Executive summary Our compact horizontal orbital stretch wrappers spiral protective film around single aluminum profiles and small bundled extrusions as they pass through a high-speed rotating ring. Three standard models cover cross-sectional package diagonals of 50–100 mm (E100), 50–200 mm (E200), and 100–300 mm (E300). Because film width, linear conveyor speed, and ring rotational speed dictate surface overlap, we engineer ring geometry and drive ratios simultaneously to guarantee protective integrity and line throughput.
Table of Contents
- How the profile wrapper works
- Three compact models
- Measuring package OD
- Speed, film width and overlap
- Unmanned film handling
- Utilities and safety
- Selection checklist for a profile wrapper
- Engineering FAQ
- Next step: from drawing to proposal
- Related reading
- Sources
How the profile wrapper works
Our horizontal orbital stretch wrapper transports aluminum extrusions along motorized infeed and outfeed roller conveyors directly through a central rotating ring. A photoelectric sensor tracks the profile leading edge, triggering the orbital ring drive, determining the exact wrapping start position, and controlling the trailing-edge cutting cycle. Non-marking, polyurethane-coated side guide rollers maintain the workpieces firmly along the conveyor centerline, preventing lateral shifting or orbital torque twist during high-speed rotation.
Ring rotation and linear conveyor travel are powered by independent variable-frequency drives (VFD). This configuration allows operators to adjust ring RPM and linear travel speed separately via the PLC touch screen. The drive system incorporates controlled S-curve acceleration and deceleration ramps, ensuring soft starts, smooth stops, and accurate automatic homing so that every profile bundle begins its wrapping cycle at the exact mechanical reference point.
Three compact models
All three standard compact models share an identical material handling footprint: a 2,000 mm motorized infeed conveyor and a 2,000 mm motorized outfeed conveyor running at adjustable speeds of 6–12 m/min. The mechanical film carriage accepts standard stretch/PE film rolls with an external diameter of 100–200 mm mounted on a standard 50 mm (2-inch) core.
| Technical Parameter | E100 Platform | E200 Platform | E300 Platform |
|---|---|---|---|
| Package OD (Diagonal) | 50–100 mm | 50–200 mm | 100–300 mm |
| Profile Length | > 1,000 mm | > 1,000 mm | > 1,000 mm |
| Payload Capacity | 8–100 kg | 8–100 kg | 15–100 kg |
| Ring Rotation Speed | 20–120 r/min | 5–15 m/min (surface speed) | 20–90 r/min |
| Linear Wrapping Speed | 3–15 m/min | Confirmed by profile drawing | 5–15 m/min |
| Conveyor Speed (In/Out) | 6–12 m/min (Adjustable) | 6–12 m/min (Adjustable) | 6–12 m/min (Adjustable) |
| Film Roll Width | 50–100 mm | 100–200 mm | 100–200 mm |
| Overlap Ratio Range | 10–90% | 10–90% | 10–90% |
| Connected Power | Approx. 2.5 kW | Approx. 2.5 kW | Approx. 2.5 kW |
| Power Supply | 380V, 3-Phase, 60Hz | 380V, 3-Phase, 60Hz | 380V, 3-Phase, 60Hz |
Our technical specifications separate wrapping linear speed through the ring from conveyor transit speeds. Because structural profiles with irregular fins create varying aerodynamic and mechanical resistance, wrapping speeds for intermediate cross-sections (E200) are confirmed against your profile drawings during engineering review.
Measuring package OD
The effective package outside diameter (OD) corresponds to the maximum cross-sectional diagonal of the profile or bundled pack, rather than width or height alone. The orbital ring inner clearance must accommodate this diagonal plus mechanical clearance margins for the rotating film carriage.
Package OD = √(Width² + Height²)
A common sizing mistake in extrusion plants is selecting a machine based on side dimensions rather than the true circumscribed diagonal. Consider a square bundle measuring 100 × 100 mm:
Diagonal = √(100² + 100²) = √(10000 + 10000) ≈ 141.4 mm
Although each side is 100 mm, this pack cannot enter the E100 (50–100 mm OD envelope). Attempting to wrap it on an E100 will cause mechanical interference with the rotating carriage. This profile must be processed on the E200 (50–200 mm) or E300 (100–300 mm) platform.
Additional engineering sizing examples:
- 60 × 40 mm architectural extrusion:
√(60² + 40²) = √(3600 + 1600) ≈ 72.1 mm. Fits cleanly inside the E100 operational envelope (50–100 mm). - 150 × 120 mm extrusion bundle:
√(150² + 120²) = √(22500 + 14400) ≈ 192.1 mm. Fits inside the E200 (50–200 mm) or E300 envelope. - 250 × 150 mm industrial bundle:
√(250² + 150²) = √(62500 + 22500) ≈ 291.5 mm. Fits inside the E300 envelope (100–300 mm).
For heavy extrusions or master packaging exceeding 300 mm OD, our product portfolio transitions to heavy-duty horizontal orbital wrappers accommodating 300–1,500 mm envelopes.
Speed, film width and overlap
With each full revolution of the orbital ring, the profile moves forward by a specific pitch distance, generating a continuous helical spiral. To ensure seamless containment, the selected film width must be wide enough to span an incremental segment of the profile perimeter with adequate tensile recovery.
The surface overlap ratio (adjustable from 10% to 90%) is governed by the kinematic speed ratio between linear conveyor advance and orbital ring rotation:
Advance Pitch (mm/rev) = (Linear Wrapping Speed in m/min × 1,000) ÷ Ring Speed in r/min
Qualitatively, the overlap follows this relationship:
Overlap ≈ 1 − [Conveyor Linear Speed ÷ (Ring Rotational Speed × Effective Film Width)]
As conveyor speed increases relative to ring rotational speed, the linear advance pitch widens, reducing the overlap percentage. To maintain a target 50% overlap for transit protection, the advance pitch per ring revolution must not exceed half of the applied film roll width:
Max Advance Pitch (50% Overlap) = Film Width ÷ 2
| Platform | Film Width | Ring Speed | Max Advance (50% Overlap) | Max Linear Speed (50% Overlap) |
|---|---|---|---|---|
| E100 | 100 mm | 120 r/min | 50 mm / rev | 6.0 m/min |
| E300 | 200 mm | 90 r/min | 100 mm / rev | 9.0 m/min |
The maximum rated speed of 15 m/min on the E100 is achieved only at lower overlap settings (e.g., 10–30% for quick internal shop-floor transfer). For a standard 6 m profile running at 6.0 m/min under 50% overlap, net transit wrapping time through the ring is exactly 60 seconds. Because film friction, pre-stretch neck-down, and irregular profile shapes alter actual film laydown, exact VFD frequency ratios must be calibrated during on-site commissioning.
Unmanned film handling
Each wrapper integrates an automatic pneumatic clamping and cutting unit for fully hands-off, unmanned cycles. At cycle start, the pneumatic tail holder positions the film web across the profile path. As the ring rotates, the film is anchored against the workpiece; the clamp then releases automatically. At cycle conclusion, an integrated pneumatic blade cuts the film tail clean, and the holding mechanism secures the web for the next bundle.
Film tension is controlled through an adjustable mechanical friction brake with roller compensation. For delicate thin-wall profiles or fragile powder coatings, the carriage can be configured to minimize unit containment force while eliminating scratch risks. Conveyor options across all models include non-marking polyurethane rollers, modular PVC flat belts, or driven chain tracks for customized infeed integration.
Utilities and safety
| Utility / Specification | Technical Standard (E100 / E200 / E300) |
|---|---|
| Connected Electrical Load | Approx. 2.5 kW |
| Standard Electrical Supply | 380V, 3-Phase, 60Hz (Custom line voltages available upon request) |
| Pneumatic Supply Requirement | 0.5–0. Moving components, rotating rings, and transmission drive belts are fully enclosed by sheet-steel safety shrouds with transparent maintenance inspection doors. Machine design complies with ISO 12100:2010 (Risk Assessment and Reduction) and EN 415-10:2014 (Safety Requirements for Modular Packaging Machines). Electrical switchgear complies with IEC 60204-1 industrial safety standards. |
Selection checklist for a profile wrapper
- Package diagonal verification: Calculate
√(W² + H²)across profile corners or bundle battens to ensure it falls within the model OD range (E100: 50–100 mm, E200: 50–200 mm, E300: 100–300 mm). - Profile length boundaries: Minimum length must exceed 1,000 mm for dual-station roller span stability.
- Throughput targets: Calculate required profiles or bundles per hour to size ring r/min and line indexing speeds.
- Surface overlap specification: Target protective overlap percentage (10–90%) based on storage duration and transport modes.
- Surface coating sensitivity: Anodized, mill-finish, or powder-coated surfaces determine PU guide roller durometer and film tension.
- Film carriage selection: Film roll width (50–100 mm for E100; 100–200 mm for E200/E300) with 50 mm core diameter.
- Line integration: Standalone off-line operation or direct in-line synchronization downstream of an automated extrusion saw table.
Engineering FAQ
Q: Which orbital model is required for a single 60 × 40 mm aluminum profile?
A: The E100 model. Its calculated cross-sectional diagonal is √(60² + 40²) ≈ 72.1 mm, which sits cleanly within the E100 working range of 50–100 mm OD.
Q: Can a 100 × 100 mm square bundle be wrapped on the E100?
A: No. While the individual width and height are 100 mm, the cross-sectional diagonal is √(100² + 100²) ≈ 141.4 mm. This package exceeds the 100 mm maximum envelope of the E100 and must be processed on the E200 (50–200 mm) or E300 (100–300 mm).
Q: Can the E100 operate at 15 m/min while maintaining a 50% film overlap? A: No. At the maximum ring rotational speed of 120 r/min and using a 100 mm film roll, the maximum allowable linear speed for a 50% overlap is 6.0 m/min. Achieving 15 m/min requires reducing the overlap setting down to approximately 20%.
Q: Does the machine require manual cutting or film taping between cycles? A: No. All models feature an automatic pneumatic film clamp-and-cut station. The film tail is clamped at cycle start, wrapped into the first revolution, pneumatically severed at cycle end, and retained for the next profile.
Q: What is the minimum workable profile length? A: Standard machines process workpieces down to 1,000 mm. Shorter extrusions require bridge roll transitions to span across the orbital ring center.
Q: What equipment options exist for bundle cross-sections larger than 300 mm? A: Packages exceeding 300 mm OD transition to our heavy-duty horizontal orbital wrappers, which provide ring working envelopes from 300 mm up to 1,500 mm.
Next step: from drawing to proposal
We engineer and configure horizontal orbital stretch wrappers according to your specific extrusion cross-sections and packing speeds:
- Submit your profile drawings: Send cross-sectional dimensions, bundle configurations, and required pieces-per-hour to info@fhopepack.com.
- Receive an engineering proposal within 24–48 hours: We provide ring size selection, motor drive calculations, line layout footprints, and cycle-time evaluations.
Related reading
- E100 Horizontal Orbital Stretch Wrapper Specifications
- E200 Horizontal Orbital Stretch Wrapper Specifications
- E300 Horizontal Orbital Stretch Wrapper Specifications
Sources
- Machine Specifications: Fhope E-Series Horizontal Orbital Stretch Wrappers
- Machinery Safety Standards: ISO 12100:2010 Safety of Machinery — General Principles for Design
- Packaging Machinery Safety: EN 415-10:2014 Safety Requirements for Packaging Machines
- Electrical Safety Norms: IEC 60204-1 Safety of Machinery — Electrical Equipment of Machines
Last reviewed: 2026-11-05
