Handling and packaging large-diameter hose coils presents significant challenges in industrial environments. Manual wrapping is often time-consuming, labor-intensive, and can result in inconsistent package quality and potential safety hazards. Addressing these issues requires specialized automated solutions. This customized vertical hose coil wrapping machine, designed specifically for oversized coils up to 3000mm in outer diameter (OD), offers a robust and efficient alternative.
1. The Challenge of Handling Large Diameter Hose Coils
Manually wrapping extremely large and heavy hose coils poses several operational difficulties:
- Inefficiency: The process is inherently slow, requiring multiple personnel and significant time per coil.
- Inconsistent Quality: Achieving a uniform, tight wrap manually is difficult, potentially compromising product protection.
- Safety Risks: Maneuvering large, heavy coils increases the risk of worker injury from lifting, repetitive motion, or coil instability.
- Material Wastage: Lack of precise control during manual application can lead to excessive use of wrapping materials like stretch film or HDPE belts.
2. Introducing the Customized Vertical Hose Coil Wrapping Solution
The machine featured in the video is a vertical-type hose coil wrapping machine engineered by Fhopepack to handle exceptionally large coils. Its vertical orientation provides stability for tall or large-diameter coils during the wrapping process and facilitates easier loading and unloading, typically via crane. This design is particularly advantageous for coils with dimensions that make horizontal wrapping impractical.
3. Technical Specifications Deep Dive
To understand the machine's capabilities, consider these key technical parameters:
- Coil Outer Diameter (OD): Up to 3000 mm
- Coil Inner Diameter (ID): Variable (machine accommodates a range)
- Coil Width: Customizable based on application (e.g., up to 800mm or more)
- Coil Weight: Designed for heavy loads (specify capacity, e.g., up to 2000 kg or higher based on customization)
- Wrapping Materials: Utilizes both Stretch Film (LLDPE) for containment and protection & HDPE Knit Belt for added strength and durability.
- Wrapping Method: Eye-through shuttle wrapping ensures complete coverage.
- Wrapping Speed: Approximately 60 seconds per coil (cycle time varies based on coil size and overlap settings), significantly faster than manual methods.
- Rotation: Coil rotates 360 degrees on support rollers for full wrapping coverage.
- Control System: Typically PLC controlled with an HMI (Human Machine Interface) for parameter setting and operation monitoring.
- Power Requirements: Standard industrial power (e.g., 380V/50Hz/3Ph, customizable).
4. Key Design Features and Components
Several design elements contribute to the machine's effectiveness:
- Vertical Configuration: Ideal for large OD coils, providing stability and simplifying crane handling.
- Eye-Through Wrapping Ring: A shuttle carrying the wrapping material passes through the center ("eye") of the coil, enabling a secure wrap.
- Heavy-Duty Construction: Robust steel frame designed to withstand industrial environments and heavy loads.
- Dual Material Capability: Equipped with dispensers for both stretch film and HDPE knit belts, applied sequentially or simultaneously based on packaging needs.
- Adjustable Overlap & Tension Control: Allows optimization of material usage and wrap tightness via the control panel.
- Powered Support Rollers: Rotate the coil smoothly during the wrapping cycle.
- Safety Features: Includes necessary guarding, emergency stops, and sensors to protect operators.
5. Streamlined Operational Workflow
The typical operating sequence enhances efficiency:
- Loading: The large hose coil is loaded onto the machine's support rollers, usually via an overhead crane due to the size and weight involved. For smaller, yet still large coils within the machine's capability, powered roller conveyors might assist loading.
- Positioning: The coil is centered and secured.
- Cycle Initiation: The operator selects the wrapping program/parameters on the HMI and starts the cycle.
- Automated Wrapping: The wrapping ring shuttle travels through the coil eye while the coil rotates on the support rollers. Film and/or HDPE belt are applied automatically with the pre-set overlap.
- Cycle Completion: The machine automatically stops upon completion, potentially including an automated material cutting and clamping mechanism.
- Unloading: The fully wrapped, protected coil is removed from the machine, typically using a crane.
6. Tangible Benefits and Return on Investment (ROI)
Implementing this automated solution delivers significant advantages:
- Drastic Speed Increase: Reduces wrapping time from potentially hours (manual) to approximately one minute per coil.
- Labor Reduction: Frees up personnel previously dedicated to manual wrapping for other value-added tasks.
- Improved Product Protection: Consistent, tight wrapping shields hoses from dust, moisture, UV radiation, and handling damage during storage and transit.
- Enhanced Safety: Minimizes manual handling of heavy, awkward coils, reducing injury risks.
- Material Cost Savings: Precise control over material overlap and tension reduces consumption compared to manual application.
- Professional Package Appearance: Creates a uniform, secure, and professional-looking final package.
This machine represents an economic investment compared to the ongoing costs and inefficiencies of manual labor for such large-scale wrapping tasks, forming part of a wider range of coil wrapping machine solutions.
7. Customization and Diverse Applications
While demonstrated for large hose coils, the core design principles allow for customization. Dimensions (OD, ID, Width, Weight capacity) and features can be adjusted to suit specific requirements. Potential applications extend to other large coiled products like large-diameter cables, wire ropes, or even bundled pipe configurations.
8. User Insights and Operational Experience
Feedback from operations utilizing similar large-format vertical wrappers often highlights the dramatic improvement in throughput and the reduction in physical strain on workers. The consistency of the wrap is frequently noted as a key benefit, ensuring product integrity down the supply chain. While initial setup and training are required, the automated nature simplifies the day-to-day wrapping process significantly.
Conclusion
The customized super large hose coil wrapping machine provides a specialized, efficient, and safe solution for a demanding industrial packaging challenge. By automating the wrapping of coils up to 3000mm OD with materials like stretch film and HDPE knit belts, it boosts productivity, enhances product protection, improves worker safety, and offers a strong return on investment for industries handling large-format coiled products.
For further information or specific inquiries:
Website: www.fhopepack.com
Email: info@fhopepack.com
