The Palband Blog
How to Improve Load Security Without Plastic Shrink Wrap
Load security is a core safety requirement rather than a nice to have. When a pallet or stillage is not properly contained, the risk extends far beyond damaged goods. Unstable loads can injure warehouse staff, put drivers at risk and create serious hazards for other road users. For operators, a single incident can lead to downtime, insurance claims and reputational damage that is difficult to repair.
At the same time, many organisations are reviewing how they secure loads because of rising material costs and sustainability targets.
Plastic shrink wrap has often been used as the default solution, yet it does not always deliver consistent, repeatable results. Modern load security needs to combine robust containment with safer manual handling and reduced environmental impact.
Businesses across logistics, retail and manufacturing are therefore looking at more engineered solutions, such as the reusable load restraint and protective equipment available from Palband. The goal is a load security approach that protects people, assets and brand reputation while reducing reliance on single use plastics.
The UK rules that define safe load security
The code of practice explains how to choose an appropriate load securing system, what checks to carry out before loading and how to respond if a load shifts during a journey. It also highlights the need for effective risk assessments and suitable equipment for different vehicle types and cargo.
Recent updates are a reminder that the regulatory environment continues to evolve. A DVSA feature on the importance of load security links the guidance to real incidents, underlining how unsecured loads can have tragic consequences. For operators, this reinforces the need
Why plastic shrink wrap is not enough for safe loads
Plastic shrink wrap has been used for many years to bind pallets and help prevent movement in transit. It is familiar, relatively low cost per roll and easy to apply with minimal training. However, relying on shrink wrap alone for load security can create problems in both safety and performance. Film can tear, loosen or be applied inconsistently, particularly when operators are working under time pressure. Once the outer layer is cut, the stability of the entire load can be compromised.
From a compliance perspective, regulators focus on whether a load is secure, not on how much plastic has been used. A wrapped pallet that cannot withstand braking, cornering or partial unloading still falls short of the standards set out in official guidance.
Legal commentators have highlighted how the updated DVSA code of practice places greater emphasis on risk assessment and the suitability of chosen restraints, as summarised in recent legal updates on DVSA load security guidance.
There is also a sustainability impact. High volumes of plastic shrink wrap increase waste handling requirements and contribute to wider environmental concerns. As organisations seek to cut single use materials, they are reviewing whether shrink wrap should be a last resort rather than a default choice. In many cases, better results can be achieved by combining structured stacking with engineered equipment such as reusable wraps, covers and containment systems from the Palband product range, which deliver more consistent load security while reducing plastic consumption.
The fundamentals of a good load securing system without plastic
A reliable load securing system does far more than hold goods in place. It must keep the load stable during acceleration, braking and cornering, and maintain that stability as items are removed during multi drop routes. Good load security relies on choosing equipment that can withstand the forces defined in the DVSA code of practice, combined with clear risk assessments that reflect the weight, shape and behaviour of the cargo.
The DVSA explains that a safe system should prevent forward movement equal to the full weight of the load and limit sideways and rearward movement to half of that weight.
This guidance applies regardless of whether a business uses reusable wraps, nets, straps or pallet boxes. The focus is always on the effectiveness of the restraint rather than the type of material used. For operators looking for detailed technical clarification, the core reference point remains the DVSA code of practice on load securing.
Keeping these fundamentals in mind helps ensure that load containment choices support warehouse routines, transport routes and cargo safety requirements rather than depending on layers of plastic shrink wrap.
Legal commentators have highlighted how the updated DVSA code of practice places greater emphasis on risk assessment and the suitability of chosen restraints, as summarised in recent legal updates on DVSA load security guidance.
There is also a sustainability impact. High volumes of plastic shrink wrap increase waste handling requirements and contribute to wider environmental concerns. As organisations seek to cut single use materials, they are reviewing whether shrink wrap should be a last resort rather than a default choice. In many cases, better results can be achieved by combining structured stacking with engineered equipment such as reusable wraps, covers and containment systems from the Palband product range, which deliver more consistent load security while reducing plastic consumption.
Load security within the warehouse is only one part of a wider chain of responsibility. Once goods leave the site, they become part of a broader cargo safety system that spans road transport, ports, storage hubs and in some cases international shipping. A stable pallet in a warehouse helps prevent incidents further along the supply chain, improving consistency and reducing the likelihood of cargo becoming damaged or hazardous in transit.
Industry bodies regularly highlight how improper securing or incorrect packing can contribute to serious incidents. International codes of practice such as the guidance on cargo securing and packing stress the importance of choosing suitable equipment, understanding load characteristics and preventing internal movement. These principles apply to pallets, containers and roll cages alike.
Teams handling temperature sensitive items or regulated products can also strengthen safety by referring to Palband’s guidance on lithium ion battery safety. Aligning warehouse routines with these standards helps maintain stronger cargo safety throughout the journey and reduces the risk of incidents caused by unstable or poorly contained loads.
Fire services across the country are reporting a growing number of incidents involving lithium ion products, many linked to charging faults, damaged returns and incorrect storage. The National Fire Chiefs Council has warned that battery use is increasing faster than the safety standards designed to protect staff, property and first responders.
Its position statement highlights rapid flame spread, toxic vapour release and the potential for reignition even after initial suppression. Warehouses that manage large volumes of consumer electronics, power tools or mobility products are particularly exposed. By using guidance from the NFCC and implementing protective measures such as lithium battery fire blankets, fireproof covers and dedicated containment solutions from the Palband lithium battery safety range, operators can build a more resilient fire protection strategy.
A practical checklist to improve load security without plastic shrink wrap
This checklist gives operators a clear sequence to follow when preparing, securing and moving palletised goods. It is designed for busy sites where different team members may handle the same load throughout the day and helps maintain consistent load security without relying on plastic shrink wrap.
Before loading
- Inspect the pallet to confirm it is intact with no broken or weakened boards.
- Check that the pallet surface is level and free from debris.
- Review the load plan to confirm weight distribution and pallet type suitability.
While building the load
- Stack items evenly with no overhang.
- Place cartons or containers to create a positive fit, reducing gaps that can cause internal movement.
- Use dividers or containers where needed to stabilise irregular shapes.
- Confirm that the load height is suitable for the equipment chosen.
Choosing a load securing system
- Select reusable pallet covers for mixed, boxed or lightweight goods.
- Use straps for firm pressure based restraint where additional tension is required.
- Choose pallet boxes for goods that need solid side support.
- Check the condition of all equipment before use.
Before dispatch
- Confirm that the load remains stable after securing equipment is fitted.
- Record checks in your site system to maintain traceability.
- Reassess the load if any items were removed during staging or rework.
During multi drop routes
- After partial unloading, inspect the remaining items for movement.
- Reapply covers or straps if gaps have formed.
- Ensure that any equipment used is placed back on the load correctly before continuing.
Further guidance for operators
Warehouse managers can review common handling considerations through the Palband FAQs, which provide guidance on equipment selection and operational requirements. Embedding this checklist into daily routines helps maintain reliable load security and supports a stronger cargo safety culture across the site.
Conclusion and next steps for safer, plastic free load security
Improving load security without relying on plastic shrink wrap is both achievable and practical. By combining stronger warehouse discipline with engineered containment systems such as reusable wraps, covers and straps, operators can reduce movement, improve safety and cut their use of single use plastics. These changes support compliance with recognised guidance and contribute to smoother, more predictable handling across the supply chain.
Organisations reviewing their current approach can explore the full range of reusable options through the Palband product collection.
For tailored support, operators can also contact Palband to review their current restraints, identify risks and select solutions that provide consistent protection throughout the handling and transport process.
Load security is an essential part of safe and efficient operations, and choosing plastic free methods allows businesses to improve performance while supporting long term sustainability goals.
