In this article, we outline the criteria for selecting the thickness of LDPE film, when a thinner film may be sufficient, when a thicker material is warranted, and how optimising the dimensions and thickness can help to reduce costs. The article is based on a technical discussion with a client, which covered the applications of LDPE films, bags, pallet covers, construction films, packaging films and products made from recycled raw materials.

What does the thickness of the film mean?

The thickness of the film is typically in microns Please specify. A micron is one thousandth of a millimetre, that is to say:

1 micron = 0.001 mm

This means, for example, that a 30-micron LDPE film is 0.03 mm thick.

At first glance, a value measured in microns may seem very small, but in film manufacturing, even a difference of just a few microns can have a significant impact on the properties of the finished product.

Thickness may affect:

• the tensile strength of the film,
• its elongation,
• its puncture resistance,
• its weldability,
• its suitability for machine processing,
• the price,
• the weight of the coil,
• the amount of material used in packaging,
• the product’s protective function.

For this reason, the thickness of the film should not be considered in isolation, but must always be assessed in relation to its intended use.

Why isn’t thicker cling film always the better choice?

Many people automatically assume that thicker film is better, stronger and safer. This may be partly true, but not in every case.

A film that is too thin may indeed tear, develop holes or fail to provide adequate protection. At the same time, a film that is too thick can lead to unnecessary use of raw materials, higher costs and greater amounts of waste.

The aim of choosing the right film is not to use the thickest possible material, but rather to the required function is safely fulfilled using as few components as possible.

This is particularly important in high-volume industrial applications, where even a deviation of a few microns can result in significant annual differences in material usage and costs.

For example, if a company has been using an oversized film for years, but a thinner or narrower film would actually suffice given the exact product dimensions and conditions of use, this could result in significant savings in the long term.

Why isn’t the thinner film always the cheaper one?

Another common misconception is that thinner film is always cheaper and more economical.

That is not always true either.

A thinner film may indeed contain fewer raw materials, but if it is no longer strong enough for its intended purpose, it can cause problems:

• tear,
• perforation,
• packaging error,
• product damage,
• machine downtime,
• complaint,
• more rejects,
• extra work involved in the packaging process.

If, for example, the film running through an automatic packaging machine is too thin or not stable enough, the savings can quickly be wiped out by production problems.

That is why it is not enough simply to look at the cost of the materials. The total cost of use must be taken into account.

What factors should we consider when choosing the thickness of LDPE film?

In order to determine the ideal thickness, a number of issues need to be clarified.

1. What will the film be used for?

That is the most important question.

A different film thickness is required:

• for covering,
• for dust protection,
• for protection against condensation,
• for shipping packaging,
• for waste collection,
• to protect goods on pallets,
• for use with automatic packaging machines,
• for use in the construction industry,
• for agricultural use.

The thickness of the film is always determined by its function.

If the film is only intended to provide temporary protection against dust, a thinner material may be sufficient. However, if it is intended to protect a heavy, sharp or high-wear product, a thicker film may be required.

2. What sort of mechanical load is the film subjected to?

It is important to consider the stresses to which the film will be subjected.

For example:

• whether they pull it by hand,
• whether the product is lifted inside it,
• is it moved by a forklift,
• Is it used to wrap items with sharp edges,
• whether it is subject to outdoor wind loads,
• does it rub against anything during transport,
• whether it is used for goods on pallets,
• whether they are stored for a longer period.

The greater the mechanical load, the more important it is to ensure the correct thickness, tensile strength and elongation.

3. Is it designed for indoor or outdoor use?

Outdoor use generally puts the film under greater strain.

Outdoors, the film may be exposed to:

• solar radiation,
• UV exposure,
• wind,
• rain,
• temperature fluctuations,
• dust,
• chemical,
• mechanical damage.

In such cases, it is not only the thickness that matters, but also the additives. For example, UV-stabilised film may be required for outdoor storage.

In indoor applications, the environmental impact is often lower, but factors such as odour, appearance, cleanliness or machinability may be more important.

4. What sort of product are we packing?

The characteristics of the packaged product are the main factor determining the thickness of the film.

We need a different type of film:

• for lightweight fabrics,
• for heavy industrial components,
• for products with sharp edges,
• for building materials,
• for dusty or contaminated products,
• for goods sensitive to moisture,
• for wrapping mattresses or furniture,
• for waste collection.

For a smooth, lightweight product, a thinner film is often sufficient, whilst a product with a rougher surface or greater weight requires a thicker, more durable film.

5. Will the film run on an automatic machine?

Thickness is particularly important when using automatic packaging machines.

In such cases, the film must not only protect the packaged product, but also perform reliably within the automated production process.

Key considerations:

• uniform thickness,
• dimensional stability,
• weldability,
• running stability,
• tear resistance,
• correct winding,
• film properties suitable for the specific machine type.

If the film is too thin, too flexible, too stiff or cannot be welded properly, this may lead to machine downtime and waste.

For this reason, when using automated machinery, it is always advisable to start with prototyping and testing.

6. Is it made from virgin or recycled raw materials?

The thickness of the film may also be influenced by the type of raw material.

In many cases, thinner film can still be produced reliably from primary, first-class raw materials. Where recycled raw materials are used, processability and mechanical properties may depend more heavily on the quality of the regranulate.

This does not mean that it is impossible to produce thinner or higher-quality film from recycled raw materials. However, it does mean that selecting the right regranulate and the manufacturer’s experience are of paramount importance.

As mentioned in the interview, the company mainly focuses on recycled LDPE products with a thickness of over 30 microns, but if there is sufficient demand and the raw materials are available, it can also produce thinner products, such as those with a thickness of 20–25 microns. Inserted into text.txt

7. Are food additives necessary?

The properties of the film are influenced not only by its thickness but also by the additives.

For certain applications, the following may be required, for example:

• UV stabiliser,
• an anti-static additive,
• anti-corrosion additive,
• an odour-reducing additive,
• slip modifier,
• colouring,
• a flame-retardant additive.

It may be the case that a film with the correct additives and the right composition can fulfil the required function even at a thinner gauge, whilst a poorly chosen, thicker film may not function properly.

Typical film thicknesses by application

The figures below are for guidance only. The exact thickness should always be determined on the basis of the specific product, the intended application, the raw material and the manufacturing requirements.

Thin LDPE films

Thin films are typically used for applications where the mechanical load is lower, and the film primarily serves a light protective or packaging function.

Possible uses:

• light cover,
• dust protection,
• packaging of lightweight products,
• individual sachets,
• certain automated packaging tasks,
• indoor, low-load use.

With thinner films, the quality of the raw material is particularly important, as the margin for error is smaller.

Medium-thickness LDPE films

Medium-gauge films are suitable for many industrial and packaging applications.

Possible uses:

• industrial packaging,
• bin bags,
• covering films,
• flat films,
• half-hoses,
• lighter industrial sacks,
• pallet caps,
• certain types of construction film.

This is the category where recycled raw materials can often be put to good use, provided the regranulate is of sufficient quality.

Thicker LDPE films

Thicker films are designed to withstand greater mechanical stress, harsher industrial use or to provide a higher level of protection.

Possible uses:

• industrial sacks,
• heavy-duty bin liners,
• construction films,
• outdoor cover films,
• protection of goods on pallets,
• flat films designed for heavy-duty use,
• stronger technological films.

For these products, in addition to thickness, tensile strength, elongation and puncture resistance are also of paramount importance.

Construction sheeting: what thickness should you choose?

Construction films can serve various purposes, so the required thickness may also vary.

Areas of application:

• cover,
• layer selection,
• underlay,
• temporary protection,
• protection against condensation,
• additional roofing membranes,
• protection of building materials.

If the membrane is only to be used as a temporary covering for a short period, a thinner option may often suffice. However, if it is to be used as an integrated layer, a vapour barrier or for more long-term protection, a sturdier, thicker membrane may be warranted.

When it comes to construction films, recycled LDPE is often a good choice, but the exact thickness must always be determined based on the specific application.

Bin bags: what determines the right thickness?

In the case of bin liners, the thickness is primarily determined by the environment in which they are used and the type of waste.

I need a different bag:

• for office waste,
• for household waste,
• for industrial waste,
• for heavier or sharper waste,
• for outdoor collection,
• for waste collection companies.

For an office bin liner, odour control and a good user experience may be important. For an industrial waste collection bag, however, tear resistance, thickness and load-bearing capacity are the key considerations.

In many cases, bin liners can be produced from recycled LDPE, but the thickness must always be adapted to the load.

Industrial sacks: when is thicker film required?

Industrial sacks are often subjected to greater mechanical stress than those used in the home or office.

A thicker film may be advisable if:

• it is used to collect heavier items or waste,
• comes into contact with a sharper, rougher material,
• moved by hand or by machine,
• is at risk of damage during transport,
• it should last for a longer period,
• It is also used outdoors.

In the case of industrial sacks, as well as the thickness, the quality of the welds and the design of the sack are also important, as these factors together determine the product’s actual load-bearing capacity.

Pallet lids: when is a thinner one sufficient, and when do you need a stronger one?

The pallet cover primarily serves a protective function. Its purpose may be to provide protection against dust, moisture, rain or dirt.

The required thickness depends on:

• is designed for indoor or outdoor storage,
• how long it protects the goods,
• whether it is exposed to sunlight,
• Is the pallet moved frequently,
• how sensitive the packaged product is,
• Is UV stabilisation required?.

A thinner pallet cover may be sufficient for indoor dust protection, but for outdoor storage or longer-term protection, a stronger, reinforced film may be required.

Shrink wrap: why is it not just the thickness that matters?

In the case of shrink film, in addition to thickness, the quality of the raw material and its shrinkage behaviour are particularly important.

If the film is not made from the correct raw material, then during shrinkage:

• may spring a leak,
• may come away,
• does not stick properly,
• does not present a consistent packaging image,
• does not provide adequate protection for the product.

The use of recycled raw materials in shrink film requires specific testing. The quality, purity and particle size of the regranulate are of paramount importance, as defects can quickly become apparent during the shrinkage process.

For this reason, when it comes to shrink film, it is not enough simply to look at the thickness of the film in microns. The entire formulation and the application process must also be examined.

What film thickness is required for an automatic packaging machine?

In the case of automatic packaging machines, the thickness of the film also affects the machine’s operation.

If the film is too thin:

• it tears more easily,
• it may run erratically,
• the weld may deteriorate,
• more rejects may be produced.

If it is too thick:

• it may not be suitable for welding,
• may slow down the process,
• it may be more expensive,
• may result in unnecessary use of raw materials.

For this reason, when using a packaging machine, the film must always be adjusted to suit the specific machine, product and packaging speed.

In such cases, prototyping and trial production are particularly important.

Thickness of recycled LDPE film: what should we look out for?

In the case of films made from recycled raw materials, the thickness is closely linked to the quality of the raw material.

Using regranulate of the right quality, it is possible to produce reliable, stable film for many industrial applications. However, if the raw material contains too many foreign substances or impurities, this can cause problems, particularly with thinner films.

When it comes to recycled plastic film, it’s worth bearing in mind:

• the origin of the PCR or PIR raw material,
• the purity of the regranulate,
• the odour risk,
• tensile strength,
• elongation,
• processability,
• the product’s function,
• the stability of the thickness.

The aim is not to make every product as thick as possible, but to produce film from the relevant recycled raw material that is of a thickness sufficient to fulfil its purpose safely.

How can plastic film usage be reduced without posing any risk?

Many companies have been using the same film size and thickness for years because that is how their manufacturing or packaging processes were originally set up.

However, this does not mean that this is still the best solution today.

Plastic film consumption can be reduced, for example:

• by choosing a more accurate size,
• by replacing the oversized film,
• by optimising thickness,
• by choosing more suitable raw materials,
• with an improved welding design,
• with packaging recommendations tailored to the product,
• through prototyping and testing.

A minor adjustment to the dimensions or a reduction in thickness of a few microns can result in significant savings when produced in large quantities, whilst maintaining the product’s protective function.

However, this only works well if the reduction is not carried out at random, but on a technical basis.

What mistakes do buyers often make?

There are several common mistakes made when selecting the thickness of LDPE film.

They base their decision solely on price

The cheapest film isn’t necessarily the best. If it tears, doesn’t run through the machine properly or doesn’t protect the product, it will end up costing more overall.

They do not specify the intended use precisely

If the manufacturer does not know exactly what the film is to be used for, it is more difficult to recommend the right thickness and raw material.

They are using the old size as a basis

Many companies automatically reorder the same film they have been using for years, even though there might be a more cost-effective or sustainable solution.

They are not testing the new solution

Before changing the thickness or the raw material, it is worth requesting a sample and testing it in a real-world environment.

They do not take the raw material into account

The same thickness may behave differently depending on whether the raw material is virgin or recycled; therefore, thickness must always be considered in conjunction with the raw material.

When should you seek advice from the manufacturer?

A consultation with the manufacturer is particularly useful when:

• They are looking for film for a new product,
• they would switch from virgin raw materials to recycled ones,
• I would like to reduce material consumption,
• there are too many rejects or tears,
• The film does not run smoothly on the automatic machine,
• whether it is for outdoor or specialised use,
• They would optimise packaging for ESG or sustainability reasons,
• It is not certain that they are the correct thickness.

An experienced film manufacturer not only advises on the appropriate film thickness, but also helps to determine the correct dimensions, raw materials, additives and production design.

Summary

Choosing the right thickness for LDPE film is not simply a matter of microns. The appropriate thickness always depends on the intended use, the product being packaged, the mechanical load, environmental factors, the raw material and the processing method.

Thicker film is not always better, and thinner film is not always more cost-effective. The optimal solution is one that safely fulfils the required function whilst using as little raw material as possible.

Different factors must be taken into account for construction films, bin liners, industrial sacks, pallet covers, shrink films and films for automatic packaging machines. In the case of recycled LDPE film, the quality of the regranulate and the manufacturer’s experience are particularly important.

The basis for a good decision lies in defining the exact intended use, selecting the appropriate raw material and, where necessary, applying a pattern. In this way, the film will not only be competitively priced but also reliable in terms of its functionality.

Frequently Asked Questions

What thickness of LDPE film should I choose?

The correct thickness always depends on the intended use. Different thicknesses are required for covering, bin liners, industrial sacks, pallet collars, construction applications or automatic packaging machines.

What does ‘micron’ mean in relation to films?

A micron is a unit of measurement for the thickness of film. One micron is 0.001 millimetres. For example, a 30-micron film is 0.03 mm thick.

Is thicker plastic always better?

Not necessarily. Thicker film may be stronger, but it can also lead to unnecessary use of raw materials and higher costs. The thickness must always be tailored to the intended function.

Is thinner film always cheaper?

Not necessarily. If the thinner film tears, causes wastage or fails to protect the product, it may end up being more expensive overall than a suitably chosen thicker film.

Is it possible to produce a thinner product from recycled LDPE film?

In some cases, yes, but this requires high-quality regranulate, appropriate production settings and experience. The margin for error is smaller with thinner films.

How thick should construction film be?

This depends on whether it is used for covering, as a separating layer, for vapour control or as an integrated layer. The exact thickness must always be determined on the basis of its function.

How do you choose the right film for an automatic packaging machine?

For automated machinery, consistent thickness, dimensional stability, weldability and stability during machine operation are important. In such cases, it is advisable to start with prototyping and trial production.

How can we reduce the use of plastic film?

Film consumption can be reduced through size optimisation, selecting the appropriate thickness, changing the raw materials and precisely defining the packaging function. It is important that this reduction does not come at the expense of product protection.