch film overconsumption.
STABUSTRAP® provides a simple solution:
- ultra-resistant elastic band,
- powerful and controlled load containment,
- reusable for dozens of cycles,
- quick and safe installation.
It replaces most of the stretch film wrapped around pallets, particularly for:
- internal transportation,
- homogeneous pallet loads,
- short and repetitive logistics flows.
Depending on the site, STABUSTRAP® can achieve a 50% to 80% reduction in stretch film usage.
2.3. STABUSTOP®: Anti-Slip Pallet Feet to Secure the Base
Pallet stability starts at the base.
STABUSTOP® is an exclusive anti-slip pallet foot system designed to:
- prevent pallet drift on conveyors,
- improve rack stability,
- limit deformation during impacts or braking.
Combined with STABULON®, STABUSTOP® absorbs part of the vibrations and prevents tipping something stretch film can never achieve.
It also contributes to a drastic reduction in fall risks.
3- Plastic Reduction: How to Integrate the COMBO Solution into a Warehouse ?
3.1. Flow Analysis
Every warehouse has specific characteristics:
- load types,
- product homogeneity,
- transportation methods,
- customer requirements (retail chains, export, etc.).
An audit phase helps identify where stretch film is overused and where it can be replaced.
3.2. Progressive Implementation
The transition to less plastic can be achieved in three steps:
Step 1 — Stabilize Internal Loads
→ Add STABULON® between layers.
Result: less slipping and greater stability.
Step 2 — Reduce or Replace Wrapping
→ Implement STABUSTRAP® for internal and repetitive logistics flows.
Step 3 — Secure the Base
→ Integrate STABUSTOP® to prevent any pallet movement.
3.3. Measured Results in Warehouses
Customer feedback shows:
- 30% to 80% reduction in stretch film usage,
- 98% reduction in plastic consumption on certain internal flows,
- 20% to 40% reduction in packaging costs,
- 15% to 25% reduction in instability-related disruptions,
- zero plastic waste on intra-logistics pallets.
4- Direct Benefits for Warehouse and Supply Chain Managers
✔ Immediate reduction of plastic packaging
Less stretch film, less waste, lower disposal costs.
✔ Improved pallet stability
The anti-slip sheet acts where stretch film has no effect.
✔ Enhanced operator safety
Fewer cutters, fewer risks, fewer musculoskeletal disorders.
✔ Faster operations
A quicker wrapping cycle means a more efficient warehouse.
✔ Measurable environmental impact
Each STABUSTRAP® cycle replaces several meters of stretch film.
✔ Enhanced customer image
Plastic reduction is becoming a major commercial advantage.
5- Conclusion: The COMBO Solution, A Practical Alternative to Plastic
Reducing plastic packaging in logistics is no longer an option.
Thanks to the COMBO Solution STABULON® + STABUSTRAP® + STABUSTOP® warehouses finally have a structured, sustainable, and high-performance approach to reducing, and sometimes eliminating, stretch film.
This combination delivers greater stability, less waste, lower costs, and increased productivity.
The transition toward more responsible logistics packaging starts here:
📩 Request an audit or a trial for your warehouse.
Our team will help you find the solution that meets your needs.