What is an A Load in Stretch Wrapping?

Stretch Wrapping: Why It Matters for Every Facility

In today’s supply chain, stretch wrapping is one of the most important steps in end-of-line packaging. It’s the final layer of protection before your products leave the warehouse and travel to their destination.

Done correctly, stretch wrapping keeps loads secure, reduces product damage, cuts down on film waste, and ensures shipments arrive safely and on time. Done poorly, it leads to costly damage claims, safety risks, and inefficiencies that ripple across operations.

The key is that not all pallet loads are the same. The type of items you’re shipping — their shape, stability, and how they’re stacked — plays a huge role in how they should be wrapped.

Choosing the right method, film, and stretch wrapping machine isn’t just about securing a pallet; it’s about optimizing your entire workflow, from labor efficiency to material costs to customer satisfaction.

That’s why packaging professionals categorize loads into three groups: A, B, and C loads. Each type comes with its own challenges and best practices. This article on A loads kicks off our series, where we’ll explore what makes each load type unique and which stretch wrapping solutions are best suited for them.

What Is an A Load? The Easiest Pallet Loads to Wrap and the Best Stretch Wrapper Solutions

In packaging and shipping, not every pallet is created equal. Some are messy and unstable, while others are bulky and irregular. But then there are A loads — the gold standard of pallet stability. These are the easiest loads to wrap, transport, and protect, and they’re often the most cost-effective to handle with stretch wrapping equipment.

If your facility primarily deals with A loads, you’re in a fortunate position. With the right stretch wrapper, you can maximize efficiency, reduce film costs, and streamline operations.

In this article, we’ll break down:

• What defines an A load
• Which industries commonly work with them
• The advantages and potential risks of wrapping A loads
• The best types of stretch wrappers (turntable, rotary arm, orbital, robotic, automatic) for A loads
• How facilities benefit from wrapping A loads with modern equipment

We’ll also showcase solutions from our trusted partners — Robopac, Cousins, Handle It, and Highlight Industries.

Understanding Load Types: A, B, and C

Before we dive in too far, it’s important to understand that there are three main categories of pallet load groupings:

• A Loads: Uniform, cube-shaped, and stable.
• B Loads: Semi-stable, with some inconsistencies.
• C Loads: Irregular, unstable, or fragile.

A loads are the most ideal scenario — products are uniform, cases stack neatly, and the pallet forms a perfect or near-perfect cube. Wrapping these loads is straightforward, but the right machine still makes a huge difference in cost savings, speed, and consistency.

What Exactly Is an A Load?

A loads are defined by their uniformity and stability.

Characteristics include:

• Identical case sizes stacked evenly.
• No overhang — cartons fit neatly within pallet dimensions.
• Cube-shaped profile — clean, vertical edges.
• Minimal shifting — products don’t move inside cartons.
• Consistent Size & Weight — each pallet is built in a repeatable, predictable way.

In other words, A loads are predictable and easy to stabilize. They allow facilities to take full advantage of automated or semi-automated stretch wrapping equipment without needing specialized adjustments.

Industries That Commonly See A Loads

While not every shipment is an A load, many industries regularly work with them:

• Food & Beverage: Pallets of bottled water, canned goods, or neatly packaged snack boxes.
• Consumer Packaged Goods (CPG): Large runs of identical product shipments.
• Pharmaceutical & Healthcare: Uniform case packs of medication or medical supplies.
• Retail Distribution: Straightforward replenishment orders in identical cartons.
• Electronics & Appliances: Smaller boxed units packaged consistently.

If your operation ships large volumes of the same product in uniform packaging, you’re likely dealing with A loads.

Wrapping Challenges for A Loads

Compared to B or C loads, A loads are straightforward — but that doesn’t mean they’re challenge-free.

Common considerations include:

• Over-Wrapping: Employees may apply more stretch film than necessary, wasting material.
• Labor Costs: Hand wrapping even stable loads is time-consuming and can be labor intensive.
• Throughput Bottlenecks: Without automation, wrapping may slow down shipping operations.
• Inconsistent Wrap Quality: Manual wrapping still risks variation between operators.

The key to optimizing A loads isn’t stability — it’s efficiency and cost savings.

How Stretch Wrappers Help Facilities with A Loads

Since A loads are stable, facilities have the widest range of stretch wrapper options.

The right equipment ensures:

• Film Savings: Pre-stretch technology reduces material usage significantly.
• Speed & Throughput: Automation increases pallets wrapped per shift.
• Labor Reallocation: Employees spend less time hand wrapping and more time on higher-value tasks.
• Consistency: Machines deliver the same tight, professional wrap every time.

ROI: A loads are the easiest category to see fast payback on stretch wrapping equipment.

Which Stretch Wrappers Work Best for A Loads?

With stable pallets, nearly any wrapper will work. The choice depends mostly on volume and production needs:

1. Turntable Stretch Wrappers – Best Value for A Loads

• Most common choice for uniform, stable loads.
• The pallet spins on a turntable while the film carriage applies film.
• Cost-effective and efficient for low- to medium-volume operations.

Example: Handle It offers reliable turntable machines that provide excellent value for stable, cube-shaped loads.

2. Rotary Arm Stretch Wrappers – For High Throughput

• The load stays stationary while the arm rotates around it.
• Often chosen in higher-volume facilities because of faster wrap cycles.
• Provides consistency at scale, even though A loads don’t require the added stability benefits.

Example: Cousins rotary arm systems are built for speed and durability in busy operations.

3. Robotic Stretch Wrappers – For Flexibility

• Mobile robots drive around the load to apply film.
• Great for facilities with multiple wrapping stations or limited space.
• While not strictly necessary for A loads, robots add flexibility for mixed-load environments.

Example: Robopac robotic wrappers are a popular choice in multi-use facilities.

4. Orbital Stretch Wrappers – Specialty Situations

• Not commonly needed for A loads, but useful if wrapping long, uniform items like flooring or paneling.
• Most facilities with A loads will not need orbital systems, or if they do it will be for very niche circumstances.

5. Fully Automatic Systems – For Maximum Efficiency

• Integrated into conveyor lines for continuous, hands-free operation.
• Ideal for high-volume facilities wrapping hundreds of A loads per day.
• Offers the fastest throughput and lowest long-term labor costs.

Example: Highlight Industries builds automated systems designed for distribution centers that process thousands of uniform pallets.

Key Considerations for A Load Wrapping

Because A loads are stable, facilities can often start with entry-level equipment and scale up as volume grows.

Here are some numbers we’ve pulled together based on industry trends to help you get an idea for what an investment may be or a new stretch wrapper machine.

Keep in mind that these values are a range and depend upon the machine and any customizations you choose:

• Semi-Automatic Turntable Wrappers: $6,000–$12,000. Affordable entry point.
• Rotary Arm Machines: $15,000–$25,000. For higher throughput operations.
• Robotic Wrappers: $15,000–$25,000. Flexible but not always necessary.
• Fully Automatic Systems: $50,000+. Designed for large-scale distribution centers.

ROI Factors – How You’ll See Your Investment Returned:

• Film savings from pre-stretch (30–50%).
• Reduced labor hours and costs from automation.
• Higher throughput, fewer bottlenecks in shipping.

Questions To Help Find Your Solution

When deciding which wrapping system makes the most sense for your operations, here are some important questions to answer to help you find the best system:

Volume: How many pallets per day are you wrapping?

• More than 75? An automatic wrapper will be beneficial.
• Between X and Z? A turntable, rotary arm or robot may be best.

Film Type: What type of film do you use?

• Ensure compatibility between the stretch wrapper’s pre-stretch capabilities and your chosen film.
• See more on film below.

Budget: What is your investment level?

• Certain stretch wrappers require more upfront investment, but the ROI is often quickly realized through labor savings and reduced film use.
• Nassco packaging experts can show you

Space Constraints: Do you have room for a permanent machine?

• Depending on your answer, a machine with more movable flexibility like a robot could be the best solution.

The Best Machine Stretch Film for A Loads:

One of the considerations for determining the right wrapping equipment includes analyzing the type of film you use to packaging your products.

Here are our packaging experts’ feedback on the type of film usually best for A loads:

• Cast film works well, offering clarity and cling for uniform cases.
• Gauge 60–70 is typically sufficient.
• Pre-stretch film ensures cost savings and consistent application.
• Specialty films are rarely needed unless pallets are unusually heavy.

Real-World Example: Automating A Load Wrapping

A Midwest beverage distributor shipped thousands of pallets of bottled water each week. While the loads were stable, hand wrapping was slow and inconsistent.

After installing a semi-automatic turntable wrapper from Handle It, they saw:

• Wrapping time cut from 5 minutes to 1.5 minutes per pallet
• Film usage reduced by 40%
• Consistent, professional wraps every time

The machine paid for itself in under a year, with savings continuing year after year.

Trusted Manufacturers for A Load Wrapping Solutions

At Nassco, we partner with manufacturers that we trust so we can deliver efficiency, innovation, and proven reliability:

• Robopac – Industry leader in robotic, rotary arm, and automatic solutions.
• Handle It – Cost-effective turntable solutions for stable A loads.
• Highlight Industries – High-performance automated systems for distribution centers.
• Cousins Packaging – Rugged rotary arm and automatic systems built for speed.

Final Thoughts: Wrapping A Loads Efficiently

A loads are the easiest type of pallet to wrap, but that doesn’t mean facilities should rely on hand wrapping or outdated equipment. By investing in the right stretch wrapper, companies can:

• Cut film costs by up to 50%
• Increase throughput
• Free up valuable labor
• Deliver consistent, professional wraps every time

For most facilities with A loads, turntable wrappers are the ideal choice. High-volume operations may benefit from rotary arm or fully automatic systems, while robotic options add flexibility in multi-use environments.

With trusted partners like Robopac, Cousins, Handle It, and Highlight Industries, Nassco helps businesses wrap smarter, save money, and keep their operations running smoothly.

Want To Maximize Efficiency Wrapping A Loads?

Connect with a packaging equipment expert at Nassco today to explore the best stretch wrapper type for your facility.

Looking Ahead: From A to C Loads

A loads may be the most straightforward pallets to secure, but they’re just one part of the bigger picture. As operations shift to handling more mixed products or irregular shipments, pallets often move into the B and C load categories, where stability becomes more of a challenge.

This article is the first in our three-part series on understanding load types and choosing the right stretch wrapping solution. Stay tuned as we dive deeper into B loads and C loads — exploring the unique challenges they present and the equipment best suited to keep them secure.