Executive Summary Direct-coupling flexible hose extrusion to automated packing requires continuous downstream handling to prevent line backpressure. Sizing a turnkey packaging line—spanning coiling, toroidal eye-through wrapping, and robotic cartoning—demands reverse pacing from plant output rather than arbitrary machine speeds. Taking 30 coils/hour as the pacing target from the line datasheet, the total cycle budget is 120 s per coil. Each station must therefore finish its mechanical sequence inside that 120 s slot; the 20 % headroom you keep for stoppages is a plant decision, not a machine rating. This technical bulletin provides station cycle pacing, Cartesian box sizing formulas, film roll changeover intervals, and machine parameters across standard industrial envelopes.
Line architecture
Continuous extrusion of flexible PVC, PE, and rubber hose requires uninterrupted downstream packaging to eliminate buffering bottlenecks. The turnkey Hose Coil Packaging Line links five mechanical modules into a continuous flow:
[Extruder Infeed] │ ▼ [01: Automatic Coiling Station (FCL-V600)] ───► Mandrel collapse & tail cut │ ▼ [02: Servo Handoff Mechanism] ───────────────► Horizontal indexing │ ▼ [03: Toroidal Wrapping Station (FPH Series)] ──► Radial through-eye film wrap │ ▼ [04: Cartesian Gantry Pick-and-Place] ────────► Drop-in cartoning │ ▼ [05: Case Taper & PP Strapping Station] ──────► Outfeed to palletizing
- Automatic Coiling Station: Collects continuous extruded tube via traversing pitch guides onto an expanding cantilever mandrel, bounded by a pneumatic containment flange.
- Servo Handoff Mechanism: Mechanical clamp arm unloads the coiled, tied product from the mandrel and transfers it onto the wrapping cradle.
- Toroidal Eye-Through Wrapping Machine: Dual polyurethane cradle rollers rotate the coil along its horizontal axis while an orbital ring drives stretch film through the coil center core (“eye”) for 100% radial coverage.
- Gantry Pick-and-Place Cartoning Cell: A 2-axis Cartesian overhead gantry with pneumatic clamps lifts the wrapped coil and lowers it into an erected corrugated shipping carton.
- Inline Case Finishing Line: Side-belt driven top-and-bottom tape sealer coupled with an automatic polypropylene (PP) arch strapper.
The three stations and their cycles
Continuous balancing across stations ensures non-accumulating throughput. The operational sequence partitions motion profiles across three primary work cells:
| Station ID | Operation & Kinematics | Core Mechanism | Nominal Action Time |
|---|---|---|---|
| Station 1: Coiling | Traversed winding, metering (20–100 m), cut, and tail clamp | Collapsible mandrel with top flange | 40–90 s (Speed-dependent) |
| Station 2: Wrapping | Through-the-eye orbital wrap, film cut, and clamp wiper | Dual driven rollers, orbital shuttle ring | 20–35 s (Small) / 30–55 s (Large) |
| Station 3: Cartoning | Gantry clamp, Z-axis lower into case, tape seal, and strap | Cartesian gantry, side belts, arch strapper | 40–50 s |
Bottleneck Rule: The station with the longest physical duration (T_bottleneck = max(T_coil, T_wrap, T_pack)) sets the maximum production velocity. Inter-station handoffs execute concurrently.
Pacing: 30 coils per hour backwards
To pace packaging machinery against continuous extrusion, the engineering budget calculates backward from targeted warehouse handoff:
| Engineering Parameter | Calculation & Derivation | Target Pacing |
|---|---|---|
| Target Plant Throughput | Standard packaging line shift output | 30 coils/hour |
| Gross Cycle Budget (T_gross) | 3,600 s ÷ 30 coils | 120.0 s/coil |
| Net Design Cycle (T_design) | T_gross × 80% Net Operating Efficiency (OEE) | 96.0 s/coil |
| Station 1 Budget (Coiling) | Extrusion meters per coil (20–100 m) ÷ Line speed + cut | ≤ 96.0 s |
| Station 2 Budget (Wrapping) | Shuttle ring acceleration, wrap cycles, auto-cut | ≤ 120 s takt (published 20–35 s/pcs for FPH-200N, 30–55 s/pcs for FPH-400W) |
| Station 3 Budget (Cartoning) | Gantry X-Z stroke, flap folding, taping, strapping | ≤ 120 s takt (cartoning cycle measured on your floor) |
Pacing Constraint: Every machine cycle—including clamp actuation, carriage traverse, film cutting, and home-position reset—must complete inside the 120 s takt that 30 coils/hour implies. Because wrapping (20–55 s) and cartoning both finish well inside that window, overall line throughput is fundamentally governed by extruder output and coiling speed.
Equipment envelopes: FCL-V600, FPH-200N, FPH-400W
Matching physical coil profiles to dedicated machinery envelopes prevents dimensional interference:
| Machine Platform | FCL-V600 Vertical Coiler | FPH-200N Coil Wrapper | FPH-400W Coil Wrapper |
|---|---|---|---|
| Coil Outer Diameter (OD) | 400–600 mm | 450–800 mm | 700–1500 mm |
| Coil Inner Diameter (ID) | 200–400 mm | 250–650 mm | 300–1250 mm |
| Coil Width / Height | 40–120 mm (B), 40–200 mm (Mid), 100–300 mm (C) | 120–280 mm | 150–400 mm |
| Hose Outer Diameter | 2–16 mm (B), 8–20 mm (Mid), 15–30 mm (C) | Process application specific | Process application specific |
| Coil Weight Capacity | Matched to hose schedule | 5–30 kg | 10–100 kg |
| Cycle Speed | Metering: 20–100 m | 20–35 s/pcs | 30–55 s/pcs |
| Ring Rotation Speed | Mandrel controlled | Max 100 r/min | Max 100 r/min |
| Drive Power & Utility | Pneumatics: 6 bar | 1.5 kW; 380V, 60Hz, 3-Phase | 1.5 kW; 380V, 60Hz, 3-Phase |
| Film Roll Envelope | N/A (Winding station) | Roll OD 100–140 mm, ID 50 mm, Width 60–80 mm | Roll OD 100–150 mm, ID 50 mm, Width 90–120 mm |
For heavy-duty structural applications, engineered wrapper platforms support extended payloads up to 300 kg+ with coil outer diameters scaling across 500–650 mm.
Carton sizing from coil OD and height
Corrugated box dimensions must accommodate coiled hose geometry plus dynamic clearance tolerances for robotic vacuum or expanding-clamp tooling.
Internal Box Clearance Formulas
Inner_Length ≥ OD_coil + (2 × C_clearance)
Inner_Width ≥ OD_coil + (2 × C_clearance)
Inner_Height ≥ H_coil + C_vertical
Where C_clearance is the side clearance and C_vertical the head space you set on the guides — both are measured on your floor, not fixed by the catalogue.
Equipment Envelope Carton Requirements
- FPH-200N Series (Coil OD 450–800 mm, Height 120–280 mm):
- Minimum internal carton:
480 mm × 480 mm × 130 mm - Maximum internal carton:
850 mm × 850 mm × 300 mm - FPH-400W Series (Coil OD 700–1500 mm, Height 150–400 mm):
- Minimum internal carton:
750 mm × 750 mm × 160 mm - Maximum internal carton:
1550 mm × 1550 mm × 420 mm
Note: For coils approaching 1,500 mm OD, cartoning typically transitions from manual/erected corrugated cases to wood crates or palletized skid strapping due to box corner tear risks.
Film rolls and changeover frequency
Toroidal wrappers utilize LLDPE stretch film, PE, PVC, or woven tape to encapsulate radial coils. Overlap ratio is programmable across 10% to 90% via HMI roller-to-ring drive synchronization.
Consumable Specifications
- FPH-200N: Film roll OD 100–140 mm, core ID 50 mm, film width 60–80 mm (LLDPE of the gauge you buy).
- FPH-400W: Film roll OD 100–150 mm, core ID 50 mm, film width 90–120 mm.
Changeover Frequency Estimation
Film roll consumption is governed by coil surface envelope and overlap ratios:
- Film length per roll:
L_roll = π × (OD_film² − ID_film²) / (4 × t), with OD/ID and gauge taken from the roll you actually buy. - Usage per coil:
L_coil = turns × π × OD_coil, withturns = height / pitch; a 200 mm high coil at 50 mm pitch needs 4 turns. - Coils per roll:
N = L_roll / L_coil, rounded down. - Shift impact: at the line pacing you measure,
rolls per hour = N_coils_per_hour / N. Operators plan the roll change intervals every 18 to 25 minutes, or deploy an optional dual-roll shuttle head to double run time between maintenance stops.
Guarding, air and controls
Industrial safety standards mandate rigorous physical and electrical separation between operators and moving tooling:
- Safety Compliance: Built in conformance with ISO 12100:2010 (Risk Assessment) and EN 415-6 (Safety Requirements for Wrapping Machines).
- Perimeter Fencing & Interlocks: Welded mesh guards enclose the coiling station, orbital shuttle ring, and pick-and-place envelope.
- Pneumatic Isolation: Automated lockable dump valves (LOTO compliant) isolate and vent stored air pressure across the line; operating supply requires regulated clean, dry air at 6 bar.
- Drive Interlocking: Safety PLCs and category-rated interlocks drop the orbital ring motor and gantry servo drives into Safe Torque Off (STO) upon gate actuation, mechanical interlock tripping, or E-stop depression.
Selection checklist
Validate the following mechanical and production boundary parameters before locking machine specifications:
- Hose Geometry: Hose outer diameter (2–16 mm, 8–20 mm, or 15–30 mm) and minimum bend radius.
- Coil Dimensions: Target minimum/maximum OD, ID, core width, and individual coil weight (5–30 kg, 10–100 kg, or heavy-duty 300 kg+).
- Cut Length Range: Extrusion cut length per coil (20–100 m standard).
- Line Speed Requirements: Target shift output (m/min and coils/hour).
- Carton Specifications: Single-wall vs. double-wall box design, interior dimensions, and top flap score lines.
- Consumable Selection: Stretch film, PE, PVC, or protective woven tape, including roll core ID (50 mm standard).
- Facility Infrastructure: 380V 60Hz 3-phase power, 6 bar pneumatic line, and entry/exit vector orientation.
Engineering FAQ
How do we calculate the packaging cycle time budget from extruder speed?
Divide target meters per hour by cut length per coil to obtain required coils per hour. Divide 3,600 seconds by this coil count to establish gross cycle time (T_gross). Multiply by an operational OEE factor (such as 80%) to calculate net station cycle budget (T_design).
What determines whether we select an FPH-200N or an FPH-400W wrapping unit?
Selection depends on coil dimensions and weight. The FPH-200N accommodates coil outer diameters of 450–800 mm and weights up to 30 kg, while the FPH-400W handles coil ODs of 700–1500 mm and payloads up to 100 kg.
How does the gantry pick-and-place mechanism secure coiled hose without deforming it?
The Cartesian gantry uses multi-point perimeter clamps or internal core expanding pneumatic mandrels lined with soft polyurethane pads. Grip pressure is software-regulated to match coil rigidity, preventing outer wrap deformation.
Can the line package unboxed coils directly to palletizing stations?
Yes. Cartoning stations can be bypassed via motorized roller conveyors. The wrapped coil proceeds straight from the toroidal wrapper to automatic strapping or directly to downstream robotic palletizing.
Next step
To verify station cycle times against live extrusion capacity:
- Submit Line Data: Send coil OD/ID/Height envelopes, cut lengths, hose rigidity ratings, and carton specs to info@fhopepack.com.
- Kinematic Cycle Review: Receive a layout proposal, cycle time allocation chart, and station clearance budget within 24 to 48 hours.
- Technical Walkthrough: Finalize mechanical interfaces, pneumatic schematics, and electrical interlocks with our system engineering team.
Last reviewed: 2026-11-05
