Hose Pipe Wrapping Machine and Coil Packing Machines for Steel

Executive summary The FPH-500W wraps flexible rubber and hydraulic hose coils weighing 20–200 kg, utilizing manual front loading and surface-protecting guide rollers. The FPS-400 packs heavy slit steel, wire, and strip coils weighing 100–2,000 kg, featuring a structural top-opening ring frame configured for direct overhead crane or forklift loading. Both models operate on the eye-vertical (horizontal-axis) orbital wrapping principle, where a motor-driven shuttle ring passes through the coil bore to apply protective film, woven tape, or crepe paper under regulated tension.

Table of contents

Same principle, different loads

Both systems are industrial orbital coil wrappers designed for the eye-vertical orientation: the coil rests upright on its outer diameter (OD) upon twin motorized drive rollers, its central eye aligned with the rotating wrapping ring. The ring rotates the packaging material through the coil bore while the support rollers index the coil about its horizontal axis.

  • FPH-500W — Specialized for elastomeric, plastic, and multi-spiral wire hydraulic hose coils weighing 20–200 kg, engineered to prevent core collapse and outer deformation during high-speed wrapping.
  • FPS-400 — Engineered for structural steel, slit coils, copper strips, and wire packs weighing 100–2,000 kg, featuring a segmented, top-opening ring arch that allows overhead gantry cranes or fork attachments to lower heavy bundles straight into the packing station.

Because the packaging material traverses both faces and the inner and outer diameters simultaneously in a single pass, surface coverage is continuous. Each revolution of the ring advances the wrapping material along the coil periphery by a distance governed by the ratio of ring rotational speed to roller index speed:

Advance Pitch = Tape Width × (1 - Overlap Ratio)

Variable-frequency drives (VFDs) provide precise electronic synchronization, allowing operators to adjust material overlap continuously between 10% and 90% to meet storage and shipping specifications.

What a hose pipe coil wrapper needs

A hose pipe wrapping machine handles medium-weight, resilient products that require delicate tension management and positive external stabilization:

  • Anti-Deformation Support System: Dual bottom polyurethane-coated rollers with adjustable center distance to distribute load evenly and prevent ovalling or pinching on soft rubber carcasses.
  • Adjustable Lateral Restraint Rollers: Ergonomically adjusted vertical guide rollers stabilize tall, narrow hose coils and stop axial tipping during high acceleration.
  • Tension-Regulated Payoff Brake: A mechanical friction brake with adjustable spring pre-load maintains stable tape tension (15–40 N), preventing collapse of corrugated walls or non-reinforced conduits.
  • Dual Operating Modes: Switchable manual jog mode for coil staging and fully automatic wrapping cycles controlled via a unified push-button operator pedestal.
  • Adjustable Friction Drive: A hard-anodized aluminum or polyurethane-tired wheel drives the main orbital ring, with pneumatic spring tension adjustment to eliminate rotational slip during rapid stops.

Typical wrap media include stretch film (PE), high-density polyethylene (HDPE) film, and woven polypropylene tape, creating a sealed barrier against moisture, UV degradation, and workshop particulates.

What a steel coil packing machine needs

A steel coil packing machine must endure severe dynamic impact loads, sharp slit edges, and continuous industrial operation:

  • Top-Opening Ring Architecture: The upper arch of the orbital ring unlocks and tilts open via a pneumatic cylinder. This clear opening allows overhead crane C-hooks or wire rope slings to place coils of up to 2,000 kg directly onto the cradle rollers without machine frame collisions.
  • Dual Pneumatic Ring Lock Pins: Positive mechanical interlocks secure the closed ring before rotation begins, eliminating joint separation under centrifugal loading at speeds up to 100 r/min.
  • Heavy-Duty Polyurethane Rollers: Thick-wall steel rollers coated in high-durometer PU (Shore 90–95 A) resist extreme contact stress, preventing indentation while defending the coil edge from burrs and micro-scratching.
  • Integrated PLC and HMI Automation: Siemens S7-1200 or Mitsubishi FX-series PLC linked to an operator touchscreen for setting automated wrap sequences, reinforced tail-end overwraps, and motor diagnostics.
  • CE-Compliant Safety Interlocks: Multi-beam safety light curtains around the loading station and category 3 dual-channel emergency stop circuits immediately halt machine movement if personnel breach the hazardous perimeter.
  • Pneumatic Utility: Operates on a standard factory air supply of 0.5–0.7 MPa (5–7 kgf/cm²) to power ring opening cylinders and safety clamp assemblies.

FPH-500W vs FPS-400 at a glance

Engineering Aspect Hose Pipe Coil Wrapper (FPH-500W) Steel Coil Packing Machine (FPS-400)
Payload Profile Flexible, lightweight hose / pipe (20–200 kg) Dense, rigid carbon / stainless steel (100–2,000 kg)
Material Loading Manual front insertion / workstation hoist Overhead crane, hoist with C-hook, or counterbalanced truck
Structural Frame Enclosed annular C-ring with front access Hinged top-opening ring arch with safety interlock pins
Coil Centering Adjustable nylon / PU vertical lateral guide rollers Solid, heavy-gauge steel cradle rollers with heavy PU lining
Tension Range Low to medium (15–40 N) to avoid collapse Medium to high (40–100 N) for secure tight wrapping
Control System Relay logic / VFD manual-auto console Industrial PLC (Siemens) + color HMI interface

FPH-500W and FPS-400 data

Technical Parameter FPH-500W (Hose / Pipe) FPS-400 (Steel / Slit Coil)
Coil Inner Diameter (ID) 300–800 mm 508 / 610 mm (Standard Mandrel Sizes)
Coil Outer Diameter (OD) 600–1,400 mm 800–1,400 mm
Coil Width / Height 150–400 mm 100–400 mm
Maximum Load Capacity 200 kg 2,000 kg
Single Cycle Time 28–40 s (geometry dependent) 30–60 s (determined by layer count)
Ring Rotation Speed 20–100 r/min (inverter controlled) 20–100 r/min (application specific)
Overlap Ratio Range 10%–90% (linear pitch synced) 10%–90% (linear pitch synced)
Installed Power 3.5 kW, 380 V, 60 Hz, 3-Phase 4.0 kW, 380 V, 50 Hz, 3-Phase
Pneumatic Supply Requirement Not required (or optional 0.6 MPa) 0.5–0.7 MPa (filtered, dry clean air)
Consumable Roll Sizing Stretch film: ID 50 mm, OD 100–140 mm, W 90 mm
Paper: ID 50 mm, OD 200–450 mm, W 90 mm		 Film / Paper / Woven: ID 50 mm, OD 100–450 mm, W 100–150 mm

Values for ring speeds and throughput cycle times are verified against customer coil geometry and chosen wrapping materials.

Electrical Specification Note: Standard build for FPH-500W is 380 V, 60 Hz, 3-Phase; FPS-400 is standard 380 V, 50 Hz, 3-Phase. Motors and controls can be wound and certified for alternate international supplies (such as 460 V, 60 Hz or 415 V, 50 Hz) upon order engineering confirmation.

Worked example: same size, different coil

Consider an identical mechanical envelope: Outer Diameter (OD) = 1,200 mm, Inner Diameter (ID) = 610 mm, and Width (W) = 200 mm. The target wrapping specification requires 50% overlap across the outer circumference.

1. Mass and Volume Derivation

  • Front Ring Face Area: Area = (π / 4) × (OD² - ID²) = (3.1416 / 4) × (1.20² - 0.61²) = 0.839 m²
  • Total Coil Volume: Volume = Area × Width = 0.839 m² × 0.20 m = 0.168 m³
  • As a Solid Steel Coil (Density ρ = 7,850 kg/m³): Mass = 0.168 m³ × 7,850 kg/m³ = 1,318 kg Assessment: Exceeds the 200 kg maximum limit of FPH-500W by more than 600%. It must be processed on the heavy-duty FPS-400.
  • As a Rubber Hydraulic Hose Pack (Typical bundled bulk density = 600–900 kg/m³): Mass ≈ 100–150 kg Assessment: Well within the 200 kg payload rating. It can be loaded and wrapped on the FPH-500W.

2. Kinematics, Overlap Geometry, and Cycle Time

In toroidal eye-vertical wrapping, the inner diameter always experiences a higher material overlap than the outer diameter. To guarantee complete weather protection without exposed edges, the cycle configuration is governed by the outer circumference (C_OD):

C_OD = π × OD = 3.1416 × 1,200 mm = 3,770 mm

Kinematic Variable FPS-400 (using 150 mm material roll) FPH-500W (using 90 mm material roll)
Linear Advance Pitch at 50% Overlap 150 mm × (1 - 0.50) = 75 mm 90 mm × (1 - 0.50) = 45 mm
Inner Eye Overlap Ratio (at ID = 610 mm) 1 - (75 / (3.1416 × 610 / 51)) ≈ 75% 1 - (45 / (3.1416 × 610 / 84)) ≈ 75%
Required Ring Revolutions 3,770 mm / 75 mm ≈ 51 turns 3,770 mm / 45 mm ≈ 84 turns
Cycle Wrapping Time at 100 r/min (51 / 100) × 60 s ≈ 31 seconds (84 / 100) × 60 s ≈ 50 seconds

Summary: The wider film carriage on the FPS-400 cuts total ring revolutions and finishes the cycle 38% faster than the narrower 90 mm hose-standard carriage on the FPH-500W, illustrating the direct throughput advantage of matched roll widths on large outer diameters.

Selection checklist

Provide the following production and material details to determine the appropriate system configuration:

  1. Core Coil Dimensions: Minimum and maximum ID (Ø, mm), OD (Ø, mm), and Width (mm).
  2. Total Mass Bounds: Minimum and maximum weight per unit (kg).
  3. Cross-Sectional Rigidity: Rigid steel strip, wire bundle, soft rubber hose, or crush-sensitive plastic tube.
  4. Handling Logistics: Loading via overhead factory crane, jib hoist, counterbalanced forklift, or manual transfer.
  5. Protective Media Specifications: LLDPE stretch film (thickness 20–35 µm), VCI anti-corrosion crepe paper, or woven PP tape.
  6. Production Target: Coils per hour, shift duration, and upstream cut-to-length line synchronization.
  7. Utility Standards: Available shop air pressure (MPa) and electrical grid configuration (Voltage, Frequency, Phase).

Safety: EN 415-10 and ISO 12100

Both machines comply with EN 415-10 (Safety of Packaging Machines: General Requirements) and are verified by formal risk assessments in accordance with ISO 12100:2010.

  • Perimeter Safeguarding: The high-speed rotating orbital ring is enclosed inside high-visibility steel mesh guards.
  • Optical Perimeter Defense: The FPS-400 features Category 4, Performance Level d (PL d) safety light curtains guarding the loading envelope. Breaking the optical plane during an active cycle triggers an immediate safe stop.
  • Pneumatic Interlock Validation: On the top-opening FPS-400, electrical safety gate switches verify that the locking pins are mechanically seated before the drive inverter can energize the main motor.
  • Emergency Interventions: Ergonomic, red mushroom-head emergency stop buttons with positive detent are located on both the main frame and the remote operator pendant.

Engineering FAQ

Q: Can the FPH-500W hose wrapper be used for light steel coils? A: Yes, provided the steel coil does not exceed the structural limit of 200 kg and its outer diameter remains within 1,400 mm. However, sharp slit burrs may quickly groove the light-duty polyurethane rollers, so hardened high-durometer PU roll options are recommended.

Q: How does the top-opening frame on the FPS-400 maintain alignment? A: The opening upper section features precision-ground locating pins and dual heavy-duty pneumatic clamp jaws. When lowered, proximity sensors verify mechanical closure before enabling the safety circuit, preventing ring binding or gear-drive misalignment.

Q: Why is film overlap higher on the coil inner diameter? A: This is an inherent property of toroidal wrapping geometry. Because the inner circumference (π × ID) is significantly shorter than the outer circumference (π × OD), an advance pitch set for 50% overlap at the outer perimeter naturally converges inside the bore, creating a thicker, multi-layer protective barrier against internal moisture and abrasion.

Q: Can these machines apply dual-layer materials in a single step? A: Yes. An optional dual-material carriage allows simultaneous application of VCI anti-rust paper and protective outer stretch film in a single automated cycle.

Next step

  1. Submit Coil Dimensions: Send your minimum/maximum ID, OD, width, and package weights to info@fhopepack.com.
  2. Engineering Review: Our packaging team confirms the correct machine frame size, roll width, and roller configuration.
  3. Formal Proposal: Receive an itemized engineering layout, functional specification, and price quotation within 24 hours.

Related reading

Sources

  • FHOPE Systems: Orbital Ring Packaging Machine Operating & Engineering Guidelines (Series FPH & FPS).
  • European Committee for Standardization: EN 415-10:2014 — Safety of packaging machines — Part 10: General requirements.
  • International Organization for Standardization: ISO 12100:2010 — Safety of machinery — General principles for design — Risk assessment and risk reduction.
  • ASM International: Properties and Densities of Wrought Carbon and Alloy Steels.

Last reviewed: 2026-10-19

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