Copper Tube Coil Packing and Shrinking Machine

Executive Summary Small, horizontal copper tube pancake coils can be hermetically enclosed in centre-folded POF shrink film using an automatic L-bar sealer, then heat-shrunk in an air-recirculation tunnel. Our production-proven packaging combination—the FP-400LA L-bar sealer paired with the SH-450C shrink tunnel—delivers 10 to 25 packs per minute depending on coil dimensions. Correct equipment selection depends strictly on the orthogonal cross-sectional envelope: coils up to 350 mm outer diameter (OD) and 125 mm coil stack height, where width + height does not exceed 400 mm. Oversized coils require either a continuous side-motion sealer or a dedicated through-the-eye orbital stretch wrapper.

Table of Contents

Process Overview and Kinematics

Automated packaging of flat copper tubing coils (pancake coils) follows a synchronized four-stage transfer sequence to secure individual turns and prevent atmospheric oxidation:

  1. Infeed Transfer: The coiled copper product is loaded horizontally onto the infeed belt conveyor. Integrated optical sensors confirm product alignment and trigger the packaging cycle.
  2. Film Inversion and L-Cut Sealing: Single-wound centre-folded POF film is inverted over a precision triangular forming shoe, fully enveloping the coil. An electro-pneumatic L-shaped sealing frame descends to simultaneously sever and heat-seal the trailing transverse edge and the longitudinal outer edge.
  3. Tunnel Shrinking: A powered variable-speed silicone-sleeve roller conveyor transfers the loose film envelope into the SH-450C recirculating hot-air chamber. Balanced air turbulence activates bi-axial film shrinkage, drawing the polymer skin tight against the coil geometry.
  4. Outfeed and Solidification: The tightly bound coil discharges onto an accumulation roller bed, cooling rapidly to room temperature to form an abrasion-resistant, moisture-tight barrier.

Shrink packaging provides a dust-proof barrier, inhibits surface tarnishing during transit, and locks pancake coil winds against axial displacement. The benchmark system for this duty is the FP-400LA Automatic L-Bar Sealer combined with the SH-450C Heat Shrink Tunnel.

Automatic L-bar shrinking machine FP-400LA with centre-folded POF film unwind, triangular forming frame, and heat shrink tunnel
Figure 1: FP-400LA L-bar sealer coupled to the SH-450C recirculating shrink tunnel for flat copper pancake coils.

Checking the Coil Against the Sealing Window

Because a flat copper coil rests in a horizontal pancake configuration, its orthogonal footprint presents an identical width and length equal to its outer diameter (Width = Length = OD). The coil cross-section must clear four physical mechanical limits of the FP-400LA jaw assembly:

Physical Limit FP-400LA Sealing Envelope
Maximum Sealing Height (H) ≤ 125 mm
Maximum Coil Width (W = OD) ≤ 350 mm
Combined Cross-Sectional Constraint Width + Height (W + H) ≤ 400 mm
Longitudinal Clearance Limit Length + Height (L + H) ≤ 480 mm

Sizing Verification Examples

  • Example A: OD 300 mm, Height 60 mm

    • Width = 300 mm (≤ 350 mm limit)
    • Height = 60 mm (≤ 125 mm limit)
    • Combined Width + Height = 300 mm + 60 mm = 360 mm (≤ 400 mm threshold)
    • Combined Length + Height = 300 mm + 60 mm = 360 mm (≤ 480 mm threshold)
    • Result: Fully compatible with the FP-400LA sealing frame.

  • Example B: OD 380 mm, Height 60 mm

    • Width = 380 mm (> 350 mm maximum permissible jaw opening)
    • Combined Width + Height = 380 mm + 60 mm = 440 mm (> 400 mm threshold)
    • Result: Incompatible with the L-bar frame. Requires upgrade to a continuous side-motion sealer.

Technical Specifications

The operational baseline for the packaging cell is detailed below:

Engineering Parameter Value / Specification
Sealing Architecture Reciprocating electro-pneumatic L-bar
Packaging Throughput 10–25 packs/min (dependent on coil OD and tunnel thermal dwell)
Primary Packaging Material Centre-folded polyolefin (POF) film (typically 15–25 µm)
Maximum Film Roll Specification Roll width: 530 mm Outer diameter: ≤ 280 mm
Sealer Connected Power 1.5 kW (control logic, drives, and sealing elements only)
Infeed Conveyor Elevation 780–850 mm (adjustable leveling feet)
Sealer Unit Mass 390 kg

At nominal line speeds of 10–25 units per minute, individual cycle time ranges between 2.4 and 6.0 seconds.

Note on Thermal Utilities: The 1.5 kW rating applies strictly to the FP-400LA sealing chassis. The SH-450C heating tunnel incorporates an independent three-phase heating bank (typically 8.0 to 12.0 kW) to maintain chamber setpoints between 150°C and 180°C. Total supply load must account for both sub-assemblies.

Alternative Solutions for Larger Coils

When copper coil dimensions exceed the rigid geometric envelope of the FP-400LA, production lines deploy alternative packaging kinematics:

  • Continuous Side Sealer (Model MO-900): Eliminates longitudinal sealing length restrictions by pairing an intermittent transverse cross-seal bar with a continuous rotary side-trim sealer. Handles products where Width + Height ranges from 400 mm to 900 mm, accommodating product heights up to 300 mm. Coil Example B (OD 380 mm + Height 60 mm = 440 mm) runs smoothly on this platform, requiring a heavy-duty shrink tunnel with heating capacities up to 28 kW.
  • Through-the-Eye Orbital Coil Wrapper: Designed for large industrial copper tube coils (Level Wound Coils / LWC or heavy refrigeration coils) with ODs ranging from 600 mm to 1,200 mm and weights from 50 kg to 300 kg. Rather than shrink film, an orbital rotating ring passes stretch film, VCI anti-corrosion film, or reinforced crepe paper radially through the coil eye with an overlap ratio adjustable from 20% to 90%.

Film Processing and Sealing Architecture

  • Sealing Knife Construction: Cast aluminium-alloy sealing jaw coated with industrial-grade DuPont PTFE (Teflon). Resists thermal degradation, eliminates polymer carbonization, and prevents film adhesion during rapid dwell cycles.
  • Closed-Loop Temperature Control: Driven by an Omron digital PID controller to ensure ±1.5°C thermal stability across continuous start-stop duty.
  • Optical Product Registration: Dual horizontal and vertical photo-electric eye arrays detect thin profiles and light-reflective copper coils, preventing premature cut-down and blade collisions.
  • Micro-Perforation and Film Unwind: Integrated pinwheel punch perforator punctures microscopic air-escape holes across the film web, allowing expanding air to vent freely during tunnel thermal shrinking to prevent ballooning. Automatic motorized scrap-edge take-up spools collect trim waste.
  • Interfacing: Direct dry-contact and Profinet/EtherNet/IP integration capabilities enable fully unattended operation within high-speed copper draw lines.

Utilities, Pneumatics, and Safety Standards

Plant Utility Specification Requirement
Electrical Service 380 V ±10%, 50/60 Hz, 3-Phase, PE (Neutral as required)
Pneumatic Supply 0.5–0.7 MPa (5.0–7.0 bar) dry, filtered, non-lubricated compressed air
Air Consumption ~120 NL/min at nominal operating speed

Safety Systems and Standard Compliance

The sealing carriage integrates mechanical anti-crush sensors and electronic torque/resistance feedback alarms; if an obstruction is encountered during descent, the jaw instantly reverses stroke and triggers an operational interlock.

Machinery compliance is governed by internationally recognized packaging safety standards:

  • ISO 12100:2010: Basic concepts and general principles for risk assessment and risk reduction.
  • EN 415-10:2014: Safety requirements for packaging machines, wrapping machines, and form-fill-seal lines.
  • Pneumatic Isolation: Lockout/Tagout (LOTO) compliant quick-exhaust air dump valves.

Selection Checklist for Copper Coil Shrink Packing

Prior to equipment sizing, verify the following baseline production criteria:

  • Smallest and largest coil outer diameter (OD), inner diameter (ID), and axial stack height.
  • Maximum and minimum single-pack coil mass (kg).
  • Required line output (coils per minute continuous vs. surge demand).
  • Film specifications: Centre-folded POF film gauge (15, 19, or 25 µm), roll core diameter (76 mm), and maximum roll width.
  • Operational layout: Offline manual loading vs. inline integration with upstream coiler/take-up stations.
  • Available electrical service (voltage/frequency) and pneumatic supply pressure at the drop point.

Engineering FAQ

What are the maximum coil dimensions suitable for the FP-400LA L-bar sealer?

The machine accommodates flat coils with a maximum outer diameter (OD) of 350 mm and an axial height of 125 mm. The combined cross-sectional envelope must satisfy the conditions: Width + Height ≤ 400 mm, and Length + Height ≤ 480 mm.

What is the maximum cycle rate of this shrink-packaging system?

Throughput ranges from 10 to 25 packs per minute. Production speed is governed by coil dimensions, conveyor line transfer pitch, and the thermal transfer dwell time required inside the SH-450C shrink tunnel.

How should a 380 mm OD copper pancake coil be packaged?

A 380 mm coil exceeds the 350 mm maximum width limit of the FP-400LA. It must be routed to a continuous side-motion sealer such as the MO-900, which handles cross-sections up to Width + Height = 900 mm.

Why is micro-perforation necessary for POF shrink wrapping?

Because the L-bar creates an airtight perimeter weld, entrapped air expands when exposed to heat inside the shrink tunnel. Mechanical pin perforations provide uniform micro-channels that allow heated air to evacuate, ensuring the film shrinks tightly and uniformly without ballooning or seam rupture.

What packaging equipment is recommended for heavy copper coils above 50 kg?

Heavy coils ranging from 600 mm to 1,200 mm OD are packaged on an orbital through-the-eye wrapping machine. This process applies continuous radial wraps of stretch film, VCI film, or woven poly-weave via a rotating shuttle rather than heat-shrink film.

Next Step

Our engineering department validates machine selection using product samples and CAD layout integration:

  1. Submit Product Data: Send coil OD, ID, height, weight, and target cycles per minute to info@fhopepack.com.
  2. Review Engineering Layout: Receive a certified quotation and 2D/3D footprint layout within 48 hours.
  3. Line Integration Consultation: Coordinate with our technical sales engineers to integrate upstream uncoilers, weigh stations, or accumulation conveyors.

Related Solutions

Reference Standards and Sources

Last reviewed: 2026-10-03

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