Executive Summary
An orbital coil wrapping machine applies stretch film, HDPE weave, or anti-corrosion VCI paper through the eye and around the circumferential profile of any ring-shaped load—including passenger car tyres, flexible hydraulic hoses, wire coils, and cold-rolled steel strip coils. The workpiece rests on edge across motorized support rollers while an annular rotating ring carries the film dispenser directly through its inner bore. While the kinematic operating principle remains uniform across product lines, machine frame sizing is strictly determined by four physical boundaries: minimum inside diameter (ID), maximum outside diameter (OD), cross-sectional width, and gross payload weight. This engineering guide details the mechanical kinematics, evaluates standard frame envelopes (FPH, FPCA, and FPS series), and walks through a full clearance calculation for a standard 205/55R16 passenger car tyre.
Table of Contents
- One Wrapping Principle for Many Products
- The Two-Station Layout Shown Here
- Models by Product Specification
- Worked Engineering Example: Sizing a 205/55R16 Tyre
- Technical Selection Checklist
- Machinery Safety Compliance: EN 415-10 and ISO 12100
- Engineering FAQ
- Next Step: Technical Proposals & RFQ
- Related Engineering Documentation
- Standards & Technical Sources
One Wrapping Principle for Many Products
Every workpiece evaluated here represents a toroidal geometry defined by a continuous center bore. The product is loaded vertically on edge upon dual motor-driven polyurethane cradle rollers, orienting the product core concentric to the path of the rotating shuttle ring.
As the structural ring rotates around its orbital trajectory:
- The film carriage mounted inside the ring tracks through the inner aperture (eye), sweeping across the bottom face, exterior OD, top face, and interior ID.
- The supporting base rollers concurrently drive the workpiece in controlled rotation around its horizontal center axis.
- This synchronized two-axis compound motion generates a continuous, helical overlap of packaging material until the 360° toroidal surface is fully encapsulated with uniform tension.
[ Shuttle Ring Rotation: Orbiting Film Reel ]
│
▼
┌───────────────────────────────┐
│ Workpiece Bore │
│ (Eye) │
└───────────────┬───────────────┘
│
[ Dual Driven Base Rollers ]
(Workpiece Indexing Around Axis)The fundamental mechanics remain identical across all industrial applications. What dictates structural variation is the required internal ring opening diameter, the mechanical cantilever rating of the roller cradle, and the drivetrain gear ratio. A lightweight 8 kg passenger tyre and a 1,000 kg heavy steel wire coil demand distinct structural weldments and roller bearings, but they rely on the same geometric wrapping dynamics.
The Two-Station Layout Shown Here
The production system highlighted in the installation above features two compact orbital ring wrappers arranged in a side-by-side parallel cell. Each station operates under independent cycle logic, enclosed within its own perimeter interlocked safety mesh guard and dedicated PLC operator panel.
[ Station A: Wrapping Cycle ] [ Station B: Operator Loading ]
┌───────────────────────────┐ ┌───────────────────────────┐
│ [Yellow Mesh Enclosure] │ │ [Interlocked Guard Open] │
│ • Ring rotating │ │ • Machine de-energized │
│ • Green stack light ON │ │ • Fast load / unload │
└─────────────┬─────────────┘ └─────────────┬─────────────┘
└───────────────────┬─────────────────────┘
▼
[ Integrated Outfeed Roller Conveyor ]This dual-station architecture eliminates operator idle time during cycle execution:
- Zero-Wait Takt Alignment: The operator opens Station A’s interlocked door, loads the unshielded workpiece onto the cradle rollers, closes the safety enclosure, and commands cycle start.
- Continuous Utilization: While Station A executes its automated orbital wrap program (monitored via green cycle beacon), the operator safely unloads the finished coil and positions the next workpiece in Station B.
- Material Takeaway: Completed products discharge directly onto an integrated inline roller conveyor, establishing an ergonomic single-operator packing station capable of reaching up to 100–120 units per hour.
Models by Product Specification
Frame selection begins by matching workpiece boundaries against standard machine envelopes. Below are three benchmark platforms configured for hoses, light cable/tubing, and heavy industrial wire:
| Parameter | FPH-200 (Hose & Conduit) | FPCA-300 (Wire & Cable) | FPS-300 (Heavy Wire Coil) |
|---|---|---|---|
| Coil Inner Diameter (ID) | 300–600 mm | 250–510 mm | 508–610 mm |
| Coil Outer Diameter (OD) | 400–900 mm | 400–900 mm | 600–1,200 mm |
| Coil Width / Height (W) | 50–200 mm | 60–300 mm | 100–300 mm |
| Payload Capacity | 5–50 kg | 20–200 kg | 20–1,000 kg |
| Ring Rotation Speed | 20–90 RPM (VFD controlled) | 10–90 RPM (VFD controlled) | Adjusted to coil inertia |
| Typical Cycle Duration | 15–35 s | 20–38 s | Calculated per mass |
| Film Overlap Range | 20%–90% (programmable) | 10%–90% (programmable) | 10%–90% (programmable) |
| Drive Power Rating | 1.5 kW | 2.4 kW | 1.5 kW – 3.0 kW |
| Compatible Media | LLDPE stretch film, PE, PVC | LLDPE, PVC, Crepe paper | LLDPE, Woven HDPE, VCI paper |
Note: Dedicated tyre packaging machines share mechanical architecture with the FPCA frame, modified with custom drive roller compounds and optional pneumatic overhead stabilizing arms.
Worked Engineering Example: Sizing a 205/55R16 Tyre
To illustrate proper boundary verification, consider a standard passenger car tyre specified as 205/55R16, wrapped using 100 mm wide LLDPE film at a nominal 50% overlap ratio.
1. Geometric Boundary Derivation
- Width (W): Direct nominal measurement =
205 mm - Inner Bore (ID): 16-inch wheel rim diameter:
ID = 16 × 25.4 mm = 406.4 mm - Sidewall Height (H_side): 55% profile ratio of section width:
H_side = 205 mm × 0.55 = 112.75 mm - Outer Diameter (OD): Rim diameter plus double sidewall thickness:
OD = 406.4 mm + (2 × 112.75 mm) = 631.9 mm (≈ 632 mm)
2. Machine Envelope Verification
| Selection Metric | Physical Constraint | Model Verification Result | Engineering Conclusion |
|---|---|---|---|
| FPH-200 Suitability | Maximum width limit: 200 mm | Product width = 205 mm | Rejected: Exceeds width by 5 mm; film shuttle collisions will occur. |
| FPS-300 Suitability | Minimum ID clearance: 508 mm | Product ID = 406.4 mm | Rejected: Shuttle ring profile cannot penetrate a 406 mm bore. |
| FPCA-300 Suitability | ID: 250–510 mm, OD: 400–900 mm, W: 60–300 mm | All dimensions within bounds | Accepted: Mechanically compatible envelope. |
3. Kinematic Wrap and Material Consumption Calculations
[ Cross-Sectional Geometry ]
┌──────────────────┐
│ Width: 205 mm │
Sidewall: │ │ Sidewall:
113 mm │ │ 113 mm
└──────────────────┘- Effective Envelope Perimeter per Wrap (P_section):
P_section ≈ 2 × (H_side + W) = 2 × (112.75 + 205) = 635.5 mm (0.636 m) - Mean Toroidal Centerline Circumference (C_mean):
D_mean = (OD + ID) ÷ 2 = (632 + 406) ÷ 2 = 519 mmC_mean = π × D_mean = 3.1416 × 519 mm ≈ 1,630.5 mm - Required Ring Revolutions (N_turns):
With a 100 mm film web and 50% target overlap, the linear advance per ring cycle is
100 mm × (1 - 0.50) = 50 mm:N_turns = C_mean ÷ 50 mm = 1,630.5 ÷ 50 ≈ 32.61 (Round up to 33 wraps) - Total Stretch Film Consumption:
L_film = N_turns × P_section = 33 × 0.636 m ≈ 21.0 m (unpre-stretched) - Cycle Time at 60 RPM Ring Speed (t_wrap):
t_wrap = (N_turns ÷ Ring RPM) × 60 s = (33 ÷ 60) × 60 s = 33 seconds
4. Mechanical Drive Verification for Light Loads
A standard 205/55R16 passenger tyre weighs approximately 8.5 to 9.5 kg, which falls below the standard FPCA-300’s nominal rating (20 kg minimum). Under low gravitational normal forces, high film wrapping tension can overcome roller friction, causing the tyre to slip rather than rotate.
Factory Countermeasure: For dedicated automotive tyre lines, the standard drive roller is equipped with high-friction nitrile/polyurethane elastomer coatings, or paired with an optional top pneumatic hold-down wheel to guarantee uninterrupted indexing.
Technical Selection Checklist
Before issuing an RFQ or approving mechanical drawings, gather the following line parameters:
- Dimensional Min/Max Matrix: Define absolute minimum and maximum values for ID, OD, Face Width, and Gross Weight across all stock-keeping units (SKUs).
- Packaging Medium & Barrier Layer: Identify the primary substrate (linear low-density polyethylene stretch film, woven plastic tape, crepe kraft paper, or volatile corrosion inhibitor [VCI] film) and required overlap percentage (10% to 90%).
- Target Takt Time: Target output rate (units per hour), which dictates whether a single-station manual cell or a twin-station alternating system is required.
- Material Handling Integration: Specify manual roll-in loading, overhead crane drop, or motorized walking-beam/roller conveyor automation.
- Secondary Operations: Define integration requirements for automated label applicators, belly-band tape dispensers, or automated outfeed stacking tables.
Machinery Safety Compliance: EN 415-10 and ISO 12100
All orbital coil wrapping machines are categorized as power-driven rotating industrial packaging machinery and must strictly conform to EN 415-10 (Safety of Packaging Machines: Modular Packaging Lines and Orbital Wrappers) and follow risk reduction procedures per ISO 12100:2010.
┌─────────────────────────────────────────────────────────────┐
│ EN 415-10 & ISO 12100 SAFETY MATRIX │
├───────────────────────┬─────────────────────────────────────┤
│ Primary Hazard │ Orbital shuttle ring high-inertia │
│ │ entrapment and pinch points │
├───────────────────────┼─────────────────────────────────────┤
│ Mechanical Shielding │ Hardwired interlocked mesh doors │
│ │ (EN ISO 14120 compliant) │
├───────────────────────┼─────────────────────────────────────┤
│ Control Reliability │ Category 3 / PL d safety circuit; │
│ │ fast dynamic motor braking │
├───────────────────────┼─────────────────────────────────────┤
│ Operator Status Indication │ High-visibility 3-color stack light │
└───────────────────────┴─────────────────────────────────────┘The rotating ring constitutes the primary kinematic hazard. The dual-station model mitigates this through fully enclosed physical guarding. Ring rotation cannot energize while an access door is ajar. Infeed access triggers immediate de-energization via dual-channel safety relays, allowing safe ergonomic loading while the neighboring station cycles.
Engineering FAQ
Q: Can a single machine package both industrial hose coils and passenger tyres?
A: Yes, provided every SKU falls inside the machine’s physical ID, OD, width, and weight capacity windows. If small hose coils run alongside car tyres, verify that the smallest hose inner diameter does not interfere with the film carriage radial sweep path.
Q: What is the primary operational advantage of a two-station wrapper layout?
A: Parallel duty cycles. In a single-station machine, the operator is non-productive during the 30-second wrapping cycle. In a two-station configuration, loading Station B masks Station A’s cycle time, yielding near 100% station utilization without increasing foot-traffic hazards.
Q: When should crepe paper or HDPE woven wrap replace stretch film?
A: LLDPE stretch film provides moisture barriers and surface dust sealing. Crepe kraft paper is selected when breathable packaging is required to prevent condensation sweating in rubber compounds, whereas HDPE woven cloth is preferred for abrasive steel wire bundles to prevent tear-through.
Q: What compliance certifications govern these orbital ring systems?
A: Machinery safety compliance requires adherence to EN 415-10 for structural safety integration, EN ISO 13849-1 for safety control circuits, and ISO 12100:2010 for baseline hazard identification and risk mitigation.
Next Step: Technical Proposals & RFQ
- Submit Workpiece Dimensions: Forward your minimum and maximum coil ID, OD, width, and gross weights to
info@fhopepack.com. - Engineering Envelope Matching: Our engineering team checks your profiles against standard ring frames and supplies 3D envelope clearance studies.
- Commercial & Technical Quotation: Receive an itemized technical proposal, layout drawing, and cycle time calculation within 24 hours.
Related Engineering Documentation
- Cable Coil Wrapping Machine FPCA-300: Technical Specifications
- Industrial Hose Coil Wrapper FPH-200: Machine Envelope Guide
- Heavy-Duty Steel Wire Coil Packing Machine FPS-300
- Application Video: Automated Hose and HDPE Pipe Coil Orbital Wrappers
- Application Video: Automotive Tyre Wrapping Machine Engineering Layout
Standards & Technical Sources
- FHOPE Packaging Machinery System Specifications: Series FPH, FPCA, and FPS Engineering Data Sheets.
- Machine Video Archive: Two-Station Symmetrical Ring Wrapper System Reference (
LbFaW3zUM9U). - Dimensional Standard: Tire and Rim Association (TRA) Metric Tyre Designation Sizing Formulas (ISO 4000-1).
- Harmonized Safety Standards: EN 415-10:2014 (Safety of Packaging Machines – Part 10: General Requirements) and EN ISO 12100:2010 (Safety of Machinery – General Principles for Design – Risk Assessment and Risk Reduction).
Last reviewed by Principal Packaging Automation Engineer: October 2026
