In industrial manufacturing and distribution, ensuring the safe transit of long, potentially delicate products like heater tubes is paramount. The Horizontal Bubble Film Orbital Wrapper represents a specialized automated packaging solution engineered to provide robust protection using bubble film, minimizing damage and streamlining the packaging process. This system is specifically designed for items where traditional pallet wrapping is unsuitable due to length or shape.
1. Addressing Packaging Challenges for Heater Tubes
Heater tubes, often characterized by their length and potentially sensitive surfaces or components, present unique packaging hurdles. Manual wrapping is time-consuming, inconsistent, and can leave products vulnerable. This horizontal orbital wrapper directly addresses these issues by:
- Providing consistent, tension-controlled wrapping along the entire length.
- Utilizing bubble film for superior cushioning against impacts and abrasions.
- Automating the process, reducing manual labor and increasing throughput.
2. Core Functionality and Operational Workflow
The machine operates through a sequenced, automated process:
- Infeed: Products like heater tubes are placed onto the automated infeed conveyor, which transports them towards the wrapping station.
- Securing: A pneumatic or mechanical top press device gently descends to hold the product stable during wrapping, preventing movement and ensuring a tight wrap.
- Wrapping: The core of the system is the rotating ring carrying the bubble film roll. As the product conveys horizontally through the ring, the ring orbits around it, dispensing and applying the bubble film circumferentially. The overlap of the film can typically be adjusted for varying levels of protection.
- Outfeed: Once wrapping is complete, the press device retracts, and the fully wrapped product moves onto the outfeed conveyor, ready for dispatch or further processing.
3. Key Components and Design Features
The effectiveness of this orbital wrapper stems from its well-engineered components and robust design:
- Heavy-Duty Frame: Constructed typically from welded steel for stability and longevity in industrial environments.
- Conveyor System: Motorized roller or belt conveyors (infeed and outfeed) with adjustable speeds to match production line requirements. Guide rollers often assist in keeping long products aligned.
- Top Press Device: Usually pneumatically actuated, providing adjustable pressure to secure various product sizes without causing damage.
- Wrapping Ring: A precisely balanced aluminum or steel ring driven by a dedicated motor. Ring speed (RPM) is often variable to control the wrapping speed (m/min).
- Film Carriage: Mounted on the ring, this holds the bubble film roll and features adjustable tension control to ensure optimal film stretch and application without tearing. Quick-change mechanisms for film rolls are common.
- Control System: Typically utilizes a Programmable Logic Controller (PLC) with a Human-Machine Interface (HMI) touchscreen for easy operation, parameter adjustment (e.g., wrap speed, overlap, conveyor speed), and diagnostics.
- Safety Features: Includes emergency stops, safety guarding around moving parts, and often light curtains or safety interlocks compliant with industry standards.
4. Technical Specifications Overview (Typical Example)
While exact specifications vary based on model and customization, typical parameters include:
- Wrapping Material: Primarily Bubble Film; potentially compatible with Stretch Film or other materials.
- Maximum Package Length: Often customizable, commonly handling lengths from 1m up to 6m or more.
- Maximum Package Cross-Section (W x H): Varies, e.g., 300mm x 300mm, 500mm x 500mm, etc.
- Ring Speed: Variable, e.g., up to 80-100 RPM.
- Conveyor Speed (Wrapping Speed): Variable, typically 10-20 meters per minute.
- Film Overlap: Adjustable via PLC/HMI, often ranging from 10% to 90%.
- Bubble Film Roll Specs: Max Outer Diameter (e.g., 250mm), Core Inner Diameter (e.g., 76mm), Width (e.g., 100-250mm).
- Control System: PLC (e.g., Siemens, Allen-Bradley) with Color Touchscreen HMI.
- Power Requirements: e.g., 480V/3Ph/60Hz or tailored to regional standards.
- Air Requirements (for pneumatics): e.g., 6 bar (approx. 90 PSI).
5. Benefits for Industrial Operations
Implementing a horizontal bubble film orbital wrapper yields tangible advantages:
- Enhanced Product Protection: Consistent bubble film application significantly reduces scratches, dents, and breakage during handling and shipping.
- Increased Efficiency: Automation drastically cuts down wrapping time compared to manual methods, boosting overall packaging throughput.
- Reduced Labor Costs: Frees up personnel previously assigned to manual wrapping for other value-added tasks.
- Material Optimization: Controlled tension and adjustable overlap minimize excessive bubble film usage.
- Improved Load Security: Tightly wrapped bundles are more stable and easier to handle.
- Professional Package Appearance: Consistent wrapping provides a neat, professional look for shipped goods.
6. Customization and Integration
Leading manufacturers like FHOPE specialize in tailoring these machines. Customization options can include:
- Adjusting conveyor heights and lengths.
- Modifying ring sizes and speeds for specific product dimensions.
- Integrating automatic film cutting and clamping devices.
- Designing for specific environmental conditions (e.g., washdown environments).
- Integrating the wrapper seamlessly into existing automated production or packaging lines.
7. User Experience and Maintenance
From a user perspective, modern orbital wrappers are designed for ease of use:
- Intuitive Controls: HMI interfaces allow straightforward setup and operation with minimal training.
- Easy Film Loading: Film carriages are designed for quick and simple roll replacement.
- Low Maintenance: Built with durable components, routine maintenance typically involves periodic lubrication, inspection of moving parts (belts, rollers, ring), and sensor checks. Access points are generally designed for convenience.
In summary, the horizontal bubble film orbital wrapper for heater tubes is a strategic investment for manufacturers and distributors dealing with long, sensitive products. Its automated operation, robust protection capabilities, and potential for customization deliver significant improvements in packaging efficiency, product safety, and overall operational cost-effectiveness.
More horizontal orbital packing solution in special requirement avaible from FHOPE.
