2026 Field Case | Moisture-proof Upgrade for Bagged Flour on Pallets – Top-sheet Wrapping Machine Delivers 5-side Stretch Wrapping

Flour is a highly hygroscopic grain product. Most commercial packages adopt 25kg composite woven bags or inner film bag combinations. Fine flour particles quickly absorb moisture and cake once exposed to humidity, which can render an entire pallet of goods unusable. Most flour mills use conventional turntable stretch wrappers after palletizing. These machines only wrap the vertical sides of pallet loads, leaving the top fully uncovered and unprotected. During long-term warehousing, loading on rainy days, and open-air transfer in long-haul logistics, rainwater, ambient moisture and dust penetrate the stack through the top gap. Orders shipped to southern humid regions suffer most: extended transit time and temperature fluctuations inside trucks frequently lead to moisture regain and caking of top-layer flour bags, resulting in after-sales complaints.

To compensate for insufficient top protection, many flour mills rely on workers to manually cover pallet loads with plastic tarpaulins and fasten them with adhesive tape after wrapping. Manual tarp covering has obvious drawbacks: tarpaulins rarely fit pallet dimensions perfectly and stay loose, so they shift or fall off easily during transportation. Each pallet requires manual laying, stretching and fixing, adding repetitive work and slowing down packaging throughput. Consistency is poor due to varied operation standards among workers — some stacks are well-covered while others leave large gaps, making quality control difficult. Besides, flour workshops are dusty, and repeated manual tarp handling creates an uncomfortable working environment.

This flour processor in Central China maintains stable daily output of bagged flour. Its customers include local supermarkets, food manufacturers and grain distributors across multiple southern provinces, with long delivery routes and strict requirements for moisture and dust protection. The packaging area is an independent workstation with forklift pallet handling and uniform, neat stack profiles. After comparing multiple equipment options, the mill selected Dahong Intelligent top-sheet wrapping machine instead of standard single-side wrappers. The unit supports 5-side wrapping: besides wrapping the vertical perimeter, the film carriage automatically travels over the stack to apply the top sheet, forming a continuous stretch film barrier covering the sides and top of the load.

All control parameters are independently adjustable via the touchscreen, including wrapping cycles for sides, top film layers, film carriage travel speed and pre-stretch tension. Given the soft texture and easy deformation of flour bags, operators can set gentle and stable wrapping tension to ensure the film clings tightly to the stack without tearing the bags. Adequate overlap is reserved on the top sheet for reliable sealing against moisture and dust. Once the forklift positions the palletized flour stack, one-touch start triggers the full automatic cycle of side wrapping and top sheeting, with no manual tarp covering or film laying required.

After commissioning, the packaging workflow was greatly optimized. The separate manual tarp covering step was eliminated; workers only handle pallet loading and unloading. Cycle time per pallet is reduced and labor pressure at the workstation is relieved. Uniform 5-side wrapping removes reliance on operator experience. Defects such as flour caking and dust contamination caused by inadequate top protection have dropped sharply, and customer complaints for cross-region long-distance shipments decreased significantly. Equipped with a stable pre-stretch system, the solution cuts overall packaging material cost compared with the traditional combination of standard wrapping plus tarpaulins. The neat, consistent packaging also facilitates warehouse stacking and loading inspection.

Top-sheet 5-side stretch wrappers are ideal for manufacturers of highly hygroscopic bagged grain products including flour, starch and rice flour. If you are troubled by pallet top moisture and dust issues and want to replace inefficient manual tarp operations with stable protection for storage and transport, contact Dyehome Intelligent. We can customize a suitable wrapping solution based on your pallet size, stack height and daily packaging capacity.