Understanding Semi-Stable Pallet Loads and the Best Stretch Wrapper Solutions
In the world of shipping and logistics, not all pallets are created equal. Some are perfectly neat and easy to stabilize, while others are fragile and irregular, making them tough to secure for transport. Most fall somewhere in between — and those are B loads.
If your facility deals with loads that are mostly stable but not quite perfect, you’re working with B loads. While not as straightforward as A loads, which we discussed in our previous article, they’re also not as unpredictable as C loads.
With the right stretch wrapping equipment, facilities handling B loads can strike the perfect balance between efficiency, safety, and cost savings.
In this article, we’ll cover
- What defines a B load
- Which industries frequently handle them
- The unique challenges B loads present
- The best types of stretch wrappers (turntable, rotary arm, orbital, robotic, automatic) for B loads
- Why wrapping B loads efficiently saves time, film, and labor costs
- Bonus: Frequently Asked Questions
We’ll also highlight trusted manufacturers — Robopac, Cousins, Handle It, and Highlight Industries — who offer proven solutions for B load environments.
Understanding Load Types: A, B, and C
Before we dive into B loads, let’s recap the difference between the different types of pallet loads we learned about during the A Load article discussion first. Stretch wrapping professionals categorize pallet loads into three basic groups:
- A Loads: Uniform, cube-shaped, and stable.
- Example: a pallet of identical cereal boxes.
- B Loads: Semi-stable. Some inconsistencies in shape, size, or stacking, but generally manageable.
- Example: a pallet with mixed-sized cartons or slight overhang.
- C Loads: Irregular, unstable, or fragile.
- Example: bagged flour, bulky furniture, or odd-shaped items.
B loads sit in the middle of the spectrum. They aren’t perfectly uniform like A loads, but they also don’t require the extra caution C loads demand.
What Exactly Is a B Load?
B loads are defined by partial instability. They aren’t neat cubes, but they also aren’t completely chaotic.
Common characteristics include:
- Mixed carton sizes: Not every box is identical, leading to uneven stacking.
- Light overhang: Some boxes extend slightly beyond pallet edges.
- Semi-irregular shapes: The overall pallet isn’t a perfect cube but still holds some structure.
- Shifting potential: If wrapped poorly, items may shift slightly during transit.
While B loads are generally secure enough to transport with proper wrapping, they still need more attention than A loads.
Industries That Commonly See B Loads
Many industries encounter B loads daily, especially those with moderate product variety or irregular shipping patterns:
- Food & Beverage: Pallets with a mix of different sized cases or multi-SKU shipments.
- Retail & E-Commerce: Mixed orders with slightly uneven stacking.
- Pharmaceutical & Healthcare: Assorted case sizes with some overhang.
- Consumer Packaged Goods (CPG): Seasonal promotions or combo packs that mix carton dimensions.
- Manufacturing: Parts and components that vary slightly in size or weight.
Facility that handle mostly uniform pallets with occasional irregularities are most likely wrapping B loads.
Challenges of Wrapping B Loads
At first glance, B loads may look stable, but their inconsistencies can cause problems if not wrapped correctly.
Typical challenges include:
- Film Waste: Over-wrapping to “play it safe” when loads are semi-stable.
- Load Shifting: Without consistent film tension, pallets can loosen in transit.
- Edge Crushing: Applying too much film force risks crushing weaker boxes.
- Slower Throughput: Operators may take extra time when wrapping B loads manually.
How Stretch Wrappers Help Facilities with B Loads
Investing in the right stretch wrapper makes handling B loads more efficient and cost-effective.
Key benefits include:
- Consistent Containment: Machines apply uniform tension, keeping semi-stable loads intact.
- Material Savings: Pre-stretch technology reduces film use by 30–50%.
- Labor Efficiency: Automated wrapping saves workers time and reduces fatigue.
- Reduced Damage Risk: Properly contained pallets arrive in better condition.
- Higher Productivity: More pallets can be wrapped per hour with less strain on employees.
Which Stretch Wrappers Work Best for B Loads?
Not all wrappers are equal when it comes to B loads. The best choice depends on your operation volume, typical load sizes, and degree of instability of your pallets when stacked.
1. Turntable Stretch Wrappers – Best All-Around for B Loads
- The load spins on a turntable while the film carriage applies film.
- Works well for pallets that are mostly stable with slight irregularities.
- Affordable and efficient for medium-volume operations.
Example: Handle It turntable wrappers are known for their balance of cost-effectiveness and reliability in semi-stable load environments.
2. Rotary Arm Stretch Wrappers – Best for Higher Instability
- The load stays stationary while the arm rotates around it.
- A smart choice if your B loads lean toward instability or often have moderate overhang.
- Faster and more stable than turntable wrappers for mid-to-high throughput.
Example: Robopac’s rotary arm machines ensure consistent containment without risk of tipping or shifting.
3. Robotic Stretch Wrappers – Best for Flexibility
- Mobile robots drive around the pallet, applying film.
- Excellent for facilities with limited space, multiple wrapping areas, or mixed load profiles (Best for A and B loads).
- Portable and easy to move where needed.
Example: Robopac and Handle It both offer robotic models ideal for facilities with varied wrapping needs.
4. Orbital Stretch Wrappers – For Specific B Load Applications
- The film carriage circles horizontally around the load.
- Not common for most B loads, but valuable if the load contains longer or bulkier items (like flooring, windows, or doors).
- More niche, but effective in building materials and furniture industries.
Example: Highlight Industries offers customizable orbital systems to handle long, oversized and awkward C loads.
5. Fully Automatic Systems – For High-Volume Operations
- Integrated into production lines to wrap pallets continuously.
- Best suited for facilities moving hundreds of B loads daily.
- Consistent, fast, and labor-free.
Example: Highlight Industries builds fully automated systems tailored to medium-instability load environments.
Cost Considerations for B Load Wrapping
Choosing the right stretch wrapper is an investment that pays for itself quickly.
- Semi-Automatic Turntable Wrappers: $7,000–$15,000. Perfect for B loads in mid-volume operations.
- Rotary Arm Machines: $15,000–$45,000. Worth it for higher throughput or semi-unstable B loads.
- Robotic Wrappers: $15,000–$25,000. Best for flexibility across multiple areas.
- Fully Automatic Systems: $50,000+. Ideal for large-scale facilities.
ROI Factors:
- Film savings of up to 30–50% from pre-stretch.
- Labor savings from automation and reducing manual wrapping.
- Fewer damaged loads, cutting down on product loss and returns.
Film Recommendations for B Loads
Film selection matters as much as machine type. Did you know that there are different types of film for wrapping machines versus film for hand wrapping?
Our machine stretch film solutions include different films recommended by our packaging experts and also includes information about how it’s different from hand-applied stretch film.
For B loads, however, you need a film that can stretch around product edges, without crushing the product. The balance is choosing a film that secures the load without squishing it.
For B loads:
- Machine-grade film designed for pre-stretching is essential.
- Cast film often works well, providing clarity and good cling for semi-stable loads.
- Blown film may be required for loads with sharper edges.
- Gauge: Typically, 60–80 is sufficient, depending on load weight and stability.
Real-World Example: Wrapping B Loads More Efficiently
A Midwest CPG company shipping mixed beverage cases faced frequent pallet instability when hand wrapping. Operators often over-wrapped pallets, wasting film and taking 4–5 minutes per load.
After installing a semi-automatic turntable wrapper from Handle It, they saw:
- Wrapping time drop to under 2 minutes per load
- Film usage reduced by 35%
- Fewer product shifts in transit
- The machine paid for itself in film and labor savings in less than a year.
Trusted Manufacturers for B Load Wrapping Solutions
At Nassco, we partner with top manufacturers known for their innovative, durable equipment:
- Robopac – Industry leader in rotary arm and automatic systems.
- Cousins Packaging – Heavy-duty, reliable wrappers for mid-range and high-volume operations.
- Handle It – Cost-effective turntable and robotic solutions for flexible B load wrapping.
- Highlight Industries – Customizable systems, including orbital and automatic options.
Our packaging equipment experts work with each of these manufacturers and more to stay ahead of industry trends. They are always on the lookout for equipment that can make your packaging operations more efficient.
Plus, Nassco service technicians are factory-trained to provide elite support for all packaging systems. From installation to repairs or routine maintenance, we’re ready to help you get the most out of your stretch wrapper.
Final Thoughts: Wrapping B Loads the Smart Way
B loads represent the “in-between” category of pallet stability: not perfectly cube-shaped, but not completely unstable either. With the right stretch wrapper, facilities can:
- Secure semi-stable loads consistently
- Reduce film and labor costs
- Improve throughput and efficiency
- Minimize damage in transit
For most B load environments, turntable wrappers are the go-to solution. Facilities with higher throughput or more unstable B loads benefit from rotary arm or, in some cases, robotic options too.
Nassco helps businesses select the right equipment from trusted manufacturers to streamline packaging operations and keep pallets moving safely.
Bonus Content: Frequently Asked Questions about B Load Stretch Wrapping
What is a B Load in stretch wrapping?
A B Load is a pallet with some irregularities—such as mixed case sizes, partial overhang, or gaps between packages. These pallets require a more careful approach than cube-shaped A Loads to balance product protection with secure containment.
How do B Loads differ from A and C Loads?
A Loads are uniform, cube-shaped pallets that are the easiest to wrap. C Loads are the most irregular and unstable, often needing advanced wrapping strategies. B Loads fall in between: they are less stable than A Loads but more manageable than C Loads, making machine and film adjustments critical.
What type of stretch wrapper works best with B Loads?
Turntable wrappers can handle balanced B Loads, but for taller, lighter, or more fragile loads, a rotary arm or ring wrapper is often recommended. These machines keep the pallet stationary during wrapping, reducing the chance of collapse.
What containment force should I target on a B Load?
There is no one-size-fits-all answer. Typically, B Loads benefit from stepped force: applying higher wrap force at the pallet’s base and top, and lighter force along fragile or crushable panels. Always verify stability with containment-force measurements.
Which film and pre-stretch settings are recommended?
Cast films with reliable puncture resistance are often preferred. Many operations run 200–250% pre-stretch for B Loads, but exact settings depend on product weight and fragility. The goal is to maximize stability without causing film neck-down or product damage.
How can I prevent product damage on B Loads?
Reduce force in areas where cartons may deform, use corner protection, and reinforce only where necessary. Additional wraps at the pallet’s base and top can help secure the load while preventing over-tension on fragile goods.
What are common mistakes when wrapping B Loads?
Some frequent errors include using one uniform wrap force, under-securing the base, overlooking containment-force checks, and failing to adjust settings when packaging changes.
When should I consider upgrading from a turntable to a rotary arm or ring wrapper?
If your operation handles tall, light, or fragile B Loads—or if you need higher throughput with consistent containment—it may be time to consider stationary-pallet systems like rotary arms or rings.
How do I validate that my B-Load wrapping recipe is working?
Perform containment-force tests at multiple heights, run tilt or transport simulations, and monitor film usage per pallet. A good recipe balances stability, product protection, and film efficiency.
Can automation reduce labor and film waste on B Loads?
Yes. Automated stretch wrappers with force feedback and programmable wrap recipes can improve consistency, cut down on rewraps, and optimize film use while maintaining stability targets.
