The main types of plastic pallet covers are gusseted pallet cover bags (clear, black UV-inhibited or colored), pallet top sheets, heat-shrink pallet bags, stretch wrap and stretch hoods, and heavier tarps or insulated covers for outdoor and temperature-sensitive loads. Most are made from low-density or linear low-density polyethylene. The right one depends on three things: does the load need to be held together, does it need a roof against dust and water, and will it sit in the sun.
Below we go through each type, the sizes US distributors stock, and what to specify when you import pallet covers by the container.
Pallet covers at a glance
| Type | What it does | Typical gauge | Best for | Trade-off |
|---|---|---|---|---|
| Clear gusseted pallet cover | Bag dropped over the load, keeps off dust and drips | 1–3 mil (25–76 µm) | Warehouse storage, visible inventory | Does not hold the load together |
| Black UVI pallet cover | Opaque, UV-inhibited bag | 2–3 mil (51–76 µm) | Outdoor storage, light-sensitive goods, hiding contents | You cannot see what is inside |
| Pallet top sheet | Flat sheet laid on top or between layers | About 1 mil and up | Cheap dust cover, layer separation | Covers the top only |
| Shrink pallet bag | Bag shrunk tight with a heat gun or tunnel | Heavier gauge | Machinery, outdoor or export loads that need a sealed cover | Needs heat equipment, slower |
| Stretch wrap | Film stretched around the load | Thin cast or blown film | Holding cartons together in transit | Leaves the top open unless you add a top sheet |
| Vented stretch wrap | Net-like stretch film with open holes | Varies | Produce, cold storage, loads that must breathe | No dust or rain protection |
| Tarps and insulated covers | Reusable heavy covers | Heavy woven or foam-lined | Long-term outdoor storage, temperature control | High cost per unit, not disposable |
Gusseted pallet cover bags
This is what most US warehouses mean by “pallet cover”. It is a very large bag with side gussets, made from linear low-density polyethylene, perforated on a roll so a picker can tear one off and drop it over a load. The same bags are used as Gaylord box liners and machinery covers.
A gusseted cover protects the load from dust, dirt, roof drips and moisture. It does not stabilize the load. Most shippers stretch-wrap first, then put the cover over the top, or slide the cover on and then wrap over it so the cover cannot blow off.
Clear pallet covers
Clear film lets staff read carton labels and count stock without opening anything. It is the default for indoor storage. Clear covers without UV stabilizer will degrade faster if pallets sit outside, and sunlight passes straight through to the product.
Black UVI pallet covers
“UVI” means UV inhibitor, the additive that slows polyethylene breakdown in sunlight. Black UVI covers block light completely, which matters for light-sensitive goods, and they hide the contents, which helps against theft on a yard or dock. They are the standard choice when pallets sit outside, on construction sites or in open storage.
We add UV stabilizer to Hanpak pallet covers and poly sheeting on request. Tell us how long the cover will be outdoors and in what climate, and we set the dose for that, rather than just ticking “UV yes”.
Colored covers
Blue, yellow, white and other colors are used to code stock by customer, status or department, so a forklift driver can spot the pallet from across the building. White film also reflects heat better than black in hot climates. Color comes from masterbatch added at extrusion, so the cost difference over clear is small at volume.
Pallet cover sizes
US distributors list two sets of numbers: the pallet load the cover fits (length x width x height) and the cover size itself (width x depth x height). The cover is taller than the load because the gusseted top has to fold down. The examples below are taken from a major US distributor’s catalog.
| Fits pallet load (L x W x H) | Cover size (W x D x H) | Cover size in cm |
|---|---|---|
| 36 x 24 x 40 in | 41 x 31 x 56 in | 104 x 79 x 142 cm |
| 42 x 36 x 51 in | 42 x 42 x 72 in | 107 x 107 x 183 cm |
| 48 x 40 x 27 in | 48 x 42 x 48 in | 122 x 107 x 122 cm |
| 48 x 40 x 45 in | 48 x 42 x 66 in | 122 x 107 x 168 cm |
| 48 x 40 x 49 in | 48 x 46 x 72 in | 122 x 117 x 183 cm |
| 48 x 40 x 72 in | 48 x 48 x 96 in | 122 x 122 x 244 cm |
| 48 x 48 x 51 in | 51 x 48 x 75 in | 130 x 122 x 191 cm |
The 48 x 40 in pallet (often called the GMA pallet) is the standard in the US and Canada, so most US cover programs are built around it. European customers mostly ship on the EUR pallet, 1200 x 800 mm (about 47 x 31.5 in), and need covers sized for that footprint. If you sell into both markets, keep separate size lists.
Gauge runs from 1 mil (25 µm) for light indoor dust covers to 2 mil (51 µm) as the general workhorse and 3 mil (76 µm) for heavier, outdoor or rough-handling use. 3 mil resists tears and punctures from carton corners much better than 1 mil.
Pallet top sheets
A top sheet is a flat square of polyethylene laid on the top of the load, or between layers, usually dispensed from a perforated roll. It keeps dust and drips off the top cartons and stops a leaking carton from soaking the layer below. It is the cheapest cover there is, and it pairs well with stretch wrap: the wrap holds the sides and pins the top sheet down.
Shrink pallet bags and shrink wrap
A shrink bag looks like a gusseted pallet cover, but the film is made to contract when heated. You pull it over the load and run a heat gun or shrink tunnel over it, and the film tightens around the load into a sealed, weather-resistant skin. Shrink is common for machinery, outdoor storage and export cargo where the load must be protected on every side.
The trade-offs: you need heat equipment and trained staff, it is slower than stretch wrapping, and the film is cut off and thrown away at the destination. Shrink film is also usually heavier gauge than stretch film, which raises cost per pallet.
Stretch wrap
Stretch wrap is not a cover in the strict sense. It is thin, clingy polyethylene film stretched around the load to hold cartons together so the pallet does not shift or collapse. It needs no heat, it is fast on a machine, and it is the cheapest way to stabilize a load.
There are two production methods. Cast stretch film is extruded through a flat die onto chilled rollers. It is clear, quiet off the roll and has very even gauge. Blown stretch film is extruded as a bubble. It is tougher and resists puncture better, but it is hazier and usually costs more. Most US hand-wrap and machine-wrap programs run cast film.
We make stretch film in hand and machine rolls, with stretch film and poly sheeting together running at about 2,000 tons a month.
Vented stretch wrap
Vented wrap has rows of open holes so air can move through the load. It is used on fresh produce, cold storage and anything that sweats, where solid film would trap condensation. It holds the load but gives no protection from dust or rain.
Tarps and insulated pallet covers
Woven polyethylene tarps are laminated, reusable and much stronger than film covers. They suit long outdoor storage and covering equipment. Insulated or thermal pallet covers have a foil or foam layer and are used to slow temperature change on food, pharmaceuticals and chemicals in transit. Both cost far more per unit and are meant to be used many times, so they are a different buying decision from disposable film covers.
Buying tips for importers
- Size from the load, not the pallet. Give us length x width x height of the loaded pallet, plus the pallet type (48 x 40 in, EUR 1200 x 800 mm or other).
- State gauge in mil or microns, and whether it is a dust cover or must survive rough handling.
- UV stabilizer: say how long the cover will be outdoors.
- Color: clear, black, white, or a color for stock coding.
- Format: perforated on a roll, or flat-packed individual bags.
- Print: your logo or handling text can be printed on the cover. See our private label and custom printing page.
- Packing and labels: your own carton design, barcode labels and shipping marks.
We make pallet covers to custom size, so you are not stuck with a catalog list. Lead time is 4–6 weeks for a first printed order and 3–4 weeks for repeats. Plain stock samples are free.
FAQ
What size pallet cover do I need for a 48 x 40 pallet?
It depends on load height. As a guide from US catalogs, a 45 in high load on a 48 x 40 pallet takes a 48 x 42 x 66 in cover, and a 72 in high load takes about 48 x 48 x 96 in. Measure the loaded pallet, including any overhang, and size from that.
What is the difference between a pallet cover and stretch wrap?
A pallet cover is a bag that goes over the load to keep dust and water off. Stretch wrap is film wound around the load to hold it together. Many shippers use both: wrap for stability, cover for protection.
What does UVI mean on a pallet cover?
UVI stands for ultraviolet inhibitor. It is an additive in the polyethylene that slows breakdown in sunlight, so the cover stays flexible and strong longer outdoors. Black UVI covers also block light from the product.
What thickness should a pallet cover be?
1 mil (25 µm) is fine for light dust protection indoors. 2 mil (51 µm) is the general-purpose choice. Go to 3 mil (76 µm) for outdoor storage, sharp-cornered loads or covers that get handled several times.
Are plastic pallet covers recyclable?
Polyethylene film is recyclable, and covers and stretch film from a warehouse are usually clean, single-material film, which is what recyclers want. Whether it gets collected depends on your waste hauler or a local film recycler. Keep it free of tape, labels and dirt.
If you run a pallet cover program, or want a second source for one, send us your size list with gauge, color, UV needs and annual volume. We will send samples and a quote on FOB, CFR or CIF terms, payment by T/T or L/C.