Automatic Hose Coil Winding Machine: Twin-Station Coiling, Strapping and Specs

Executive summary We build automatic hose coil winding machines that take hose straight from the extruder, count the length, wind the coil, cut and strap it. A twin-station head switches coils without slowing the line. Our FCL-V400 series covers tube OD 4–30 mm and coil OD 300–500 mm on Siemens PLC control. This guide covers the process, specifications, coil-length sizing and how to match coil cycle time to continuous extrusion speed.

Table of Contents

How twin-station hose coil winding works

The FCL-V400 dual-head coiler operates on a 180° indexing turret designed for continuous extrusion lines. Instead of stopping the line for package changeovers, the system divides the cycle into coordinated kinematic phases:

  1. Phase 1: Infeed Standby & Dual-Station Indexing. The active head receives hose directly from the line while the secondary station rests in unload/prep position. A synchronized dancer arm buffers slight speed differentials, allowing the main haul-off to run at continuous line speed without backpressure or line jerking.
  2. Phase 2: Core Clamping & Spindle Acceleration. Pneumatic segments on the active core expand to the target inner diameter (ID). The clamping jaws grip the hose leading end, and the spindle inverter ramps up to synchronize winding surface speed with extrusion feed.
  3. Phase 3: Synchronized Traverse Layering. As the spindle turns, a servo-driven traverse guide lays the hose across the coil face layer by layer. The pitch advances at approximately 1.02–1.05 × tube OD per turn to prevent cross-winding while preventing line pinching. Tension is continuously balanced through guide rollers to keep thin-walled tubes round.
  4. Phase 4: Meter-Cut, Auto-Transfer & Unloading. Once the encoder reaches target cut-length, a pneumatic shear cuts the tube squarely. The turret indexes 180° in under 3.5 seconds to transfer infeed to the empty spindle, while the completed coil on the outer spindle moves directly to strapping and pneumatic pusher discharge.
Enclosed automatic hose and pipe coiling machine with guarded winding station, touch screen panel and hose feed guide
Automatic hose coiler. Guarded winding station with touch screen and hose feed guide.

FCL-V400 hose coiler specifications

Values from our standard FCL-V400 automatic coiling and strapping line, covering tube outer diameters from 4 mm to 30 mm across three dedicated chassis configurations:

Parameter FCL-V400A FCL-V400B FCL-V400C
Coil OD Φ300–400 mm Φ300–500 mm Φ300–500 mm
Coil height (width) 40–120 mm 80–200 mm 150–300 mm
Coil ID (core size) Φ200–300 mm Φ250–400 mm Φ250–400 mm
Tube OD range 4–10 mm 10–20 mm 15–30 mm
Set coil length range 10–50 m 20–100 m 20–100 m
Air supply required 0.6 MPa (6 bar) 0.6 MPa (6 bar) 0.6 MPa (6 bar)

Coil OD, coil ID, and coil height are independent adjustable mechanical ranges rather than fixed steps. Always confirm that target radial thickness fits within the frame boundaries.

For heavier pipe dimensions, the FCL-V600 handles coil ODs up to 600 mm, while our horizontal FCL series supports rigid poly pipe up to 63 mm OD and 1600 mm coil OD.

Coil sizing: how much hose fits on one coil

Coil capacity is determined by package geometry. Calculate usable volume before selecting the model frame:

  • Radial layers = (Coil OD − Coil ID) ÷ (2 × Hose OD)
  • Turns per layer = Coil height ÷ Hose OD
  • Total length ≈ Radial layers × Turns per layer × π × Mean coil diameter
  • Mean coil diameter (D_mean) = (Coil OD + Coil ID) ÷ 2

Worked example (FCL-V400A):

  • Hose OD: 10 mm
  • Coil parameters: 400 mm OD, 300 mm ID, 80 mm coil height
  • Radial layers = (400 − 300) ÷ (2 × 10) = 5 layers
  • Turns per layer = 80 ÷ 10 = 8 turns
  • Total turns = 5 × 8 = 40 turns
  • Mean diameter = (400 + 300) ÷ 2 = 350 mm (0.35 m)
  • Estimated length ≈ 40 × π × 0.35 m ≈ 43.98 m (within the 10–50 m counter range)

Critical engineering checks:

  • Minimum bend radius: The selected core ID must be ≥ 2 × the minimum bend radius specified on the hose raw material datasheet to prevent permanent kinking.
  • Corrugated profiles: Always calculate using peak external crown diameter rather than nominal inside bore.

Coil cycle time matched to extrusion line speed

Continuous production demands that secondary handling (strapping, indexing, ejection) never exceeds the extrusion coiling duration:

  1. Winding time per coil = Set coil length ÷ Line haul-off speed.
    • Example: A 44 m coil running at 25 m/min extrusion speed provides exactly 105.6 seconds of winding time.
  2. Offline station cycle limit: The non-winding head must complete indexing (3–5 s), automatic PP strapping at 2–4 points (12–20 s), and pneumatic ejection (4–6 s) well within the available 105 s window.
  3. Machine speed capability: The FCL-V400 spindle inverter supports surface coiling speeds exceeding 60 m/min, handling production outputs between 40 and 60 coils per hour.

When running short coil cut lengths (30 m/min), program strapping to 2 points rather than 4 to preserve line synchronization.

Strapping and packing the hose coil

Integrated packaging ensures dimensional integrity before the coil releases from core tension:

  • Orbital / Radial strapping: Automatic indexing feeds polypropylene (PP) strap (9–12 mm width) through radial slots in the spindle plates at 2, 3, or 4 radial positions with heat-seal jointing.
  • Controlled tensioning: Infeed guide rollers feature micro-adjustable pneumatic backpressure, maintaining tight wraps without flattening low-durometer PVC or soft polyurethane tubes.
  • Automatic discharge: Finished coils drop onto a motorized unloading arm or gravity roller track, ready for transfer to downstream shrink wrapping, orbital stretch wrapping, or polybagging lines.
Black plastic pipe coil strapped at several positions on the winding head of an automatic coiling and strapping machine
Strapped coil. Industrial plastic coil secured with automated radial straps on the indexing head prior to ejection.

PLC controls and length counting

The FCL-V400 operates on a proven industrial automation suite:

Component Make / Function
PLC, HMI touch screen & VFD Siemens S7-1200 / Simatic series
Precision length counter Autonics dual-wheel optical encoder (±0.2% accuracy)
Pneumatic actuators & valves Airtac / Festo, filtered 0.6 MPa compressed air
Safety & switchgear Schneider Electric, safety relays & category-rated E-stops
Recipe management Store up to 50 product recipes (OD, length, pitch, strap points)

Target lengths are input directly into the touchscreen. The encoder measures line travel directly over calibrated ground urethane wheels, triggering the auto-cutter and head index sequence automatically upon target count.

Installation at the extruder

The coiler replaces conventional manual coiling racks directly at the tail of the extrusion line:

  • Line alignment: Position the infeed guide directly along the center extrusion axis downstream of the haul-off puller and cooling bath.
  • Utility connections: Dedicated 3-phase power drop (matched to local voltage: 380V/480V, 50/60 Hz) and clean, dry industrial compressed air (0.6 MPa, 3/8″ drop).
  • Safety compliance: Guarded enclosures comply with ISO 12100 safety risk assessments and EN 415 machine packaging standards, featuring interlocked access panels and optical infeed light curtains.

Selection checklist for a hose coil winding machine

Please provide the following operational parameters to confirm sizing:

  • Hose outer diameter (OD), wall thickness, and material type (PVC, PE, PU, rubber, corrugated).
  • Minimum allowable bend radius (from material datasheet).
  • Required coil dimensions: Min/Max coil OD, target coil ID, and maximum coil width.
  • Cut lengths per coil (e.g., 25 m, 50 m, 100 m).
  • Extrusion haul-off speed range (m/min) and single vs. dual extrusion output.
  • Preferred strapping: 2 or 4 radial bands (PP strap width: 9 mm or 12 mm).
  • Facility electrical voltage, frequency, and compressed air availability.

Engineering FAQ

Q: Does the extrusion line need to stop or decelerate during coil indexing? A: No. The dual-spindle indexing turret executes the 180° head switch in under 4 seconds while the pneumatic accumulator buffers the continuous infeed. Haul-off speed remains entirely constant.

Q: Can the FCL-V400 handle flexible, soft elastomer tubes without ovalizing them? A: Yes. The traverse guide utilizes non-marking polymer rollers, and winding tension is regulated via closed-loop pneumatic dancer control, preventing radial compression and oval distortion.

Q: What is the maximum coiling linear speed? A: The standard winding drive supports linear infeed speeds up to 60 m/min. Total output typically ranges between 40 and 60 coils per hour depending on strapping cycles and coil length.

Q: How accurate is the inline length measurement? A: Using dual-wheel spring-loaded rotary encoders riding directly on the tube surface, length measurement accuracy is maintained within ±0.2% across standard runs.

Q: What utilities are required at the installation bay? A: Standard electrical supply (3-phase 380V/415V/480V ±10%, 50/60 Hz) and a clean, dry pneumatic air line supplying 0.6–0.7 MPa with a minimum flow rate of 350 L/min.

Next step

We engineer and deliver turnkey coiling stations tailored to your extrusion output:

  1. Submit your product specification: Forward tube OD, coil OD/ID targets, line speeds, and facility layouts to info@fhopepack.com.
  2. Receive engineering proposal within 48 hours: Including kinematic cycle time verification, tooling layout, and complete quotation.
  3. Line integration & sign-off: Factory acceptance testing (FAT) followed by on-site commissioning and haul-off interlocking.

Sources

Last reviewed: 2026-10-03

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