What Are Pallet Caps? | HDPE Pallet caps demo
We recently made this demo video on our clear HDPE pallet caps, so we thought we would write an updated blog.
Protecting palletised goods is an important part of any warehouse, logistics, or manufacturing operation. While many businesses focus on wrapping and securing loads from the bottom and sides, the top of a pallet is often left exposed to dust, dirt, moisture and weather. Clear HDPE pallet caps offer a simple solution to this problem by adding a protective layer over the top of pallet loads before wrapping. They are widely used across Australia for export freight, warehouse storage and in production environments where cleanliness, presentation and product integrity are priorities.
At MPSPack, pallet protection solutions are an important category within our industrial packaging range. Clear pallet caps are one of the most cost-effective ways to improve pallet presentation and reduce damage caused by environmental contamination. They integrate perfectly with stretch wrap systems and can be applied quickly as part of a standard packing routine.
What Are Pallet Caps?
Pallet caps are sheets of plastic that are placed over the top of a palletised load before it is stretch wrapped. Their purpose is to provide protection from above, acting as a dust cover and moisture barrier. Once a pallet cap is placed over the load, it is held in position by the stretch wrap applied during palletising.
Pallet caps are commonly used in warehouses, distribution centres, manufacturing plants, food production facilities, 3PL operations and export packing environments. They are especially useful for pallets that are stored outdoors under awnings, moved in open transport, or stored for long periods in dusty conditions.
Unlike full pallet covers or pallet bags, pallet caps only cover the top surface of the load, making them an economical option where full coverage is unnecessary.
What Is HDPE?
HDPE stands for High Density Polyethylene, a strong, lightweight and durable thermoplastic material commonly used in packaging. It is known for its excellent strength-to-weight ratio, moisture resistance and puncture resistance. HDPE is also fully recyclable under classification code #2 plastic.
Benefits of Clear Pallet Caps
Clear HDPE pallet caps offer several key advantages in industrial packaging:
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Cleanliness
Clear pallet caps act as a dust and dirt barrier, protecting palletised goods during storage and transport. This is beneficial in production environments such as food, pharmaceutical, plastics and electrical manufacturing where dust prevention is important. -
Moisture Protection
When combined with stretch wrap, pallet caps help prevent water from seeping into the top of loads during transport or storage. This reduces the risk of carton collapse, product staining or material swelling due to moisture exposure. -
Compatibility
Pallet caps work with standard pallet wrapping equipment and processes. They can be used with manual hand stretch wrap, machine stretch wrap and blown or cast film types. -
Cost Effective
Clear pallet caps offer top-layer protection without the expense of full pallet covers. They are a low-cost solution to improve packaging security and pallet presentation. -
Versatility
They can be used across many industries including manufacturing, food packaging, warehousing, third-party logistics, printing, paper goods, metal components and more.
Pallet cap demo video
The pallet cap is placed over the top of the load before wrapping. Once stretch wrap is applied around the pallet, the film secures the edges of the cap and locks it into position. This simple method provides reliable top coverage without adding complexity to the packing process.
They do not require any special tools or attachment equipment. Pallet caps are supplied perforated on rolls for compact storage.
Thickness and Size Options
Clear pallet caps are available in different sizes and film thicknesses depending on load requirements. A common specification is 840/1680 mm x 1680 mm x 20 micron, suitable for standard Australian pallets measuring 1165 x 1165 mm.
The 20-micron thickness used in most warehouse environments offers a good balance of durability, tear resistance and cost efficiency. However if you want thicker we can always make it for with our custom made plastic options
Pallet caps with a pallet wrapping machine:
The correct way to apply pallet caps for waterproofing is apply a layer of stretchwrap first. then the pallet cap, then wrap the pallet gain to secure the cap on. This makes sure that any water instead of coming down the side of the goods directly can only down the side of stretchwrap because of the increased layering. We use a pallet wrapping machine for this See our video here:
If you liked this we have a full blog on this video methods to apply a pallet cover
Application Tips
To get the best performance from pallet caps, consider the following tips:
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Centred placement: Ensure the cap covers the full top of the pallet
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Wrap tension: Use good wrap tension to hold the cap in place
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Overlap: Make sure stretch wrap overlaps the cap edges
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Load stability: Use corner boards if necessary to protect sharp edges
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Environment: Store pallet caps away from direct sunlight to prevent film degradation
Industries That Rely on Pallet Caps
Clear pallet caps are used in a wide range of industries in Australia:
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Manufacturing and assembly
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FMCG
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Food production
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Commercial printing and labels
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Electronics
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Engineering components
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Powder and chemical packaging
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Pharmaceuticals
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3PL warehouse services
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Exporters and freight forwarders
Their ability to protect while maintaining visibility makes them useful in any industry that values clear product presentation and easy identification.
MPS Packaging
MPSPack has a wide range of pallet protection products including clear HDPE pallet caps, black pallet caps, shrink covers, drum covers and gusseted pallet bags. Our pallet caps are manufactured from quality polyethylene to ensure consistent thickness, tear resistance and durability. They are engineered for Australian conditions, offer great load coverage and suit both manual and automated wrapping processes.
Warehouse managers and production supervisors use pallet caps to improve pallet quality control, reduce weather exposure risk, and maintain cleanliness standards in busy operations. Whether storing pallets outdoors or transporting goods across long distances, pallet caps are a valuable first line of defence.
