The accompanying video showcases the operational testing of a large-scale, automatic horizontal orbital stretch wrapper integrated with a top film covering system. This specific unit demonstrates its capability by handling an exceptionally large package with dimensions measuring approximately 1800mm in radius (3600mm diameter/width) and 6 meters in length, weighing up to 6 metric tons. Such machinery represents a critical asset in industries requiring robust protection and stabilization for oversized or heavy products during transit and storage.
This article delves into the technical specifications, design features, operational benefits, and application versatility of advanced horizontal wrapping systems like the one featured.
1. Core Functionality: Horizontal Wrapping and Film Covering
Horizontal orbital wrappers operate by passing a roll of stretch film through a rotating ring carriage as the product is conveyed horizontally through the ring's aperture. This creates a continuous spiral wrap around the product's length.
- Orbital Wrapping Mechanism: The core component is the rotating ring carrying the film dispenser. Its speed and the product's conveyor speed are synchronized to control the film overlap percentage, ensuring consistent tension and coverage.
- Automatic Film Covering Unit: Integrated systems often include a top (or top and bottom) film applicator. This unit automatically dispenses and applies a separate layer of film across the leading and trailing faces, or the top surface, providing complete encapsulation and enhanced protection against environmental factors like dust and moisture.
- Automated Film Management: Features typically include automatic film clamping, cutting, and wiping/sealing at the end of the cycle, minimizing manual intervention and maximizing throughput.
2. Design and Structural Highlights
Handling substantial loads necessitates a robust and durable machine design:
- Heavy-Duty Frame Construction: Typically built with welded heavy-gauge steel for structural integrity and vibration damping, ensuring stability during high-speed operation with heavy products.
- Precision Ring Bearing and Drive System: The rotating ring requires high-precision bearings and a reliable drive system (often employing durable belts or direct gear drives) to ensure smooth, consistent rotation under load.
- Reinforced Conveyor System: Input and output conveyors are engineered to support the maximum specified product weight and dimensions, often featuring heavy-duty rollers or belt systems designed for industrial environments.
3. Key Components and Technology
Modern horizontal wrappers incorporate advanced technology for efficiency and control:
- PLC Control System: A Programmable Logic Controller (PLC) serves as the machine's brain, managing all functions, timings, and synchronization between the ring, conveyors, and film covering unit.
- HMI (Human-Machine Interface): Touchscreen panels allow operators to easily set parameters (wrap counts, tension, overlap, product recipes), monitor machine status, and perform diagnostics.
- Variable Film Pre-Stretch: Advanced film carriages offer powered pre-stretching capabilities (often up to 250-300%), significantly increasing film yield and improving load containment force while reducing material consumption. Learn more about Stretch Wrap Film properties.
- Sensors and Safety: Photo-eyes detect product presence and position for automated cycle start/stop. Comprehensive safety features, including interlocked guarding, emergency stops, and light curtains, are essential for operator protection.
4. Representative Technical Specifications (Standard Models)
Important Note: The specifications listed below represent typical parameters for large-scale horizontal orbital wrappers. The machine shown in the video demonstrates capabilities exceeding these standard ranges, likely representing a custom-built or heavy-duty configuration designed for specific extreme requirements (like the 6T, 6m L, 3.6m W package). For precise specifications matching your application, including capabilities seen in the video, please contact us directly.
- Machine Type: Automatic Horizontal Orbital Stretch Wrapper with Film Covering
- Control System: PLC with HMI Touchscreen
- Typical Max Product Dimensions (Standard Large Models):
- Length: Up to 6000mm (longer possible with customization)
- Width/Diameter: 1500mm - 2500mm
- Height: 1500mm - 2500mm
- Typical Max Product Weight: 2000kg - 5000kg (higher capacities available)
- Ring Rotation Speed: Variable, typically 15 - 40 RPM (application dependent)
- Conveyor Speed: Variable, typically 5 - 15 m/min
- Film Type Compatibility: Standard Stretch Film (e.g., LLDPE)
- Film Roll Specifications:
- Outer Diameter: Up to 250mm
- Inner Diameter: 76mm (3 inches)
- Width: 500mm (20 inches) or 750mm (30 inches)
- Film Pre-Stretch Ratio: Powered, adjustable up to 250% or 300%
- Power Requirements: Typically 380V/480V, 3-Phase, 50/60Hz (region specific)
- Compressed Air Requirement: Typically 6-8 Bar (for pneumatic components)
5. Performance and Efficiency Gains
Investing in automated horizontal wrapping systems yields significant operational advantages:
- Increased Throughput: Automated cycles are significantly faster and more consistent than manual wrapping.
- Reduced Labor Costs: Frees up personnel from manual wrapping tasks for more value-added activities.
- Improved Load Security: Consistent tension control and precise overlap ensure superior load stabilization, reducing product damage during handling and shipping.
- Material Savings: Powered pre-stretch optimizes film usage, potentially cutting film consumption by 50% or more compared to manual methods.
- Enhanced Protection: Complete encapsulation with top/bottom film covers provides excellent protection against dirt, dust, moisture, and minor impacts.
6. Application Showcase: Versatility in Industrial Packaging
These machines excel in industries handling long, bulky, or heavy products:
- Building Materials: Wrapping bundles of lumber, pipes, extrusions (metal or plastic), insulation panels, and roofing materials.
- Furniture Industry: Securing large items like assembled cabinets, tables, sofas, and mattresses for shipping, protecting surfaces and ensuring stability.
- Metal Processing: Bundling metal bars, sheets, coils, or fabricated components, preventing shifting and surface damage.
- Textiles and Flooring: Wrapping large rolls of carpet, fabric, or artificial turf.
- Large Appliances & Equipment: Packaging oversized items like industrial machinery components, HVAC units, or large appliances where vertical wrapping is impractical. The machine shown handling the 6-ton load is a prime example of its utility for extremely heavy industrial equipment.
7. Operational Insights and User Experience
While highly automated, effective operation involves:
- Ease of Parameter Setup: Modern HMIs simplify programming different wrap patterns for various product types (recipes).
- Routine Maintenance: Regular checks on rollers, bearings, film carriage components, and safety systems are crucial for longevity and reliability. Film roll changes are typically designed for quick execution.
- Operator Training: Ensuring operators understand parameter settings, safety procedures, and basic troubleshooting enhances uptime and safety.
8. Choosing the Right Configuration
Selecting the appropriate horizontal wrapper depends heavily on:
- Product Range: Maximum and minimum dimensions (L x W x H) and weight of products to be wrapped.
- Throughput Requirements: Number of packages needing wrapping per hour/shift.
- Wrapping Needs: Requirement for full encapsulation (top/bottom film), level of film stretch needed, specific load containment challenges.
- Factory Integration: Available floor space, power/air supply, and integration with existing upstream/downstream conveyor lines.
Customization is often necessary to perfectly match machine capabilities to specific industrial packaging challenges, such as the heavy-duty application demonstrated in the video.
For detailed information, custom configurations, or specifications tailored to your unique packaging needs, please contact us.
info@fhopepack.com