Executive summary Copper busbar is long, flat and easily marked, and a scratched or tarnished face can be rejected by the switchgear maker. Our automatic packing machine wraps each bar in clear film with a horizontal orbital ring, while roller conveyors carry the bar through it. Film use follows from the bar’s section, its length and the overlap set. All are set per project.
Table of Contents
- What the video shows
- How the busbar wrapper works
- Estimating film per bar
- Why wrap copper busbar
- Controls and safety
- Selection checklist for a busbar packing machine
- Engineering FAQ
- Next step
- Related reading
- Sources
What the video shows
Long flat copper bars run lengthwise on yellow roller conveyors through the ring of our white orbital wrapper. The ring turns round each bar as it passes and lays clear film along it in a spiral.
The wrapped bar runs on along the outfeed rollers. In some shots an operator stands beside the machine, and in others the line runs on its own. A caution sticker sits on one section of the guarding, and the FHOPE GROUP mark appears in the clip.
How the busbar wrapper works
| Step | What happens |
|---|---|
| Infeed | The bar runs lengthwise onto the infeed rollers |
| Orbital wrap | The ring turns round the moving bar and lays film on it |
| Film cut | The film is cut after the bar leaves the ring |
| Outfeed | The wrapped bar runs on for stacking |
The bar moves straight through and is never turned, so its flat faces and edges are not rubbed. The film keeps air and handling marks off the copper.
Estimating film per bar
Illustrative example for a bar 100 mm wide, 10 mm thick and 4,000 mm long, with 100 mm film at half overlap:
| Item | Value |
|---|---|
| Bar section perimeter, 2 × (100 + 10) | 220 mm |
| Film width (illustrative) | 100 mm |
| Advance per ring turn at half overlap | 50 mm |
| Ring turns, 4,000 ÷ 50 | 80 |
| Film laid, 80 × 0.22 m | about 17.6 m |
A thin bar has a small perimeter, so film per bar is low even at full cover. Bundles of several bars can be wrapped together the same way.
Why wrap copper busbar
| Risk | How the film helps |
|---|---|
| Tarnish | Film keeps air and moisture off the faces |
| Scratches | Bars do not rub each other in the stack |
| Fingerprints | Faces stay clean until fitting |
| Mixed sizes | Labels can go on the film |
Clear film lets the customer see the copper without unwrapping it.
Controls and safety
The ring turns at speed round the bar, and guarding with a caution sticker covers parts of the machine. Keep hands away from the ring and the rollers while the line runs.
The standards that apply depend on the destination market. For CE markets, ISO 12100 sets the risk-assessment method and EN 415-10 sets general requirements for packaging machines.
Selection checklist for a busbar packing machine
- Bar width, thickness and length range.
- Single bars or bundles.
- Bars per hour.
- Film cover: full or banded.
- How bars reach and leave the wrapper.
- Labelling and stacking after wrapping.
Engineering FAQ
Q: Why an orbital wrapper for busbar? A: The ring turns round the bar, so the bar moves straight through without being turned or rubbed.
Q: How much film per bar? A: Ring turns times the section perimeter. Our 4,000 mm example lays about 17.6 m.
Q: Can bundles be wrapped? A: Yes. Several bars can pass through the ring together.
Q: Does it run without an operator? A: In parts of our video the line runs unattended. Loading and unloading are planned per project.
Q: Why clear film? A: The customer can see and check the copper without unwrapping it.
Next step
We plan your busbar packing machine in three steps:
- Submit your layout drawing with bar sizes and output to info@fhopepack.com.
- Receive a proposal within 48 hours, with the film and ring plan.
- Book a site survey to check the conveyor layout and floor space.
Related reading
- Orbital stretch wrapper
- Rotary ring stretch wrapping machine
- Video: rod orbital wrapper and bar wrapping machine
Sources
- Machine content: FHOPE engineering team, 2026-10-04
- Film example: our worked example, illustrative values
- Machine in action: our video on YouTube
- Standards scope: ISO 12100:2010, EN 415-10:2014
Last reviewed: 2026-10-04
