Executive summary Our fully automatic pallet wrapping line conveys each load onto a roller turntable, wraps it, cuts the film and sends it out without an operator. It is rated at a minimum of 24 loads per hour, for loads up to 1,800 kg. The carriage runs at 2.9 m/min, so load height largely sets the cycle. The operator only replaces film rolls and other consumables.
Table of Contents
- How the unmanned cycle runs
- Specifications
- Cycle time from load height
- Load size and turntable
- Film per shift
- Strapping before wrapping
- Controls and utilities
- Selection checklist
- Engineering FAQ
- Next step
- Related reading
- Sources
How the unmanned cycle runs
We build this line so loads arrive, are wrapped and leave without anyone at the machine. Our video shows this sequence on a tall load, from the infeed conveyor across the roller turntable and out. Each cycle has five steps:
- Infeed. A forklift places the pallet on the infeed conveyor, and the motorized conveyor moves it to the wrapping position.
- Measure. A photocell sensor reads the load height.
- Wrap. The chain-driven roller turntable turns while the pre-stretch carriage runs up and down.
- Clamp, cut and wipe. Scissors-like gripper bars hold the film, an instant heating wire cuts it, and a soft brush wipes the tail onto the load.
- Outfeed. The turntable resets automatically and the load moves out for forklift pick-up.
Fully automatic pallet wrapping line specifications
| Parameter | Value |
|---|---|
| Output | min. 24 loads per hour |
| Max load weight | 1,800 kg (turntable rated 2,000 kg) |
| Turntable | 2,200 mm diameter, max. 12 rpm, about 400 mm high |
| Carriage speed | 2.9 m/min |
| Film | LLDPE, 500 mm wide, 76 mm core, 500–1,500 m rolls |
| Pre-stretch | 250% (100–300% optional) |
| Wrap layers | bottom, middle, top: 0–99 winds each |
Infeed and outfeed conveyors are optional, so the same wrapper can start with forklift loading and add conveyors later.
Cycle time from load height
With a 2.9 m/min carriage, the carriage travel usually takes longer than the turns themselves. An illustrative tall load:
- Travel. A 2.0 m load needs about 4.0 m of carriage travel, up and down.
- Carriage time. 4.0 m ÷ 2.9 m/min ≈ 1.4 min, or about 83 s.
- Turns in that time. At 12 rpm, the turntable makes about 16 turns during the carriage travel.
- Budget. 24 loads per hour leaves 150 s per load, so about 67 s remain for the programmed bottom and top reinforcement winds, clamping and cutting, and conveying in and out.
For taller loads, or more winds at the bottom and top, the cycle grows. We check the cycle for your tallest load before we confirm the line.
Load size and turntable
The load’s diagonal must turn inside the turntable area without hitting the mast. On a 2,200 mm turntable:
- Diagonal check. A 1,200 × 1,000 mm pallet has a diagonal of about 1,562 mm, well inside the 2,200 mm turntable.
- Clearance. The diagonal must stay clear of the mast and film carriage, not just inside the table edge. For square or oversize pallets, send us the dimensions and we confirm the clearance.
- Height. The photocell sensor reads each load, so mixed heights run without resetting the machine.
The turntable is about 400 mm high, so infeed and outfeed conveyors must run at the same height.
Film per shift: how often the operator changes rolls
On an unmanned line, roll changes are the main operator task. A rough estimate for planning:
- Film per load. At 250% pre-stretch, a 1,200 × 1,000 mm pallet with 16 winds uses about 16 × 4.4 m ÷ 3.5 ≈ 20 m from the roll.
- Loads per roll. A 1,500 m roll covers about 75 loads; a 500 m roll about 25 loads.
- Per shift. At 24 loads per hour over an 8-hour shift, that is 192 loads, or about three 1,500 m rolls.
We confirm film use per load in a trial with your loads.
Strapping before wrapping
On many lines, the pallet is strapped before it reaches the wrapper, and the wrapper then wraps the strapped pallet. Straps hold the stack together; the film adds containment and keeps out dust and moisture. If your line needs a strapping station, include it in the layout drawing and we plan the conveyor between the two machines.
For dust or rain protection, our B300 version adds a film covering unit that lays a PE sheet on the load top before wrapping. For light or unstable loads, our B200 offers a pneumatic top plate that holds the top layers during rotation.
Controls and utilities
The line runs on a PLC with a pre-stretch controller, separate buttons and an HMI. The turntable has soft start and soft stop. Utilities:
| Utility | Requirement |
|---|---|
| Power | AC 380 V, 3 phase, 50 Hz |
| Motors | turntable 0.75 kW, rollers 0.75 kW, carriage 0.37 kW, pre-stretch 0.37 kW |
| Air | 6–8 kgf/cm² supply pressure |
A red mushroom-head emergency stop and a lockable electrical disconnect are standard. The standards that apply depend on the destination market. For CE markets, ISO 12100 sets the risk-assessment method and EN 415-10 sets general requirements for packaging machines.
Selection checklist for a fully automatic pallet wrapping line
- Pallet size, tallest load and maximum weight.
- Loads per hour and shift length.
- Conveyor height and direction at infeed and outfeed.
- Pallet bottom-board direction relative to the conveyor flow.
- Strapping station before the wrapper, if needed.
- Wind pattern for bottom, middle and top.
- Film roll length you buy today.
Engineering FAQ
Q: Does the line need an operator during wrapping? A: No. The operator only changes film rolls and other consumables; clamping, cutting and wiping are automatic.
Q: How long does one cycle take? A: The line is rated at a minimum of 24 loads per hour, or 150 s per load. Load height and wind settings set the exact time.
Q: How often do we change film rolls? A: About three 1,500 m rolls per 8-hour shift at 24 loads per hour, using the 20 m-per-load estimate above.
Q: What is the largest pallet that fits? A: The load diagonal must turn inside the 2,200 mm turntable with clearance to the mast; a 1,200 × 1,000 mm pallet at about 1,562 mm fits easily.
Q: Can it wrap loads that were strapped first? A: Yes. The line is designed to wrap strapped pallets coming from upstream.
Next step
We plan the wrapping line in three steps:
- Submit your layout drawing with pallet sizes, heights, weights and loads per hour to info@fhopepack.com.
- Receive a line proposal within 48 hours, with cycle check, conveyors and layout.
- Book a site survey to fit the line and any strapping station to your floor.
Related reading
- Automatic pallet wrapping machine B100
- Stretch wrapping machine
- Video: pallet wrapping machine with conveyors
- Video: rotary arm pallet wrapping machine
- Video: automatic turntable pallet wrapping machine line
Sources
- Process, specifications, film handling, utilities: B100 automatic pallet wrapping machine page
- Line in action: our fully automatic pallet wrapping line video on YouTube
- Standards scope: ISO 12100:2010, EN 415-10:2014
Last reviewed: 2026-10-03
