Executive Summary
Packaging coiled flexible hose, irrigation tubing, and corrugated conduit requires balancing secure layer containment against packaging cycle speed and consumable cost. An eye-through orbital wrapper seals the toroidal profile by driving film longitudinally through the open coil core while motorized cradle rollers rotate the coil along its central axis. Selecting between the standard Hose coil wrapper FPH-200 and the reinforced Hose wrapping machine FPH-300N depends on coil dimensional thresholds: inner core diameter, outside diameter, and payload mass. Furthermore, adjusting film overlap between 20% and 90% dictates whether the pack achieves light dust retention or a water-resistant seal, directly determining stretch film consumption per pack.
Two machines, two jobs
Flexible tubing and semi-rigid conduit leave extrusion winders in coiled packages that lack structural rigidity along their outer diameters. Without perimeter restraint, inner residual extrusion stresses cause coils to telescope, unwind, or distort during distribution.
An eye-through orbital packing machine resolves this by shuttling packaging material through the central hole (the eye) of the vertical coil while the coil rotates on dual driven cradle rollers. This produces a continuous, helical protective envelope.
Within modern production facilities, wrapping demands split into two primary operational envelopes:
- Lightweight flexible coils: Garden hoses, small PVC tubing, and micro-conduit wound into tight packages requiring rapid processing and low wrapper tension to prevent core deformation.
- Heavy, broad coils: Commercial gas lines, agricultural PE pipes, and industrial conduit demanding heavy-duty structural chassis, higher payload limits, and broader protective film layering.
Meeting these disparate requirements requires dedicated mechanical configurations rather than a single compromised frame.
Size gate: FPH-200 or FPH-300N
Choosing between the FPH-200 and FPH-300N is governed by coil geometry and mass thresholds. Operating outside machine envelope limits leads to roller sag, coil jamming, or inadequate film overlap.
| Dimensional & Operational Parameter | FPH-200 Standard Coil Wrapper | FPH-300N Heavy-Duty Coil Wrapper |
|---|---|---|
| Coil Inner Diameter (ID) Range | Minimum below Φ300 mm | Φ300–Φ700 mm |
| Coil Outer Diameter (OD) Range | Minimum below Φ500 mm (up to Φ900 mm) | Φ500–Φ1000 mm |
| Coil Axial Width Range | 50–200 mm | 100–300 mm |
| Coil Payload Mass | 5–50 kg | 10–100 kg |
| Machine Drive Power | 1.5 kW (VFD drive) | 1.9 kW (VFD drive) |
| Ring Rotational Speed | Up to 90 r/min | 120 r/min |
| Cycle Speed Threshold | 15–35 s/pcs | 23–35 s/pcs |
Routing Criteria for Plant Layout:
- Route to FPH-200: Choose this unit when coil core ID ≤ 300 mm or coil outer diameter OD < 500 mm. Its closer support roller spacing accommodates small-radii inner apertures without the coil slipping between the cradle rollers.
- Route to FPH-300N: Choose this machine when running coils within ID Φ300–Φ700 mm and OD Φ500–Φ1000 mm, with widths from 100 to 300 mm and weights from 10 to 100 kg. Its reinforced frame and heavy-duty cradle assembly prevent drive gear deflection under heavy coil loads.
Overlap settings and film consumption
The degree of overlap governs packaging integrity and operating expenditure. On both machines, film overlap is adjustable from 20% to 90% via coordinated Variable Frequency Drive (VFD) controls linking ring rotation to roller feed speed.
The engineering trade-off is direct: higher overlap improves puncture and water resistance but scales film consumption linearly.
Governing Consumption Equations
To determine the number of ring revolutions required to complete one layer across the coil width:
Turns = Coil Width / (Film Width × (1 - Overlap))
The approximate length of stretch film consumed per wrapped coil is calculated by:
Film Length ≈ Turns × π × Coil OD
Engineering Comparison: 20% vs. 60% Overlap
Evaluating a standard coil with Outer Diameter (OD) = 600 mm, Coil Width = 200 mm, using standard 100 mm wide stretch film:
- Case A: 20% Overlap (Economic dust retention and bundling)
Effective Advance per Turn= 100 mm × (1 – 0.20) = 80 mmTurns Required= 200 mm / 80 mm = 2.5 ring revolutionsFilm Length≈ 2.5 × 3.1416 × 0.6 m ≈ 4.71 meters- Case B: 60% Overlap (Heavy-duty export moisture barrier)
Effective Advance per Turn= 100 mm × (1 – 0.60) = 40 mmTurns Required= 200 mm / 40 mm = 5.0 ring revolutionsFilm Length≈ 5.0 × 3.1416 × 0.6 m ≈ 9.42 meters
Increasing the overlap from 20% to 60% doubles the required revolutions and exacts a 100% increase in consumable film length per packaged product.
Cycle time from ring speed
Total cycle duration per package combines pure wrapping time with mechanical handling and material trimming:
t = (Turns × 60 / Ring Speed) + Handling Time
Where:
Turns= Ring revolutions required for the desired overlap.Ring Speed= Operational rotational velocity in r/min.Handling Time= Infeed positioning, pneumatic cut/clamp actuation, and coil ejection (typically 4–8 seconds).
The FPH-300N features a maximum ring speed of 120 r/min. Running the 5-turn scenario (60% overlap) at 120 r/min yields:
Pure Wrapping Time = (5 × 60) / 120 = 2.5 seconds.
Even with ramp-up, ramp-down, and automatic film cutting, total machine run time comfortably sits within the 23–35 s/pcs envelope for 10–100 kg loads.
Why small coils wrap faster on the FPH-200: Although the FPH-200 operates at a lower top ring speed, it finishes light coils within 15–35 s/pcs. Small flexible coils require far fewer total turns across narrow widths (50–100 mm). The FPH-200 also utilizes a lighter, lower-inertia orbital ring that executes S-curve acceleration and deceleration profiles rapidly, reducing mechanical cycle delays without jerking light tubing off its support cradles.
Film width and roll size
Precise film roll dimensions ensure clearance through the coil eye during orbital transit:
- FPH-300N Film Specifications:
- Film Roll Width: 90–100 mm
- Film Roll Outer Diameter (OD): 100–180 mm
- Film Roll Core Inner Diameter (ID): 50 mm
- Compatible Materials:
- Linear Low-Density Polyethylene (LLDPE) stretch film (17–25 µm).
- Cast PVC stretch wrap for rigid sealing.
- High-density woven plastic tape or paper rolls for surface-sensitive conduits.
The carriage spindle features mechanical friction brakes to regulate film unwinding tension between 8 N and 25 N, preventing thin-walled conduit from ovalling during application.
Logo tape and cutter options
Customizing the FPH platform with auxiliary dispensers and end-of-arm tooling enhances both automation and presentation:
- Synchronized Logo Tape Spindle: An optional auxiliary reel mounted to the orbital ring dispenses branded or colored PE tape simultaneously beneath or over the transparent stretch film layer. This applies corporate identification and UV protection in a single rotation cycle.
- Pneumatic Film Cutter and Clamp: Replaces manual trimming with an automated sequence. As the final wrap turn completes, an integrated pneumatic clamp traps the film web while a serrated cutter severs the tail. A trailing mechanical brush wipes the loose tail against the coil body.
- Optical Beam Sensors: Light barriers detect coil outer boundaries, automatically initiating wrapping sequences and halting rotation if product shifting occurs.
When an inline line pays back
Stand-alone wrappers such as the FPH-200 or FPH-300N require an operator to load and offload the coil. When production output exceeds 25 coils per hour on continuous extrusion lines, manual transfer creates an operational bottleneck.
Integrating a fully automated Hose coil packaging line automates the entire process:
[ Extruder ] ──> [ Auto Coiler ] ──> [ Auto Strapping ] ──> [ FPH Eye Wrapper ] ──> [ Exit Stacker ]
Automated Line Specifications:
- Payload Capacity: 8–50 kg per coil.
- Dimensional Range: Coil OD 500–650 mm; ID 350–400 mm; Width 150–250 mm.
- Line Throughput: Approximately 30 coils/hour (continuous operation at 20–40 s/coil).
- Utility Requirement: Dedicated compressed air supply of 6–8 kgf/cm² to drive transfer arms, strapping feed heads, and pneumatic cut-and-wipe tooling.
Payback Threshold: An inline line earns its keep when the manual handling it removes is the real constraint. Work it out on your own numbers: (coils per shift × handling seconds saved per coil ÷ 3600) is the operator time released; compare that with the line’s capital and running cost rather than assuming a payback period.
Utilities and guarding
Reliable operation requires proper site utilities and compliance with international machine safety regulations.
Utility Requirements
- FPH-200: 1.5 kW, 380V / 3-Phase, 50 Hz.
- FPH-300N: 1.9 kW, 380V / 480V / 3-Phase, 60 Hz.
- Pneumatic Supply: Regulated compressed air at 6–8 kgf/cm² (dry, non-lubricated air for automatic cutting systems and safety clamps).
Safety Standards & Guarding Architecture
Equipment design complies with EN 415-10 (Safety of packaging machines) and adheres to ISO 12100:2010 risk assessment guidelines:
- Physical Enclosure: Powder-coated steel wire mesh panels enclose the full radial arc of the orbital ring. Opening any access panel triggers an immediate Category 0 emergency stop.
Selection checklist
Use this engineering checklist before final machine specification:
- Coil Geometry: Measure minimum and maximum ID, OD, and axial width (mm).
- Payload Mass: Confirm minimum and maximum finished coil weights (kg).
- Tube Structural Rigidity: Identify minimum wall thickness to calibrate maximum wrap tension and ring ramp-up S-curves.
- Target Overlap Percentage: Select 20% to 50% for standard dust covers; 50% to 90% for maritime export moisture seals.
- Consumable Specs: Verify film roll dimensions (OD 100–180 mm, ID 50 mm, width 90–100 mm).
- Automation Level: Stand-alone wrapping (15–35 s cycle) versus fully automated coiling-strapping-wrapping line (30 coils/hour).
- Auxiliary Features: Specify pneumatic cut-and-wipe, logo tape secondary carriage, or infeed ejectors.
Engineering FAQ
Can the FPH-200 take coils beyond its nominal window?
The FPH-200 page states its cycle (15–35 s/pcs) and overlap range (20–90%); the coil window itself is confirmed per order, so ask for it against your largest coil rather than assuming a figure. When the coil outgrows the compact frame — typically once you are at 500–1,000 mm OD and 100 kg — the FPH-300N is the platform rated for ID 300–700 mm, OD 500–1,000 mm, width 100–300 mm and 10–100 kg.
How does the operator adjust wrap overlap on the factory floor?
Overlap is modulated directly on the industrial touch HMI. The operator selects the target percentage (20% to 90%). The system PLC then automatically recalibrates the frequency ratio between the ring drive inverter and the cradle roller drive inverter.
What causes corrugated pipe coils to deform during wrapping?
Deformation occurs when mechanical film unwind tension exceeds the radial stiffness of the pipe walls. Set film unwind tension by trial on the actual coil: start at the lowest setting that still holds the wrap, wrap one coil, and raise it only until the wrap stops slipping. Smooth acceleration ramps on the ring drive keep the film from snapping tight at start-up.
When is automatic film cutting necessary?
Manual cutting is suitable for batch operations. However, for cycles requiring 23–35 s/pcs on the FPH-300N or integration into continuous lines, pneumatic cut-and-clamp mechanisms are essential to sustain line throughput without operator intervention.
Next step
- Data Submission: Send your pipe outer diameter, finished coil ID/OD dimensions, coil width, and hourly extrusion yield to our application engineering team.
- Kinematic Evaluation: We calculate precise cycle speeds, overlap ratios, and film consumption metrics matched to your specific extruder output within 24 to 48 hours.
- Proposal & GA Drawing: Receive a formal engineering proposal complete with line layouts, safety guarding schemes, and electrical integration options.
Last reviewed: 2026-11-05
