A practical decision guide for converters handling film, paper, foil, textile and pharmaceutical rolls. Three families solve three different problems — this is how to pick the right one (and when to combine them).
When a roll has to sit safely on a pallet, you have three core options: a cradle (a curved base that holds the roll), a wedge (a block that stops it rolling) and a flange / end wall (a disc that protects the faces and lets you stack). They are not interchangeable. Choosing right is mostly about answering one question: what job do you actually need done?
The three families at a glance
| Option | What it does | Reusable | Best for |
|---|---|---|---|
| Cradle / saddle | Provides a complete curved base that supports the roll on a pallet | Yes (plastic) | A finished, storage- and transport-ready roll pallet |
| Wedge / chock | Blocks a roll on a flat pallet without lifting it | Yes (plastic) | Securing a roll on pallets you already own |
| Flange / end wall | Protects the roll faces and enables suspended, stackable packaging | Yes / disposable | Shipping where edge protection and stacking matter |
1. Cradle / saddle — the complete base
A cradle (for medium and small rolls) or saddle (for large, heavy rolls) is a curved profile that cups the roll. On a roll cradle pallet it is integrated into the pallet itself, giving you a finished unit ready for the floor or the rack.
Choose a cradle when you need a complete, reusable base for storage and transport, you store on racks, or the roll is heavy and needs full support along its length. It is the most "turn-key" option and the safest for valuable or heavy rolls.
2. Wedge / chock — secure what you already have
A plastic wedge is a block placed against a roll on a flat pallet to stop it moving — without lifting the roll. It is the fastest and most economical way to secure a roll, and the hygienic plastic version replaces the wooden zeppe that splinter and fail audits.
Choose a wedge when you already own flat or Euro pallets and simply need to immobilise the roll, or you handle mixed diameters and want a flexible, low-cost solution. Pair it with a cradle adapter if you want to upgrade a flat pallet into a roll pallet.
3. Flange / end wall — protect and stack for shipping
A flange or end wall is a disc applied to the roll face. With a core plug it forms a suspended system that protects edges and lets rolls be stacked safely in transport.
Choose a flange / end wall when your priority is protecting the roll faces and edges during shipping, or you need to stack rolls without crushing them. It is about protection in transit, not about providing a base — so it is often used together with a pallet.
How to decide in one step
| Your main need | Choose |
|---|---|
| A finished, reusable roll pallet for storage/transport | Cradle pallet |
| Stop a roll moving on pallets I already have | Wedge / chock |
| Protect roll faces and stack safely when shipping | Flange / end wall |
| Turn a flat pallet into a roll pallet | Cradle adapter (+ wedges) |
| Heavy / large rolls on racks | Reinforced cradle pallet or saddle |
They often work together
These families are complementary. A typical shipped pallet might use a cradle pallet as the base, wedges to lock the roll in place, and flanges to protect the faces and allow a second layer. The right combination depends on roll weight, stacking height and transport mode.
Always check three things
Whatever you choose, match it to: diameter (Ø) — the support must accept your min/max roll diameter; weight — standard plastic cracks under concentrated loads, so heavy rolls need steel-reinforced bases; and hygiene — food, pharma and clean-room work needs closed, washable plastic, not wood.
For the full picture, see the pillar guide: Roll & Reel Handling and Storage — The Complete Guide.
Frequently asked questions
Q: What is the difference between a cradle and a wedge? A: A cradle is a curved base that supports the whole roll and forms a finished roll pallet. A wedge is a block that simply stops a roll from moving on a flat pallet. Use a cradle when you need a complete base; use a wedge when you only need to secure a roll on pallets you already have.
Q: Do I need a flange if I already use a cradle pallet? A: Only if you ship and must protect the roll faces or stack rolls. A cradle pallet provides the base; a flange/end wall adds face protection and stackability in transit. They are frequently combined.
Q: Cradle or saddle — what's the difference? A: They are the same idea at different scales: "cradle" is generally used for medium and small rolls, "saddle" for large, heavy rolls that need fuller support.