Strapping, wrapping, and top covering usually require three separate machines and two manual pallet moves. This system consolidates those three operations into a single station, allowing the load to be set down once and picked up once. The result is a streamlined workflow that reduces handling time and minimizes the risk of load instability during transfer between stations.
Overview
The system places the load on a turntable. The machine has a two-column frame with a top beam, and a film carriage that moves vertically on the beam. The turntable rotates while the carriage applies stretch film around the sides of the load; strapping and top covering run at the same station and are set per configuration.
How the One-Station Cycle Works
The primary value proposition of this configuration is the elimination of intermediate pallet moves. Traditional setups often require a pallet to move from a strapping station to a wrapper, and then to a top-covering station. This integration places all three functions on a single turntable.
The typical cycle, as configured, involves the following steps. Strapping and top-covering steps run in the same station but are set per configuration.
- Load: The pallet is positioned on the turntable.
- Strap (when configured): Bands are applied around the load to secure the stack.
- Wrap: The turntable rotates, and the carriage applies film to the sides.
- Cover (when configured): Film is applied over the top of the load, or a separate top sheet is placed.
- Remove: The finished pallet is removed for transport.
By combining these steps, the system ensures that the load is handled only at the beginning and end of the process. This reduces the physical labor required and lowers the risk of damage caused by manual handling between machines.
Stretch Film Calculation and Pre-Stretch
Film consumption is not a fixed machine specification but is determined by the load dimensions and the number of turns applied. The system uses a pre-stretch mechanism, which means the roll pays out less film than the actual length laid on the load. This pre-stretching increases film efficiency and reduces material costs.
An illustrative calculation for a load of 1,200 × 1,000 mm with a height of 1,500 mm demonstrates this principle. With a film width of 500 mm and a 50% overlap, each turn rises by 250 mm. For 10 turns, the total film laid on the sides is 44 meters. However, due to pre-stretch, the actual film drawn from the roll is less than 44 meters. These values are examples; the actual film usage will be confirmed per project based on your specific load size and desired coverage.
| Item | Value |
|---|---|
| Load footprint (illustrative) | 1,200 × 1,000 mm |
| Perimeter, 2 × (1,200 + 1,000) | 4,400 mm |
| Load height (illustrative) | 1,500 mm |
| Film width (illustrative) | 500 mm |
| Rise per turn at 50% overlap | 250 mm |
| Turns applied (illustrative) | 10 |
| Film laid on the sides, 10 × 4.4 m | 44 m |
| Film drawn from the roll | Less than 44 m, because of pre-stretch |
Configuration Settings and Recipes
The system is configurable to handle different load types and stability requirements. Key settings are adjusted based on the product being packaged. These settings are tested on trial loads and saved as recipes for consistent operation.
The primary adjustable parameters include:
- Bands per load: Determines the number of strapping bands applied to secure the stack.
- Side turns: Sets the number of film layers applied to the sides.
- Top cover: Enables or disables the top covering function to protect against rain and dust.
- Order of steps: Allows the operator to choose whether strapping occurs before or after wrapping.
For lines that require a separate top sheet rather than film, alternative configurations are available. The ability to customize the sequence and parameters ensures the machine adapts to your specific production needs rather than forcing your production to adapt to the machine.
Machine Family Reference Envelope
As a reference from this machine family, our B300-class automatic pallet wrappers pair a 2,200 mm turntable with a maximum load of 2,000 kg, turntable speeds up to 12 rpm with automatic reset, and top, middle and bottom wrap layers each set from 0 to 99 winds. Film is delivered by a powered pre-stretch carriage, typically 250% with 100% to 300% optional, running 500 mm LLDPE film under PLC and HMI control with soft start and stop. Throughput of this class starts from about 24 loads per hour. These are reference values for the family; the delivered system is engineered per project.
Safety Standards and Design
Safety is a critical component of industrial machinery design. The guarding and emergency-stop layout for a station is a project decision, because it follows the loading method and the operator positions your line defines.
When evaluating the safety of pallet wrapping machinery, it is important to distinguish between design references and certifications. EN 415-6 is a standard that provides specific safety requirements for pallet wrapping machines. It serves as a design reference for the manufacturer. ISO 12100 sets the risk-assessment method, and EN 415-10 sets general requirements for packaging machinery. These standards guide the engineering of the machine. Certification of a delivered machine is confirmed in the project ordering agreement, ensuring that the final installed unit meets the agreed-upon safety criteria for your specific market.
Selection Checklist
When considering a one-station wrapping, strapping, and covering system, buyers should evaluate their specific requirements. The following checklist helps identify the necessary specifications for a proposal.
- Load Dimensions: Provide the footprint (length and width) and height of your pallets.
- Load Weight: Specify the maximum weight per pallet to ensure the turntable and structure are adequate.
- Strapping Requirements: Determine the number of bands needed and the direction of application.
- Film Requirements: Decide on the number of side turns and whether top covering is required.
- Throughput: Estimate the number of pallets per hour to assess if the cycle time meets your production goals.
- Loading Method: Confirm whether loads will be loaded via forklift or conveyor.
Engineering FAQ
Why combine strapping, wrapping, and covering? Combining these functions reduces the number of pallet moves. The load is set down once and picked up once, instead of moving between three separate machines. This saves time and reduces handling risks.
How is film consumption calculated? Film consumption depends on the load perimeter, height, and number of turns. Pre-stretch reduces the amount of film drawn from the roll. The exact consumption is calculated based on your load specifications.
Can the system be fed by a conveyor? Yes. The loading method can be configured to match your line design, whether it involves forklifts or automated conveyors.
Does the system require manual intervention? During the automated cycle, the load remains on the turntable until the process is complete.
Can the order of operations be changed? Yes. The system allows for flexibility in the sequence of operations, such as strapping before or after wrapping, depending on the stability needs of the load.
Next Step
To receive a configuration that matches your production requirements, please provide the following data to the supplier:
- Layout Drawing: A floor plan showing the available space and existing equipment.
- Load Specifications: Dimensions (length, width, height) and weight of your pallets.
- Production Rate: The number of pallets you need to process per hour.
- Loading Method: Whether you use forklifts or conveyors for loading.
We reply with a proposal after we confirm the details. This proposal will include the recommended configuration, cycle time estimates, and film/strapping consumption calculations based on your specific inputs.
Related reading
- Automatic pallet wrapping machine
- Video: horizontal orbital stretch wrapper for pallet strapping and wrapping
- Video: pallet wrapping machinery
- Video: pallet wrapping machine with auto film cutting
Last reviewed: 2026-10-29
