Bar Wrapping Machine and Small Orbital Wrapper: Specs

Name: Bar Wrapping Machine and Small Orbital Wrapper: S200 Data and Film Pitch
Uploaded: 2018-04-17T09:15:29+00:00
Duration: 1 min 46 s
Description: > **Executive Summary:** A bar wrapping machine secures longitudinal products by rotating an orbital film carriage in a vertical plane around a horizontally advancing, non-rotating workpiece. The FHOPE S200 small orbital wrapper processes precision single bars and light rigid bundles with a cross-section of 10–200 mm (diagonal envelope), minimum length…

Executive Summary: A bar wrapping machine secures longitudinal products by rotating an orbital film carriage in a vertical plane around a horizontally advancing, non-rotating workpiece. The FHOPE S200 small orbital wrapper processes precision single bars and light rigid bundles with a cross-section of 10–200 mm (diagonal envelope), minimum length of 300 mm, and unit weights from 10 to 100 kg. Powered by a 2.1 kW drive system, it operates at variable ring speeds of 20–120 r/min and conveying speeds of 4–12 m/min. For fully automated packaging lines handling pieces exceeding 1000 mm, the E200 platform introduces automatic film clamping and cutting. Both platforms govern spiral film distribution through strict kinematics: Pitch (mm) = Conveying Velocity (mm/min) / Ring Speed (r/min).

Two machines, one decision
Why the bar never rotates
Film pitch: the three-number method
Pitch bounded by film width
Length and conveyor bridging
Centring and tension
Film materials
Controls
Safety
Checklist
FAQ
Next step
Related reading
Sources

Two machines, one decision

Horizontal orbital stretch wrapping is determined by three physical parameters: cross-sectional envelope (outer diagonal), workpiece length, and bundle weight. Within FHOPE’s orbital wrapping portfolio—comprising 5 semi-automatic, 10 fully automatic, and 14 custom-engineered models—precision bars and industrial rods are routed primarily through two standard platforms, with oversized profiles directed to custom structural frames.

The S200 Semi-Automatic Horizontal Wrapper serves short-to-medium runs, sensitive profiles, and short bars. The E200 Automatic Horizontal Stretch Wrapper is engineered for high-throughput automated lines requiring integrated pneumatic clamping, automatic hot-blade or mechanical shear film cutting, and continuous conveyor cycling.

Engineering Parameter	S200 Semi-Automatic Orbital Wrapper	E200 Automatic Horizontal Stretch Wrapper
Target Workpiece Section (OD / Diagonal)	10–200 mm	50–200 mm
Minimum Workpiece Length	300 mm	1000 mm
Payload Capacity Range	10–100 kg	8–100 kg
Infeed / Outfeed Powered Conveyors	2000 mm + 2000 mm (Standard motorized)	2000 mm + 2000 mm (Standard motorized)
Conveying Linear Speed	4–12 m/min	6–12 m/min
Ring Rotation / Drive Speed	20–120 r/min	5–15 m/min (Carriage surface speed)
Installed Drive Power	Approximately 2.1 kW	Approximately 2.5 kW
Electrical Utility Supply	380V, 3-Phase, 60Hz	380V, 3-Phase, 60Hz
Film Roll Dimensional Envelope	Width: 120–200 mm; OD: 150–200 mm; Core ID: 50 mm	Width: 100–200 mm; OD: 100–200 mm; Core ID: 50 mm
Automation Level	Semi-automatic (Manual film tie/tuck, push-button/pedal run)	Fully automatic (Optical auto-start, clamp, cut, wipe)

Note: For bundles exceeding 200 mm in outer diameter or 100 kg total mass, applications transition to heavy-duty custom rod wrapping platforms accommodating cross-sections up to 500–2000 mm and weights up to 4000 kg.

Why the bar never rotates

In orbital packaging, the bar travels strictly along a horizontal axis while the orbital ring revolves around it in the vertical plane. Rotating long or slender stock along its own longitudinal axis creates severe mechanical complications:

Elimination of Dynamic Whipping: Rotating a slender 6000 mm steel rod or extruded profile at wrapping speeds causes centrifugal deflection, dynamic whipping, and equipment vibration. Pure linear feed preserves dynamic stability.
Surface Defect Prevention: Polished steel, ground rod stock, and architectural anodized aluminum suffer scuffing, roller burnish, and tool marks if forced to rotate within stationary clamps or spinning driving beds.
Consistent Containment Force: Maintaining the product on a fixed centerline allows the pre-stretch carriage to apply continuous, uniform hoop tension across the profile’s perimeter without eccentric pull.

Film pitch: the three-number method

Pitch is how far the conveyor advances during one ring revolution: conveying speed in m/min times 1,000, divided by ring speed in r/min. Overlap is then 1 minus pitch over film width.

Three numbers set the machine:

Overlap first: 50% overlap on 200 mm film means a target pitch of 200 × 0.5 = 100 mm.
Then the ratio: a 100 mm pitch is a 10:1 ratio between linear advance and ring speed. On the S200, 4 m/min needs 40 r/min, 6 m/min needs 60 r/min, and the 12 m/min maximum uses the full 120 r/min.
Then transit: pass-through in seconds is length in metres ÷ speed in m/min × 60 — a 6 m bundle at 12 m/min crosses in 30 s.

Pitch bounded by film width

Pitch must never exceed the active film width. Push past it — 210 mm pitch on a 200 mm roll — and overlap goes negative: successive loops no longer touch, leaving a helical gap of bare metal exposed to moisture, cutting oil and scuffing, with no mechanical connection between turns.

Practical floors: at least 30% overlap for rigid bundle containment, and at least 50% where dust and transit protection matter.

Length and conveyor bridging

A bar has to bridge the throat between the infeed and outfeed beds across the ring plane, so minimum length is the throat gap plus twice the support margin.

S200, over 300 mm: close-coupled cantilevered rollers keep the throat to a minimum, so short components transfer down to 300 mm without transfer plates.
E200, over 1,000 mm: clamping jaws, photocells and a motorised cutter need clearance across the wrapping centreline, so the minimum stable length is 1,000 mm.
Conveyors: both platforms come with 2,000 mm powered infeed and outfeed beds; 6 m bundles use modular idler tables to stop cantilever sag.

Centring and tension

The throat diameter must exceed the bundle diagonal plus twice a dynamic clearance of at least 50 mm from the spinning carriage.

Hold-down: thin stock of 10–20 mm has little torsional rigidity, and film pull can lift a light bar off the rollers; adjustable pneumatic hold-down wheels apply regulated downforce to keep it seated.
Tension: a spring-loaded friction plate at the spindle sets film tension, so layers stay tight without necking a hollow profile.

Film materials

The S200 and E200 run standard packaging films matched to spindle dimensions:

S200: LLDPE stretch film, 120–200 mm wide, roll OD 150–200 mm, 50 mm core.
E200: LLDPE or PE film, 100–200 mm wide, roll OD 100–200 mm, 50 mm core.
Corrosion duty: raw steel or yard-stored rod is usually wrapped with VCI paper or heavy woven HDPE rather than plain stretch film.

Controls

A PLC with a touchscreen runs the machine:

Tracking: retroreflective photocells find the leading edge and start the ramps; the trailing edge starts deceleration and the tail reinforcement turns.
Drives: independent VFDs run the conveyor gearmotors and the ring friction wheels on coordinated S-curves, so nothing slips.
Integration: dry contacts and Ethernet let the cabinet interlock with upstream saws or downstream stackers.

Safety

A ring carries pinch and entanglement risk, so the envelope has to be closed:

Guarding: welded mesh encloses the ring perimeter and keeps operator reach out of the rotation envelope.
Design basis: risk assessment to ISO 12100, the EN 415-6 wrapping-machinery framework, and electrical construction to EN 60204-1, with dual-channel safety relays on the interlocked doors. The required performance level for each guard follows the site risk assessment.

Checklist

Section: outside diameter or diagonal inside 10–200 mm, otherwise a custom ring.
Length: under 1,000 mm and down to 300 mm goes to the S200; automated runs over 1,000 mm go to the E200.
Weight: pack mass within the 8–100 kg platform limit.
Throughput: conveyor 4–12 m/min matched to ring 20–120 r/min.
Film: LLDPE on a 50 mm core, 120–200 mm wide (S200) or 100–200 mm (E200).
Finish: coated rollers for anodised, ground or bare steel surfaces.

FAQ

Q: Can the S200 wrap bars under 300 mm? A: Not on the standard bed — shorter parts drop into the throat between the powered rollers, so they need auxiliary transfer plates.

Q: Why the 20–120 r/min range? A: It holds a constant pitch at any conveyor speed: 4 m/min needs 40 r/min for a 100 mm pitch, and 12 m/min needs the full 120 r/min.

Q: What makes thin aluminium bow during wrapping? A: Too much spindle brake tension with no hold-down pressure. Set hold-down at 0.2–0.4 MPa and ease the friction nut until the bundle is held without deflecting the walls.

Q: When does the E200 make sense? A: When parts consistently exceed 1,000 mm and the volume justifies a fully automatic cycle instead of manual clamping, cutting and transfer.

Next step

Contact FHOPE’s engineering division to validate cycle calculations or discuss custom machinery:

Specification Review: Send profile dimensions, length ranges, bundle weights, and target line speeds to info@fhopepack.com.
48-Hour Technical Proposal: Receive a complete technical evaluation, including conveyor speed synchronization tables, overlap pitch derivations, and layout drawings.
Factory Acceptance Testing (FAT): Ship sample profiles to our engineering center for trial wrapping, film yield testing, and high-speed motion validation prior to line commissioning.