Executive summary
An online cable packing line takes cable straight from the extrusion line and turns it into finished, palletized coils with no manual handling. Our line coils the cable to length, straps the coil, shrink-wraps it and stacks it on pallets with a robot. The integrated version runs up to 2 coils per minute for coils of 135–220 mm ID and 180–400 mm OD.
Cable leaves the extruder over guide wheels into the blue coiling machine with its orange guards. At the end of the line, a yellow robot arm lifts finished red cable coils and builds them up in layers on a timber pallet inside the robot cell.
Table of Contents
- Line stations
- Coil ranges
- Matching the line to the extruder
- Pallet pattern and pallet changes
- Selection checklist
- Safety: EN 415-10 and ISO 12100
- Engineering FAQ
- Next step
- Related reading
- Sources
Line stations
| Station | What it does |
|---|---|
| Cable infeed | guide wheels take the cable from the extrusion line |
| Automatic coiler | winds the cable to the set length and cuts it |
| Strapping | straps the coil with PP strap, 13 mm wide and 0.6 mm thick |
| Shrinking | wraps the coil in shrink film and shrinks it in a tunnel |
| Robot stacking | places each coil on the pallet to the programmed pattern |
| Control | PLC and HMI run the whole line from one panel |
Each station can also be supplied on its own, for example coiling and strapping only, with shrinking and stacking added later. See also our online auto cable coiling and wrapping machine.
Coil ranges
| Item | Coiling, strapping and stacking line | Coiling and strapping machine |
|---|---|---|
| Coil ID | 135–220 mm | 140–200 mm |
| Coil OD | 180–400 mm | 240–460 mm |
| Coil height | 80–130 mm | 60–100 mm |
| Cable diameter | 1.5–6 mm | 3–15 mm |
| Coil weight | custom-engineered, confirmed at quote | up to 50 kg |
| Output | up to 2 coils per minute | up to 60 coils per hour |
| Strap | confirmed at quote | 13 × 0.6 mm, min. strapping height 44.5 mm |
Matching the line to the extruder
The packing line must keep up with the extruder. The check is simple:
Coils per minute needed = extruder speed (m/min) ÷ cable length per coil (m).
| Extruder speed | Coil length | Coils per minute | Coils per hour | Line choice |
|---|---|---|---|---|
| 60 m/min | 100 m | 0.6 | 36 | either machine |
| 120 m/min | 100 m | 1.2 | 72 | 2-coils-per-minute line |
| 200 m/min | 100 m | 2.0 | 120 | at the 2 coils/min limit; dual coiler or accumulator |
Result. At 120 m/min with 100 m coils the line needs 72 coils per hour, more than the 60 per hour of the coiling and strapping machine alone. The integrated line at up to 2 coils per minute covers it with margin.
Pallet pattern and pallet changes
Take coils of 400 mm OD and 130 mm height on a 1,200 × 1,000 mm pallet, stacked to about 1,300 mm.
| Step | Calculation | Result |
|---|---|---|
| Coils per row | 1,200 ÷ 400 | 3 |
| Rows per layer | 1,000 ÷ 400 = 2.5 | 2 |
| Coils per layer | 3 × 2 | 6 |
| Layers | 1,300 ÷ 130 | 10 |
| Coils per pallet | 6 × 10 | 60 |
| Time to fill a pallet at 2 coils/min | 60 ÷ 2 | 30 min |
Result. A full pallet every 30 minutes. Plan an empty-pallet buffer or a second pallet position so the robot does not wait for a forklift. A loose stack of coils is then best stretch-wrapped before it leaves the cell, so the layers cannot shift in transport.
Selection checklist
- Cable diameter range and coil length.
- Coil ID, OD, height and weight.
- Extruder speed.
- Strap only, or strap and shrink film.
- Pallet size, stack height and pattern.
- Space for the robot cell and pallet buffer.
Safety: EN 415-10 and ISO 12100
Packing lines are covered by EN 415-10, with the risk assessment to ISO 12100:2010. The coiler, the cutter, the strapping head, the shrink tunnel and the robot are the main hazards. The robot cell is closed by interlocked fencing or light curtains, with robot safety to ISO 10218; a painted floor zone only marks it. Guarding and CE documents are agreed per project.
Engineering FAQ
Q: Can the line run in line with the extruder? A: Yes. It takes the cable directly from the extrusion line.
Q: How fast is it? A: Up to 2 coils per minute for the integrated coiling, strapping and stacking line.
Q: What cable sizes fit? A: 1.5–6 mm on the integrated line; 3–15 mm on the coiling and strapping machine.
Q: Can it run around the clock? A: Yes. Our cable rewinding and strapping machines run in continuous 24-hour operation.
Q: Is shrink film needed? A: It is optional. Strapping alone holds the coil; shrink film adds dust and moisture protection.
Next step
- Send your cable size, coil length, coil size and extruder speed to info@fhopepack.com.
- We lay out the coiling, packing and stacking line.
- We reply within 24 hours with a proposal and quotation.
Related reading
- Cable winding and strapping machine with palletizing (product)
- Cable automatic coiling and strapping machine (product)
- Automatic cable coiling and tying machine (product)
Sources
- FHOPE product pages: cable winding and strapping with palletizing; cable coiling and strapping machine
- EN 415-10; ISO 10218; ISO 12100:2010
- Our online cable packing line shown above
Last reviewed: 2026-10-19
