> **Executive Summary**
>
> A heavy-duty horizontal stretch wrapping machine secures long, rigid loads—including PVC/PE pipe bundles, aluminum extrusions, and composite panels—as they pass continuously through a powered rotating ring. The FHOPE E1000 features a 1,000 mm ring inner diameter, variable ring speeds of 10–60 r/min, and powered conveyor speeds from 3–12 m/min, providing user-adjustable film overlap from 10% to 90%. For standard 6 m bundles measuring 600 × 600 mm, the system integrates 6 m synchronized infeed and outfeed powered roller conveyors to ensure stable, hands-free packaging cycles.
---
A rigid pipe bundle passes through the high-speed orbital wrapping ring, supported by synchronized driven rollers and enclosed within interlocked safety fencing. The stretch film applies uniform radial tension in a continuous spiral, encapsulating the bundle structure and sealing vulnerable open ends against moisture and dirt ingress.
<h2 id="table-of-contents">Table of Contents</h2>
<ul>
<li><a href="#what">What a big horizontal wrapper does</a></li>
<li><a href="#sizing">Sizing the ring to the bundle</a></li>
<li><a href="#station">Wrapping station and conveyors</a></li>
<li><a href="#specs">Specifications (E1000)</a></li>
<li><a href="#example">Worked example: 6 m pipe bundle</a></li>
<li><a href="#selection-checklist">Selection checklist</a></li>
<li><a href="#safety">Safety: EN 415-10 and ISO 12100</a></li>
<li><a href="#engineering-faq">Engineering FAQ</a></li>
<li><a href="#next-step">Next step</a></li>
<li><a href="#related-reading">Related reading</a></li>
<li><a href="#sources">Sources</a></li>
</ul>
<h2 id="what">What a big horizontal wrapper does</h2>
Long, cantilevered products cannot be wrapped on conventional vertical turntable machines without structural instability or severe overhang. In a horizontal orbital wrapper, the payload rests securely on an inline conveyor and travels horizontally through the center of a revolving ring.
As the load advances, a film carriage mounted to the ring orbits around the product, laying down continuous stretch film in a tight spiral. The relationship between horizontal conveyor speed and ring rotational speed controls the linear pitch per turn, governing film overlap percentage. This continuous radial containment binds multi-piece bundles into a unified, rigid pack while protecting exterior surfaces from transit scuffing, water ingress, and airborne contamination.
<h2 id="sizing">Sizing the ring to the bundle</h2>
The inner diameter (ID) of the rotating ring establishes the absolute physical envelope for the product cross-section. Because a rectangular or square package turns through the orbital ring along its widest axis, mechanical clearance is governed by the package diagonal, never its nominal width:
**Diagonal = √(W² + H²)**
For reliable operation, the ring inner diameter must accommodate the load diagonal plus the radial clearance required for the orbiting film roll, carriage brackets, and safety margin:
**D_ring ≥ √(W² + H²) + 2 × C_clearance**
Where `C_clearance` represents the combined mechanical envelope of the carriage structure (typically 120–180 mm depending on film roll diameter):
| Bundle (W × H) | Cross-Section Diagonal | Fits a 1,000 mm Ring? | Engineering Assessment |
| :--- | :--- | :--- | :--- |
| 600 × 600 mm | approx. 849 mm | **Yes** | Standard fit; adequate radial clearance for film carriage sweep. |
| 700 × 600 mm | approx. 922 mm | **Borderline** | Only 39 mm total radial margin. Carriage interference will occur; upsize to E1200. |
| 800 × 700 mm | approx. 1,063 mm | **No** | Diagonal exceeds ring ID. Requires an oversized ring chassis (E1200 or E1600). |
<h2 id="station">Wrapping station and conveyors</h2>
- **Cast Aluminum Ring:** Heavy-duty reinforced aluminum ring (up to 60 mm contact face), dynamically balanced to minimize vibration at speeds up to 60 r/min. Supported by wear-resistant polyurethane drive and guide wheels with quick-release hubs.
- **VFD Motion Control:** Driven by an industrial geared brake-motor with variable frequency drive (VFD). Features programmed soft-start/soft-stop acceleration profiles, ring jogging mode, and an automatic home-position park sensor.
- **Film Carriage Assembly:** Dynamic mechanical friction brake or powered pre-stretch carriage maintaining steady web tension between 20 N and 80 N. Tension auto-tracks product profile changes to prevent edge puncture.
- **Bundle Stabilization:** Integrated pneumatic top-press rollers and vertical side-guide rollers prevent loose pipes or profiles from shifting, splaying, or rotating under radial film hoop stress.
- **Powered Conveyor Line:** Infeed and outfeed roller conveyors driven by independent gearmotors synchronized via inverter to match the wrapping pitch. Rollers are PU-coated to eliminate surface damage on sensitive pipes.
- **Integrated PLC Architecture:** Siemens or Delta PLC paired with an industrial HMI touchscreen. Ring speed, conveyor velocity, reinforcement wrap counts at head/tail, and pneumatic clamp/cut cycles are fully automated via optical photogate triggers.
- **Perimeter Guarding:** Interlocked mesh safety enclosures with CE-compliant emergency-stop integration isolate rotating ring hazards.
<h2 id="specs">Specifications (E1000)</h2>
| Technical Parameter | Engineering Specification |
| :--- | :--- |
| Ring Inner Diameter | 1,000 mm |
| Ring Rotational Speed | 10–60 r/min (inverter controlled) |
| Infeed/Outfeed Conveyor Speed | 3–12 m/min (synchronized) |
| Film Overlap Adjustment Range | 10%–90% (programmable on HMI) |
| Film Roll Dimensions | Width: 100–500 mm; Outer Diameter: 100–250 mm; Core: 76 mm |
| Pneumatic Supply Requirement | 0.5–0.8 MPa (5–8 kgf/cm²), dry filtered air |
| Base Machine Footprint (W × D × H) | approx. 4,800 × 1,800 × 2,000 mm |
| Electrical Rating | 4.5 kW, AC 380 V, 50 Hz, 3-Phase (customizable) |
| Conveyor Configuration (for 6 m bundle) | 6.0 m powered infeed + 6.0 m powered outfeed |
<h2 id="example">Worked example: 6 m pipe bundle</h2>
Consider a bundle of rigid PVC conduits measuring 600 × 600 × 6,000 mm, wrapped using 250 mm width stretch film with a target 50% overlap at a ring speed of 40 r/min.
| Calculation Step | Engineering Formula & Input | Calculation Output |
| :--- | :--- | :--- |
| **1. Diagonal Clearance** | `√(600² + 600²)` | 848.5 mm (clears 1,000 mm ring) |
| **2. Linear Advance per Turn** | `Film Width × (1 − Overlap Ratio) = 250 × (1 − 0.50)` | 125 mm per revolution |
| **3. Synchronized Conveyor Speed** | `Advance × Ring Speed = 0.125 m × 40 r/min` | 5.0 m/min (within 3–12 m/min spec) |
| **4. Revolutions across Bundle** | `Bundle Length ÷ Advance = 6,000 mm ÷ 125 mm` | 48 revolutions (body spiral) |
| **5. Base Film Consumption** | `48 turns × (4 × 0.6 m perimeter)` | approx. 115.2 m (unstretched) |
| **6. Net Wrapping Cycle Time** | `6.0 m ÷ 5.0 m/min` | 1.2 min (72 seconds) |
**Operational Takeaway:** Net wrapping time is approximately 72 seconds per 6 m bundle, consuming ~115 m of film in a single-layer wrap. Adding 3 reinforcement wraps at the front and tail adds ~9 seconds. Accelerating ring speed to 60 r/min increases conveyor speed to 7.5 m/min, cutting net cycle time to 48 seconds per bundle.
<h2 id="selection-checklist">Selection checklist</h2>
1. **Bundle Cross-Section & Diagonal:** Verify `√(W² + H²)` plus film carriage stroke clears the ring ID with at least 150 mm dynamic buffer.
2. **Payload Weight & Rigidity:** Maximum weight per linear meter determines conveyor roller load ratings, motor drive sizing, and intermediate support roller spacing.
3. **Film Gauge & Material:** Standard LLDPE stretch film (17–35 µm) or specialized VCI anti-corrosion/UV-barrier film rolls.
4. **Target Throughput:** Calculate required cycle times (bundles/hour) to balance ring VFD acceleration curves against factory line speeds.
5. **Upstream/Downstream Conveyance:** Match infeed/outfeed bed heights and control handshakes (dry contacts, Profinet, or Ethernet/IP) with pipe extrusion or saw tables.
<h2 id="safety">Safety: EN 415-10 and ISO 12100</h2>
Horizontal orbital wrappers are defined as industrial packaging machinery and are governed by **EN 415-10** (Safety of packaging machines – Part 10: General requirements), with comprehensive system risk assessments executed under **ISO 12100:2010**.
Primary mechanical hazards include the high-inertia rotating ring, rotating film carriage counter-weights, and conveyor infeed nip points:
- The entire wrapping ring zone is protected by perimeter interlocked safety fencing or optical light curtains.
- Opening any safety interlock trigger drops the drive circuit through a dual-channel Category 3 / PL d safety relay, engaging the pneumatic brake-motor instantly.
- Pneumatic clamp-and-cut mechanisms are enclosed beneath fixed physical hoods to mitigate pinch hazards. Full CE declaration of conformity and technical files are delivered with every machine.
<h2 id="engineering-faq">Engineering FAQ</h2>
**Q: What is the maximum cross-section the E1000 can process?**
A: While the theoretical physical maximum diagonal is under 1,000 mm, practical operation requires accounting for the film carriage sweep. A 600 × 600 mm bundle (849 mm diagonal) represents the standard recommended limit. For larger loads (e.g., 700 × 600 mm or 800 × 800 mm), our E1200 or E1600 models provide the necessary operational envelope.
**Q: How does the system maintain constant overlap if conveyor speed varies?**
A: The PLC program links the conveyor inverter frequency directly to the ring inverter output. If the line operator adjusts ring speed on the HMI, conveyor speed shifts proportionally to maintain the programmed film overlap percentage (10%–90%).
**Q: Can the machine reinforce bundle ends to prevent transport damage?**
A: Yes. The HMI allows operators to set dedicated reinforcement wraps (typically 2–5 wraps) at both the leading and trailing ends. Conveyors halt momentarily while the ring applies concentric reinforcement wraps before resuming linear travel.
**Q: What facility utilities are required for installation?**
A: A 3-phase electrical supply (380 V / 50 Hz or 480 V / 60 Hz, 4.5 kW) and a dry, regulated compressed air supply of 0.5–0.8 MPa with a 1/2" drop line for pneumatic clamping and hold-down cylinders.
<h2 id="next-step">Next step</h2>
1. **Submit Product Data:** Send your bundle dimensions (W × H × L), minimum/maximum bundle weights, and target line output to info@fhopepack.com.
2. **Kinematic Ring Clearance Verification:** FHOPE engineers will plot your maximum product diagonal against our 3D CAD carriage sweep models to confirm ring ID clearance.
3. **Engineering Proposal within 24 Hours:** Receive a comprehensive layout drawing, operational cycle time analysis, and formal commercial quotation.
<h2 id="related-reading">Related reading</h2>
- [E1000 horizontal stretch wrapper (product)](https://www.fhopepack.com/Automatic-horizontal-stretch-wrapper/E1000-horizontal-stretch-wrapper.html)
- [E600 horizontal stretch wrapper (product)](https://www.fhopepack.com/Automatic-horizontal-stretch-wrapper/E600-horizontal-stretch-wrapper.html)
- [Horizontal orbital wrapping machine for steel tubes](https://www.fhopepack.com/videos/horizontal-orbital-wrapping-machine-for-steel-tubes/)
- [Automatic horizontal orbital wrapping machine for pipes and bundles](https://www.fhopepack.com/videos/automatic-horizontal-orbital-wrapping-machine-for-pipes-and-bundles/)
- [Horizontal orbital stretch wrapping machine](https://www.fhopepack.com/videos/horizontal-orbital-stretch-wrapping-machine/)
<h2 id="sources">Sources</h2>
- FHOPE Technical Specification Archive: E1000 Horizontal Stretch Wrapper Series
- ISO 12100:2010 – Safety of machinery — General principles for design — Risk assessment and risk reduction
- EN 415-10 – Safety of packaging machines — General requirements
- Industrial Stretch Film Performance Standards (ASTM D4649)
<p><strong>Last reviewed:</strong> 2026-10-19</p>
