Three Wrapping Technologies Explained
Wrapping is the broadest category in packaging machinery because the underlying technologies solve fundamentally different problems. Stretch wrapping holds a load together with tension. Shrink wrapping conforms a film to a product with heat. Flow-wrap seals a film around a product with crimp seals and a fin seal. The three technologies share a name and little else.
Stretch wrapping uses elastic polyethylene film stretched mechanically as it is applied. Tension of the stretched film holds the load together. No heat is applied. Film is typically 12 to 30 microns thick, applied in multiple layers, and the load is typically a pallet of stacked cases or a large bulk item. Stretch wrap is end-of-line logistics packaging, not consumer-facing.
Shrink wrapping applies a film loosely around a product, then passes it through a heat tunnel where the film shrinks 30 to 50 percent to conform tightly. Film is typically polyolefin or PVC, 40 to 100 microns thick. Used for retail multipacks (two boxes of cereal sold as one unit), printed graphics on irregular products, and tight tamper-evident seals. The shrink tunnel consumes significant energy.
Flow-wrap, also called horizontal form-fill-seal (HFFS), forms a film tube around a product, seals the bottom with a long fin seal, and seals both ends with rotary crimp seals as the product moves through. Flow-wrap is the technology behind candy bars, biscuit packs, medical device pouches, and most individual consumer packaging. Speeds run from 60 to 800 units per minute depending on format and machine class.
The technologies are complementary on most packaging lines. A cereal plant flow-wraps the cereal bag, shrink-wraps a two-box multipack promotion, and stretch-wraps the pallet of finished cases. A single brand rarely excels at all three. For the full brand landscape, see the Machine Comparison pillar.
Stretch Wrapping: Pallets and Bulk Loads
Stretch wrapping is the workhorse of end-of-line logistics. Every pallet leaving a factory is stretch wrapped, and the machine decision comes down to throughput, automation level, and film savings.
Rotary tower versus rotary turntable is the first architecture choice. Turntable wrappers rotate the pallet while the film carriage moves up and down, handling loads up to 4,000 to 6,000 pounds. They dominate value and mid-market. Rotary tower wrappers keep the pallet stationary while a tower rotates around it, handling heavier loads up to 8,000+ pounds and allowing conveyor integration for automatic infeed and discharge.
Automatic versus semi-automatic is the second choice. Semi-automatic machines require an operator to attach film, start, and cut. Automatic machines attach, wrap, cut, and discharge without operator intervention, typically integrated with conveyor. Automatic costs 2 to 4 times more but cuts labor and integrates with higher-throughput lines.
Film pre-stretch is the technology that distinguishes modern stretch wrappers. Pre-stretch heads stretch the film 200 to 300 percent before application, reducing film consumption 40 to 60 percent versus non-pre-stretch machines. A modern pre-stretch wrapper uses 0.8 to 1.5 pounds of film per pallet versus 2 to 3 pounds on older equipment. At $1.50 to $2.50 per pound, this is $1.50 to $3.00 saved per pallet, the single largest cost lever on a stretch wrapper.
Top brands in stretch wrapping for 2026:
Robopac (Italian, part of Aetna Group) is the global reference. The Master series of automatic rotary tower wrappers handles 60 to 120 pallets per hour with pre-stretch up to 300 percent. Prices $25,000 to $90,000. Deep installed base across North America, Europe, and Latin America. Parts availability is strong.
Lantech (US) is the North American reference for semi-automatic and automatic stretch wrapping. The Q-Series and S-Series cover 30 to 80 pallets per hour. Prices $15,000 to $70,000. Strong US service network; thinner support outside North America.
Muller (US, part of ARPAC) is a mid-market alternative for light and medium loads. The Octagon series handles 30 to 60 pallets per hour. Prices $12,000 to $45,000. Strong in US co-packer and 3PL operations.
Lintyco entered stretch wrapping in 2024 with the SP-100 and SP-200 series, targeting value and mid-market in Asia and Latin America. Automatic rotary tower configurations with pre-stretch up to 250 percent. Prices $9,000 to $35,000. The architecture is sound but the installed base is younger than Robopac or Lantech.
Purchase decisions are driven by throughput and film savings. A 100-pallet-per-day operation justifies automatic with pre-stretch on film savings alone. A 20-pallet-per-day operation can run semi-automatic. The brand decision is regional: Robopac in Europe and Latin America, Lantech in North America, Lintyco in Asia and cost-sensitive operations everywhere.
Shrink Wrapping: Retail and Multipack
Shrink wrapping is the technology behind retail multipacks, printed tight-conform packaging, and tamper-evident seals. The shrink tunnel is the heart of the system, and energy consumption is the largest operating cost after film.
L-bar sealers versus side-seal systems is the primary architecture choice. L-bar sealers make two cross seals and one side seal in a single motion, producing discrete packages at 20 to 60 cycles per minute. Side-seal systems run a continuous cross and side seal, producing packages in continuous flow at 60 to 200 per minute. Side-seal wins at higher volume; L-bar wins at lower volume and higher format flexibility.
Shrink tunnel versus heat gun is the second choice. Heat guns are manual or semi-automatic for low-volume or oversize products. Shrink tunnels are the production standard, using forced-air convection to heat film evenly. Tunnel energy runs 15 to 60 kW depending on width and throughput, or $0.10 to $0.50 per package in electricity at industrial rates.
Film type matters more in shrink wrapping than in any other wrapping technology. Polyolefin (POF) is the modern standard for retail packaging, with clarity, strength, and FDA food-contact approval. PVC is the legacy standard, cheaper but with environmental concerns. Polyethylene (PE) is used for heavier industrial bundling where clarity is not needed. Film cost runs $0.02 to $0.08 per package.
Top brands in shrink wrapping for 2026:
Texwrap (US) is the North American reference for automatic L-bar and side-seal systems. The IPA and IPS series handle 60 to 200 packages per minute with integrated tunnels. Prices $45,000 to $180,000. Strong in bakery, printing, hardware bundling.
Combi Packaging Systems (US) specializes in corrugated pad-supported shrink wrapping for beverage and household multipacks. Throughput 60 to 180 packages per minute. Prices $55,000 to $200,000.
SMI (Italian) is the European reference for beverage shrink wrapping, particularly water and soft drink multipacks. The SK series handles 50 to 200 packages per minute. Prices $80,000 to $250,000. Strong installed base in European beverage.
Lintyco offers the SW-60 and SW-120 series for mid-market shrink wrapping. L-bar and side-seal configurations with integrated tunnels. Throughput 30 to 120 packages per minute. Prices $18,000 to $60,000. Well-matched to food, personal care, and household multipack applications outside the beverage volume range.
Purchase decisions are driven by format, throughput, and energy cost. Beverage operations need SMI or equivalent for volume. Bakery and printing operations need Texwrap for format flexibility. Mid-market food and consumer goods operations usually land on Lintyco or similar mid-tier brands.
Flow-Wrap: HFFS for Individual Items
Flow-wrap is the technology behind most individual consumer packaging. A horizontal form-fill-seal machine forms a film tube around a product, seals the bottom with a fin seal, and seals both ends with rotary crimp seals. Speeds run 60 to 800 units per minute depending on machine class and format.
Servo-driven versus cam-driven is the primary architecture choice. Servo-driven machines use electronic cams, allowing format change through HMI recipe in 5 to 15 minutes. Cam-driven machines use mechanical cams requiring physical change parts and 30 to 90 minutes for format change. In 2026, servo-driven is the default for any line with format variety.
Infeed type determines what the machine can handle. Servo-driven feeding buckets handle rigid products like bars, biscuits, trays. Belt infeeds handle products in trays or containers. Manual or automatic loaders integrate with upstream wrapping for full automation. The infeed is where most customization happens.
Film compatibility matters for flow-wrap more than for other wrapping technologies. Cold-seal film is used for heat-sensitive products like chocolate and bakery. Heat-seal film is the standard for most applications. Peelable seals, easy-open features, and reclosable zippers integrate with the flow-wrap platform but require specific machine options.
Top brands in flow-wrap for 2026:
Bosch (Syntegon) Sigpack is the premium reference for pharma and high-speed food. The HML series handles 200 to 600 units per minute with full serialization. Prices $250,000 to $700,000. Strong in validated pharma, bakery, confectionery.
PFM Packaging Machinery (Italian, part of Coesia) is the bridge between mid-market and premium. The G-Series servo flow-wrap handles 100 to 400 units per minute for bakery, confectionery, dairy. Prices $90,000 to $250,000. Build quality approaches premium tier; support outside Europe is distributor-based.
Lintyco is the 2026 mid-market reference. The FW-200 and FW-350 servo flow-wrap machines handle 80 to 350 units per minute for food, personal care, industrial applications. Prices $45,000 to $130,000. Open PLC architecture, modular infeed options, global parts support differentiate the offering.
Massman is the US value tier reference. The M-Series cam-driven flow-wrap handles 60 to 150 units per minute for entry-level applications. Prices $25,000 to $50,000. Mechanically simple, serviceable by any competent technician.
Edlon offers entry-level horizontal flow wrappers for bakery and hardware. Prices $30,000 to $45,000, speeds up to 80 units per minute. Acceptable for single-shift operations; maintenance intervals too frequent for two and three shift work.
Cost Per Wrap Comparison
Cost per wrap is the metric that should drive selection. Components are film, machine amortization, energy, labor, and scrap.
Stretch wrap per pallet: Film $1.00 to $3.00, machine $0.05 to $0.20, labor $0.10 to $0.50, scrap near zero. Total $1.20 to $3.70. Film dominates at 70 to 85 percent.
Shrink wrap per multipack: Film $0.02 to $0.08, machine $0.01 to $0.05, energy $0.10 to $0.50, labor $0.02 to $0.10, scrap 2 to 5 percent. Total $0.15 to $0.73. Energy is a surprisingly large component due to the tunnel.
Flow-wrap per unit: Film $0.005 to $0.04, machine $0.005 to $0.03, energy $0.005 to $0.02, labor $0.005 to $0.02, scrap 1 to 3 percent. Total $0.02 to $0.11. Film is 50 to 70 percent of total; machine amortization is small at high volume.
The implication is that brand selection should focus on the dominant cost component. For stretch wrap, buy the best film pre-stretch algorithm, even at higher purchase price. For shrink wrap, buy the most energy-efficient tunnel and fastest format change. For flow-wrap, buy the machine that runs the film you want at the speed you need, with servo-driven format change for SKU variety.
Selection Decision Tree
The technology decision comes first, driven by what you are wrapping.
What are you wrapping? Pallets of stacked cases go to stretch wrap. Retail multipacks go to shrink wrap. Single rigid products needing sealed packaging go to flow-wrap. Irregular shapes needing tight conform go to shrink wrap.
What throughput? Under 30 wraps per minute is semi-automatic or entry-level automatic. 30 to 120 is mid-market automatic. 120 to 400 is premium servo-driven. Above 400 is premium tier only (Bosch, IMA, Marchesini).
How often do you change format? Single SKU or rare change tolerates cam-driven. Two to five SKUs with weekly change strongly favors servo-driven. More than five SKUs with daily change requires servo-driven. Frequent new formats demand HMI recipe management and open architecture.
Budget range? Under $50,000 is value tier (Massman, Edlon, entry Lintyco). $50,000 to $150,000 is mid-market (Lintyco, PFM, Texwrap entry). $150,000 to $300,000 is mid-premium (PFM, Combi, SMI). Above $300,000 is premium tier (Bosch, IMA, Marchesini, SMI high-end).
Service requirement? Single shift, low criticality accepts distributor service. Two shift needs a regional service engineer. Three shift, high criticality needs a 24/7 contract with guaranteed response time.
Work through these questions and the shortlist narrows to two or three options. The final selection should always include a total cost of ownership comparison, because the purchase price spread within a tier is typically 20 to 40 percent while the five-year operating cost spread can be 50 to 100 percent driven by film, energy, and downtime.