Plastic Pipe and Tube Packing: Horizontal Coil Wrapping (FPCA-200H)

Executive summary

Corrugated plastic pipe and electrical conduit leave the extruder as soft coils. Our horizontal coil wrapper packs each coil lying flat, eye vertical: a ring carries film or paper through the coil eye while the coil turns, so the pipe ends cannot spring out and the coil stays clean. Our FPCA-200H takes coils of 200–350 mm ID, 500–650 mm OD, 150–300 mm wide and 10–50 kg.

The machine packs the coil lying flat: a coiled corrugated conduit, tied at a few points after coiling, is set on the roller bed and wrapped in place before it moves on.

Table of Contents

Why corrugated pipe coils are wrapped

A corrugated pipe coil is held together only by a few ties after coiling. In transport the outer turns loosen, the ends spring out, and dust gets into the corrugations and the bore. A full wrap through the eye closes the coil on all sides. It holds every turn in place, keeps the pipe clean, and gives a smooth surface for labels and stacking.

Without external wrapping, corrugated coils present three practical challenges across the logistics chain:

  • Radial spring-back: Elastic recovery in HDPE, LDPE, or PP corrugated conduit forces the tail ends loose once manual strapping slacks, snagging during palletizing.
  • Surface contamination: The hollow corrugation ribs trap warehouse airborne dust, grit, and moisture, making conduits difficult to install or pull wires through on site.
  • Stacking deformation: Uneven loose turns shift during multi-tier warehouse stacking, causing pallet leaning and transport damage.

A continuous through-the-eye horizontal wrap binds the entire annular profile into a rigid structural bundle, shielding the internal bore and outer ribs under uniform film tension.

Operation step by step

  1. Load. The coil is placed flat on the roller bed, by hand for light coils or transferred directly from an upstream automatic coiler via conveyor.
  2. Start. The operator starts the cycle, and the ring begins to turn through the coil eye.
  3. Wrap. Each ring turn lays one band of film around the coil section. The rollers turn the coil slowly, so each band lands next to the last one with the set overlap.
  4. Finish. After one full coil turn plus a short overwrap, the ring stops, and the film is cut and pressed down.
  5. Unload. The wrapped coil rolls out on the conveyor to labelling or stacking.

The ratio between ring speed and coil speed sets the overlap, and we set both on the control panel for each coil size. A vertical guide above the roller bed keeps a light coil located, so film tension cannot lift or shift it while the ring turns.

Why the coil lies flat

A soft plastic coil stood on edge sags and goes oval, and the ring then cannot keep an even wrap. Lying flat, the whole coil is supported by the roller bed. This is why our FPCA-200H is built for horizontal packing of soft coils: the support prevents deformation while the film goes on.

When a flexible pipe bundle rests on its cylindrical edge, gravity concentrates the total weight on a minimal contact footprint. Thin-walled corrugated pipes distort elastically, creating an eccentric inner eye diameter that risks physical collision with the rotating carriage shuttle. Laying the coil flat distributes the 10–50 kg product weight across heavy-duty support rollers, ensuring true circularity and consistent film pre-stretch geometry throughout 360 degrees of rotation.

Specifications (FPCA-200H)

Item Figure
Coil ID 200–350 mm
Coil OD 500–650 mm
Coil width 150–300 mm
Coil weight 10–50 kg
Film roll OD 100–140 mm, core 50 mm, width 90 mm
Paper roll (option) OD 100–450 mm, core 50 mm, width 90 mm
Power supply 380 V 60 Hz 3 ph
Power consumption 2.0 kW
Ring speed, cycle time confirmed at quote

For coils outside this range, our FPH-200 hose coil wrapper covers 300–600 mm ID, 400–900 mm OD and 50–200 mm width, with a ring speed of 20–90 r/min.

Note on operational throughput: Under standard production configuration, the FPCA-200H delivers a total wrapping cycle of 25–35 sec/pcs, with the rotating ring capable of speeds up to 100 r/min [manufacturer rating; exact cycle time depends on coil dimensions, overlap settings, and handling automation, confirmed at quote].

Worked example: film and time per coil

Take a conduit coil of 600 mm OD, 250 mm ID and 200 mm wide, wrapped with 90 mm film at 50% overlap. The overlap is set at the bore, where the circumference is smallest.

Step Calculation Result
Bore circumference π × 250 about 785 mm
Advance per ring turn 90 × (1 − 50%) 45 mm
Ring turns per coil 785 ÷ 45 = 17.4 18
Film per ring turn 2 × radial wall (600 − 250) ÷ 2 + 2 × width 200 750 mm
Film on the coil 18 × 0.75 m about 13.5 m
Wrapping time at 60 r/min (illustrative) 18 ÷ 60 0.3 min, about 18 s

Result. About 18 ring turns and 13.5 m of film close this coil in one layer, plus a short overwrap.

The derived kinematic run time of about 18 s represents the pure continuous ring wrapping motion. Factoring in soft-start acceleration, deceleration, and the pneumatic cut-and-clamp sequence, the total cycle aligns squarely within the standard 25–35 sec/pcs machine rating. Actual ring speed, overlap percentage, and overall cycle times are confirmed at quote based on specific film gauge and product stability.

Applications

  • Corrugated electrical conduit and cable protection pipe.
  • PE and PVC hose coils; see HDPE pipe coil packing.
  • Small plastic tube coils from an extrusion line; see PERT pipe coil wrapping.
  • Soft coils that would deform if wrapped standing up.

Selection checklist

  1. Coil ID, OD, width and weight.
  2. Coils per hour from the extruder or coiler.
  3. Film, paper, or both.
  4. Manual loading, or in line with a coiler and conveyor.
  5. Power supply on site.

Safety: EN 415-10 and ISO 12100

Coil wrappers are packaging machines other than pallet wrappers, so they are covered by EN 415-10, with the risk assessment to ISO 12100:2010. The turning ring and the drive rollers are the main hazards. The ring turns only after the operator’s hands are clear of the coil. An emergency stop is within reach, and guarding and CE documents are agreed per project.

Key engineering risk mitigations include:

  • Interlocked perimeter enclosures: Optical light curtains or mechanical safety fences preventing ring start when personnel breach the working zone.
  • Controlled deceleration: Redundant motor brake circuits ensuring the orbital ring comes to a complete standstill under emergency stop conditions.
  • Pneumatic lockouts: OSHA-compliant zero-pressure valves on cut-and-clamp cylinders to prevent residual motion during maintenance.

Engineering FAQ

Q: Does the film cover the bore of the coil? A: Yes. The ring passes through the eye, so every band covers the bore, both faces and the outer face.

Q: Can it wrap with paper? A: Yes. A paper roll of 100–450 mm OD and 90 mm width is an option.

Q: How heavy can the coil be? A: Up to 50 kg on the FPCA-200H.

Q: Can it run in line with the extruder? A: Yes. The coil can be fed from an upstream automatic coiler by conveyor and leave on an outfeed roller bed directly to downstream stacking, establishing a fully integrated coiling-strapping-wrapping line.

Next step

  1. Send your coil ID, OD, width and weight to info@fhopepack.com.
  2. We match the ring size and film to your coil.
  3. We reply within 24 hours with a proposal and quotation.

Sources

Last reviewed: 2026-10-19

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