Stretch Film Weight & Production Calculator | ProPac Tools

🏭 PropacTools — Industrial Calculators

Stretch Film Production
& Weight Calculators

Complete professional toolkit for stretch film manufacturers, converters, and packaging engineers — calculate roll weight, yardage, GSM, and more with precision.

8+Calculators

100%Free to Use

SIStandard Units

Roll Weight Film Length GSM / Thickness Core Weight Production Output Material Cost Yield Strength Resin Quantity All Links

⚖️

1. Roll Weight Calculator

Calculate the gross and net weight of a stretch film roll

📖 What is Roll Weight?

Roll weight refers to the total weight of a finished stretch film roll including the plastic core. In stretch film production, knowing the precise roll weight is critical for inventory management, transportation cost calculation, and customer billing. Net weight is the weight of film only (without core).

Formula:

Core OD (mm) = Core ID + (2 × Wall Thickness)
Volume (cm³) = (π ÷ 4) × [(OD/10)² − (CoreOD/10)²] × (Width/10)
Film Wt (kg) = Volume × Density ÷ 1000
Gross Wt (kg) = Film Wt + Core Wt
─────────────────────────────────────────
Film Length (m) = (π ÷ 4) × (OD² − CoreOD²) ÷ Micron × 1000 [all in mm, µm]

Enter Roll OD, Core ID + Wall Thickness (OD auto-filled), Film Width, Micron (thickness in µm), and Density. Calculator gives both Roll Weight (from geometry+density) and Film Length in meters (from geometry+micron). Core weight field is optional — use Core Weight Calculator below.

⚖️

Roll Weight Calculator

Roll Outer Diameter (OD)

in mm (full roll OD)

Core Inner Diameter (ID)

in mm — 3-inch=76mm, 2-inch=52mm

Core Wall Thickness

in mm → Core OD = ID + 2×Wall

Core OD (Auto)

mm — read only

Film Width

in mm

Film Micron (Thickness)

in µm — e.g. 17, 20, 23 micron

Film Density

g/cm³ (LLDPE default: 0.920)

Core Weight (optional)

in kg — use Core Weight Calculator below

📊 Results

Film Type	Density (g/cm³)	Standard Width	Typical Thickness
LLDPE Stretch Film	0.918 – 0.922	500mm / 450mm	17–23 microns
HDPE Stretch Film	0.940 – 0.960	500mm	10–15 microns
PP Stretch Film	0.900 – 0.910	500mm	20–25 microns
Pre-Stretch Film	0.918 – 0.922	500mm	8–12 microns

📏

2. Film Length / Yardage Calculator

Calculate total meters of film on a roll

📖 Why Calculate Film Length?

Film length (also called yardage) determines how many wraps a roll can provide on a pallet. It is specified in customer orders, and directly affects the price per meter. The length is calculated from the roll geometry and film thickness.

Core OD (mm) = Core ID + (2 × Wall Thickness)
Thickness (mm) = Micron ÷ 1000
Length (mm) = (π ÷ 4) × (Roll OD² − Core OD²) ÷ Thickness_mm
Length (m) = Length (mm) ÷ 1000
──────────────────────────────────────────────
Width cancels out — Length depends only on Roll OD, Core OD, and Micron.

Enter Micron directly (e.g. 20). Core OD is auto-calculated from Core ID + Wall Thickness. No manual OD needed.

📏

Film Length Calculator

Roll Outer Diameter (OD)

in mm (full roll OD)

Core Inner Diameter (ID)

in mm — 3-inch=76mm, 2-inch=52mm

Core Wall Thickness

in mm

Core OD (Auto)

OD = ID + (2 × Wall) — read only

Film Micron (Thickness)

in µm — e.g. 17, 20, 23 micron

📊 Results

🔬

3. GSM & Thickness Calculator

Convert between GSM, thickness (micron), and density

📖 Understanding GSM and Micron

GSM (Grams per Square Meter) is the weight per unit area of film. Micron (µm) is the thickness unit (1 micron = 0.001 mm = 0.000001 m). Both are interchangeable using density:

GSM = Thickness (micron) × Density (g/cm³)
Thickness (micron) = GSM ÷ Density (g/cm³)

Example: 20 micron LLDPE = 20 × 0.920 = 18.4 GSM

🔬

GSM / Thickness Converter

Convert From Micron → GSM GSM → Micron

Input Value

Enter micron or GSM value

Density

g/cm³

📊 Results

🧻

4. Cardboard Core Weight Calculator

Estimate the weight of paper/cardboard cores

📖 Core Weight Importance

The cardboard core (tube) adds to gross roll weight. Knowing core weight allows accurate net film weight calculation, which affects pricing and specification compliance. Standard stretch film cores are 3-inch (76mm OD), 2-inch (52mm OD). Cardboard density ≈ 1.0–1.2 g/cm³.

OD (mm) = ID + (2 × Wall Thickness)
Volume (mm³) = (π ÷ 4) × (OD² − ID²) × Length
Volume (cm³) = Volume (mm³) ÷ 1000
Weight (g) = Volume (cm³) × Density (g/cm³)
Weight (kg) = Weight (g) ÷ 1000
─────────────────────────────────────────────
Short: Wt (kg) = (π÷4) × (OD²−ID²) × Length × Density ÷ 1,000,000

✅ Example: ID=76, Wall=5 → OD=86, L=460, Density=0.73
Vol = (π÷4)×(86²−76²)×460 = 585,279 mm³ = 585.28 cm³
Wt = 585.28 × 0.73 ÷ 1000 = 0.427 kg

Enter ID (Inner Diameter) and Wall Thickness. OD auto-fills. Paper/cardboard core density ≈ 0.65–0.80 g/cm³ (default 0.73) — NOT 1.10 which is solid material density.

🧻

Core Weight Calculator

Core Inner Diameter (ID)

in mm — 3-inch=76mm, 2-inch=52mm

Core Wall Thickness

in mm

Core OD (Auto)

OD = ID + (2 × Wall) — read only

Core Length (Width)

in mm — same as film width

Cardboard Density

g/cm³ — paper core: 0.65–0.80 (default 0.73)

📊 Results

🏭

5. Production Output Calculator

Calculate daily/shift kg output from extruder line speed

📖 Line Speed to Output Conversion

In stretch film extrusion, the line speed (meters per minute or m/min) combined with film dimensions determines how many kilograms of film are produced per hour or per shift. This helps plan production schedules and raw material consumption.

Output (kg/hr) = Line Speed (m/min) × 60 × Width (m) × Thickness (m) × Density (g/cm³) × 1000

🏭

Production Output Calculator

Line Speed

meters per minute (m/min)

Film Width

in mm

Film Thickness

in microns (µm)

Film Density

g/cm³

Shift Duration

hours per shift

Efficiency (%)

machine utilization %

📊 Results

💰

6. Material Cost Calculator

Calculate cost per kg and per roll of stretch film

📖 Cost Estimation

Material cost calculation helps manufacturers set selling prices, analyze margins, and plan procurement. It accounts for resin cost, conversion cost, and target roll weight to arrive at a per-roll cost.

Cost per Roll = Roll Net Weight (kg) × (Resin Cost + Conversion Cost) per kg

💰

Material Cost Calculator

Net Roll Weight

kg (film only, no core)

Resin Price

per kg (USD/INR/any currency)

Conversion Cost

per kg (energy + labor + overhead)

Core Cost

per piece

Target Margin (%)

desired profit margin

Currency Symbol

optional (e.g. ₹, $, €)

📊 Results

💪

7. Stretch Ratio & Elongation Calculator

Calculate stretch ratio, pre-stretch %, and effective gauge

📖 Stretch Ratio & Pre-Stretch

Stretch film is stretched during application (hand wrap or machine wrap). The stretch ratio determines how much the film elongates. Pre-stretch (on machine wraps) can extend film up to 250–300% of its original length, reducing material cost per pallet.

Stretch % = [(Stretched Length − Original Length) / Original Length] × 100
Effective Thickness (µm) = Original Thickness ÷ (1 + Stretch% / 100)
Effective GSM = Original GSM ÷ (1 + Stretch% / 100)

💪

Stretch Ratio Calculator

Original Film Thickness

in microns (µm)

Original Length

in meters

Stretched Length

in meters

Original GSM

g/m² (optional)

📊 Results

🧪

8. Resin Quantity & Raw Material Calculator

Calculate resin needed for a production run

📖 Resin Planning

Before a production run, manufacturers need to know exactly how much resin (LLDPE, HDPE, metallocene, etc.) is required. This calculator accounts for scrap/waste percentage and gives total resin purchase quantity for the run.

Net Resin (kg) = No. of Rolls × Net Roll Weight (kg)
Gross Resin (kg) = Net Resin ÷ (1 − Waste% / 100)

🧪

Resin Quantity Calculator

Number of Rolls to Produce

pieces

Net Roll Weight

kg per roll (film only)

Process Waste / Scrap %

typical: 2–5%

Resin Price per kg

optional — for total cost

📊 Results

🔗

All Calculators — Quick Links

Bookmark or share individual calculators

⚖️

Roll Weight CalculatorGross & net roll weight

📏

Film Length / YardageTotal meters on roll

🔬

GSM ↔ Micron ConverterThickness & weight per m²

🧻

Core Weight CalculatorCardboard tube weight

🏭

Production Outputkg/hr from line speed

💰

Material Cost CalculatorCost per roll & per kg

💪

Stretch Ratio CalculatorPre-stretch % & effective gauge

🧪

Resin Quantity CalculatorRaw material planning

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Production Tips

Best practices for stretch film manufacturing

Core Size MattersStandard 3-inch (76mm) cores are most common. 2-inch cores for light-duty rolls. Always weigh cores in batches for accuracy.

Density VariationResin density can vary batch to batch. Always verify with the resin supplier's Certificate of Analysis (COA).

Gauge ToleranceIndustry standard allows ±10% thickness tolerance. Use calibrated gauges for QC at least every 30 minutes.

Pre-Stretch SavingsPre-stretched film at 250% stretch uses ~3× less material per pallet wrap vs non-stretch application.

Temperature EffectsFilm density slightly decreases at higher temperatures. Store resin and film in stable temperature conditions.

Waste BenchmarksWorld-class stretch film plants achieve <2% startup/changeover waste. Average is 3–5%.

PropacTools Blog — Stretch Film Production & Weight Calculators
For professional use. Always verify critical calculations with your process data. © PropacTools

Honeycomb Paper Roll Calculator — Output Metres, Rolls & Profit | ProPac Tools

ProPac Tools — Flexible Packaging

Honeycomb Paper Roll Calculator

Calculate output metres, number of rolls, raw material cost & profit — from a single kraft paper input roll.

What is Honeycomb Paper (Cushioning Wrap)?

Honeycomb paper — also called paper bubble wrap or honeycomb cushioning wrap — is an eco-friendly alternative to plastic bubble wrap. It is made from a single sheet of kraft paper that is die-cut with staggered slits and then expanded to form a hexagonal honeycomb pattern. The expanded roll provides excellent cushioning, void-fill, and surface protection.

Unlike multi-layer corrugated board, honeycomb cushioning wrap is a single-layer product. The magic is entirely in the cut-and-expand process — no lamination, no glue, no heat required.

📦 Material

Kraft paper — 40 to 80 GSM. Lighter GSM = more metres per kg. Heavier GSM = stronger cushioning.

⚙️ Process

Die-cut slits → mechanical expansion → rewinding onto output cores. Speed: 30–200 m/min depending on machine.

🌿 Application

E-commerce wrapping, fragile goods, jewellery, glassware, ceramic tiles, auto-parts — any item needing surface protection.

How is Output Calculated?

The core formula is simple — but many manufacturers get it wrong due to unit mismatch:

Flat Paper Length (m) = Roll Weight (g) ÷ [ GSM × Width (m) ]
Expanded Length (m) = Flat Paper Length × Expansion Ratio
Usable Length (m) = Expanded Length × (1 − Wastage % / 100)
Output Rolls = floor ( Usable Length ÷ Output Roll Length )
Roll Weight (kg) = Usable Paper Weight ÷ Number of Rolls

Important: Expansion only increases length — not weight. 1 metre of flat paper becomes 1.8 metres of honeycomb, but the paper weight stays exactly the same. Roll weight = usable kg ÷ number of rolls.

Worked Example

Input Parameter	Value	Result
Roll weight	50 kg = 50,000 g	—
GSM × Width	60 × 0.3 m = 18	—
Flat paper length	50,000 ÷ 18	2,778 metres
After expansion (1.8×)	2,778 × 1.8	5,000 metres
Usable (8% wastage)	5,000 × 0.92	4,600 metres
Output rolls (50 m each)	4,600 ÷ 50	92 rolls
Roll weight	46 kg ÷ 92 rolls	0.5 kg per roll

Expansion Ratio — What Does It Mean?

The expansion ratio tells you how many times the final expanded roll is longer than the original flat paper. A ratio of 1.8× means 1 metre of flat kraft paper becomes 1.8 metres of honeycomb wrap after expansion.

Ratio	Cell Size	Best For
1.5×	Tight / small	Heavy items, strong wrapping needed
1.8×	Standard	General e-commerce packaging (most common)
2.2×	Wide	Light fragile items, jewellery, glassware
2.5×	Maximum	Very light goods, maximum yield per kg

Choosing the Right GSM for Kraft Paper

GSM (Grams per Square Metre) is the key variable that controls both the strength of your product and the number of metres you get per kilogram of input paper.

GSM	Metres per kg (300mm wide)	Recommended Use
40 GSM	83.3 m/kg	Lightweight items only
50 GSM	66.7 m/kg	Light e-commerce
60 GSM	55.6 m/kg	Standard — most popular
80 GSM	41.7 m/kg	Heavy goods, fragile items
100 GSM	33.3 m/kg	Export, premium cushioning
120 GSM	27.8 m/kg	Heavy industrial packaging, auto parts
140 GSM	23.8 m/kg	Maximum strength — heavy machinery, export heavy goods

Who Uses This Calculator?

🏭 Manufacturers
Plan raw material purchase per production shift

🛒 E-commerce Sellers
Calculate how many rolls needed per 1,000 orders

📦 Distributors
Price per roll vs raw material cost analysis

🧾 Purchase Managers
Verify supplier quotes against actual output

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Frequently Asked Questions

▶ How many metres of honeycomb wrap comes from 1 kg of kraft paper (60 GSM, 300mm wide)?

Using the formula: 1000g ÷ (60 GSM × 0.3m) = 55.6 metres of flat paper. After 1.8× expansion, you get approximately 100 metres of honeycomb wrap per kg — before wastage deduction.

▶ What is a typical machine wastage percentage?

Semi-automatic machines: 8–12%. Fully automatic machines: 4–7%. Manual operations: 10–15%. Use 8% as a safe default for planning purposes.

▶ Is honeycomb wrap the same as corrugated board?

No. Corrugated board is multi-layer (liner + fluted medium + liner) made with starch adhesive. Honeycomb cushioning wrap is a single layer of kraft paper, die-cut and mechanically expanded. No glue or lamination involved.

▶ What is a standard output roll length for honeycomb wrap?

Common output lengths are 25m, 50m, and 100m depending on target market. E-commerce sellers prefer 50m rolls. Bulk industrial buyers prefer 100m. Retail/gifting formats are 25m or smaller.

▶ Does expansion increase the weight of the roll?

No. Expansion only increases length — not weight. 1 metre of flat paper becomes 1.8 metres of honeycomb, but the paper mass stays the same. Roll weight = usable kg ÷ number of rolls.

Honeycomb Paper Roll Calculator

Raw material → output rolls & profit

Input — Kraft Paper Roll

Roll weight (kg)

Paper GSM 40 GSM 50 GSM 60 GSM 80 GSM 100 GSM 120 GSM 140 GSM

Deckle width (mm)

Output Roll Lengths (ek ya zyada)

Length 1 (m)

Length 2 (m)

Length 3 (m)

Length 4 (m)

Process & Costing

Expansion ratio 1.5× tight 1.8× standard 2.2× wide 2.5× max

Wastage (%)

Paper rate (₹/kg)

Core cost (₹/piece)

Selling Price Mode

Selling price (₹/kg)

Per roll: —

Selling price (₹/roll) — pehli size

Per kg: —

Flat kraft paper
(before machine)

m  |  kg

→

After expansion
(×)

m  |  kg

→

Wastage removed
(%)

m  |  kg lost

→

Usable honeycomb
(output)

m  |  kg

Output Roll Breakdown

Roll length	Rolls	Roll weight	Sell price/roll	Margin %

Cost Analysis — Pehli Roll Size

Raw material cost

Core (tube) cost

Total input cost

Cost per roll

Total revenue

Gross profit

Margin %