Copper Tube and Pipe Coil Packing Machine: Coil Window, Overlap and Wrap Time

Executive summary

Our FPC-200 orbital copper coil wrapper secures upright coils on motorized support rollers, feeding woven compound tape, creped anti-corrosion paper, or stretch film directly through the coil eye. Engineered for coils with an outer diameter (OD) of 600–1,200 mm, an inner diameter (ID) of 300–800 mm, and payload weights from 5 to 500 kg, the system delivers an automated cycle time of 23–50 s per coil. Machine sizing and drive synchronization are calculated directly from your coil OD, ID, face width, and target shift output.

Table of Contents

How the coil wrapper works

The coil stands upright on heavy-duty drive rollers while an orbital rotating ring travels through the center eye. The motorized polyurethane (PU) support rollers rotate the copper coil circumferentially at a controlled linear speed of 2–4 m/min. Synchronized with this motion, the orbital ring revolves along an internal track, dispensing wrapping material in an overlapping helical pattern around the coil cross-section.

   [ Rotating Orbital Ring ]
         │          ▲
         ▼          │
    ┌────────┐  ┌────────┐  <-- Wrapping Shuttle feeds material
    │  Coil  │  │  Coil  │      through coil center bore (Eye)
    │  Wall  │  │  Wall  │
    └───┬────┘  └───┬────┘
        │           │
    [ Motorized PU Support Rollers ] (2–4 m/min)

To prevent surface abrasion, work hardening, or denting on sensitive ASTM B280 / EN 12735-1 refrigeration copper coils, all product contact surfaces are protected. The main drive ring is cast from high-tensile wear-resistant polyurethane, and the cradle rollers are vulcanized with 85 Shore A nitrile rubber.

The vertical support structure adjusts vertically via manual handwheel or automated screw jack to align the center of different coil diameters precisely with the ring centerline. During operation, the machine can apply an inner protective wrap (such as blue HDPE woven tape or VCI paper) followed by an outer layer of protective stretch film in a continuous automated cycle.

FPC-200 vertical copper coil wrapping machine with paper-wrapped coil

FPC-200 copper coil wrapper. Vertical orbital model equipped with dynamic balance PU ring guides and vulcanized rubber-lined drive rollers.

Does the coil fit?

Fitting a copper coil inside an orbital wrapper requires verifying both the external ring clearance and the coil eye pass-through window. The shuttle dispenser travels through the inner eye; therefore, the coil ID must accommodate the shuttle envelope, while the radial wall thickness must clear the ring throat depth.

Radial Wall Thickness:  H_r = (OD - ID) / 2
Cross-Section Diagonal: D_cross = √(W² + H_r²)
Technical Parameter FPC-200 Engineering Specification
Coil Outer Diameter (OD) 600–1,200 mm
Coil Inner Diameter (ID) 300–800 mm
OD Minus ID (Wall Clearance) ≤ 800 mm (Maximum radial wall H_r: 400 mm)
Coil Face Width (W) 10–200 mm
Coil Weight Capacity 5–500 kg
Roller Circumferential Speed 2–4 m/min (Standard variable speed range)
Wrap Cycle Time 23–50 s per coil (Geometric dependent)
Ring Rotational Speed 10–100 r/min (VFD controlled)

Sizing Verification Examples:

  • Standard Fit: A copper pancake coil with 900 mm OD, 500 mm ID, and 150 mm width fits with ample clearance. The radial wall thickness is (900 mm – 500 mm) / 2 = 200 mm (well below the 400 mm radial ceiling), and the 500 mm ID easily clears our 220 mm shuttle envelope.
  • Non-Conforming Profile: A coil with 1,200 mm OD and 300 mm ID creates an OD minus ID of 900 mm (radial wall H_r = 450 mm). This exceeds our 400 mm frame limit and will cause the outer edge of the coil to collide with the orbital ring drive chassis.

Overlap at the OD

Wrapping overlap must be calibrated at the outer diameter (OD), where circumferential surface speed is highest and tape dispersion is widest. Because linear advance is constant across the cross-section, the overlap percentage inside the eye (ID) is inherently denser than at the outer rim, providing fortified corner protection.

Advance per Ring Revolution: S = W_film × (1 - Overlap%)
Wraps per Rotation:          N_wraps = (π × OD) / S
Wrap Time:                   t_wrap = (π × OD) / V_roller
Required Ring Speed:         ω_ring = N_wraps / (t_wrap / 60)

For a standard 900 mm OD coil using 100 mm wide material at a target 50% overlap at the OD:

  • OD Circumference: π × 900 mm = 2,827 mm
  • Advance per Ring Revolution: 100 mm × (1 – 0.50) = 50 mm
  • Required Wraps per Coil: 2,827 mm ÷ 50 mm ≈ 57 ring revolutions

The synchronization between the coil drive rollers and the rotating orbital ring is maintained by dual Variable Frequency Drives (VFD) controlled via PLC:

Operating Mode Roller Linear Speed Single Coil Revolution Time Ring Speed for 57 Wraps Effective Overlap at ID (500 mm)
Manual / Setup (Jog) 2.0 m/min 85 s 40 r/min 72%
Automatic (Standard) 4.0 m/min 42 s 81 r/min 72%
High Output (Rated Max) 5.0 m/min 34 s 101 r/min 72%

A wrap time of 34 s is achieved when the PLC drives both systems at maximum rated output. For thin-wall copper tube coils susceptible to tension deformation, roller speed is stabilized at 3.0–3.5 m/min with a film tension set between 15 N and 35 N to guarantee tight encapsulation without coil necking or edge crimping.

Coils per shift

Actual shift production depends on the combined automated wrap cycle and material handling time (loading, eye centering, unstrapping, unloading).

Illustrative production rates based on a 30-second crane-assisted loading and unloading cycle:

Operational Metric 42 s Wrap Cycle (VFD Mid-Range) 34 s Wrap Cycle (VFD High-Range)
Pure Wrapping Time 42 s 34 s
Handling Allowance (Load/Unload) 30 s 30 s
Total Machine Cycle 72 s 64 s
Output at 100% Availability 50 coils/h 56 coils/h
Gross Output (8-Hour Shift) 400 coils 448 coils
Net Output (OEE 85% Factor) 340 coils 380 coils

Note: The 30 s handling allowance reflects manual hoist positioning for coils up to 80 kg. For heavy copper coils approaching the 500 kg maximum limit, overhead crane rigging or automated hydraulic lift arms extend the transfer cycle to 45–60 s. Net shift output accounts for standard roll changes (stretch film / crepe paper) and scheduled operator breaks.

Vertical or horizontal machine

Depending on upstream drawing blocks and downstream palletizing logistics, copper coils are wrapped upright (vertical eye) or flat (horizontal eye / eye-to-sky).

Engineering Parameter FPC-200 (Vertical Orbital) FPH-300W (Horizontal Wrapper)
Coil Orientation Vertical (Eye horizontal) Horizontal (Eye vertical / Eye-to-sky)
Coil Outer Diameter (OD) 600–1,200 mm 600–1,200 mm
Coil Inner Diameter (ID) 300–800 mm 500–800 mm
OD Minus ID Limit ≤ 800 mm ≤ 500 mm
Coil Face Width 10–200 mm 10–300 mm
Payload Capacity 5–500 kg 50–300 kg
Cycle Wrapping Time 23–50 s 25–45 s
Ring Rotation Speed 10–100 r/min 20–110 r/min
Conveyor Integration V-groove roll transfer Flat PU roller / slat conveyor

The vertical FPC-200 is optimal for single pancake coils and coils transferred directly from upright coilers. The horizontal machine is preferred for multi-stacked pancake coils or level-wound coils (LWC) that move along roller conveyors without upending.

Materials and controls

The FPC-200 features a mechanical friction-plate tension dispenser with dynamic mechanical braking to prevent material overrun during rapid ring deceleration.

System Subassembly Industrial Specification
Applicable Packaging Media LLDPE stretch film (15–35 µm), HDPE woven strip, VCI anti-rust paper
Material Roll Sizing Core ID: 50 mm or 76 mm; Outer Roll OD: 150–450 mm; Roll Width: 90–120 mm
Packaging Configurations Single material wrap, or synchronized two-layer combined wrap (e.g., VCI + Film)
Film Cut & Clamp Automatic pneumatic scissor cut and gripper system (optional manual cutoff)
Automation Controller Siemens S7-1200 or Delta PLC architecture
HMI Interface 7-inch color industrial touchscreen (English / Metric units, dual-language)
Diagnostics & Alarms Real-time screen fault reporting: material break, ring overload, door interlock

Three-color LED tower lights indicate operating status (Green: Automatic run; Yellow: Standby / material roll runout; Red: Emergency stop / safety fault).

Utilities and safety

The machine is engineered to meet global workplace safety regulations and industrial plant integration standards:

Utility / Standard Operational Requirement
Electrical Power 380 V AC, 3-Phase, 50/60 Hz (Optional 220 V / 440 V / 480 V configurations)
Total Connected Load 2.2 kW to 4.5 kW depending on options
Pneumatic Supply 0.5–0.7 MPa (5.0–7.0 bar) dry, filtered air (ISO 8573-1 Class 4)
Air Consumption Approximately 120 NL/min during automatic cutting cycles
Safety Directives (CE) Machinery Directive 2006/42/EC; EN ISO 12100:2010; EN 415-10:2014
Electrical Safety EN 60204-1; Category 3 Emergency Stop architecture; IP54 control cabinet

Safety equipment includes full-perimeter interlocked mesh safety guards, twin-channel E-stop buttons, and dual-circuit optical light curtains guarding the infeed and outfeed coil loading zones.

Selection checklist

Provide the following production parameters to size your orbital wrapper:

  • Coil Dimensions: Exact Minimum and Maximum OD, ID, and Width (mm).
  • Coil Weight Profile: Minimum and maximum mass (kg).
  • Copper Temper / Type: Soft annealed (ACR), half-hard, or hard drawn.
  • Coil Presentation: Upright vertical eye or horizontal flat eye.
  • Packaging Material: Stretch film only, VCI paper only, or dual-layer compound.
  • Target Throughput: Coils required per hour or per 8-hour shift.
  • Loading Mechanism: Overhead hoist, jib crane, C-hook, or inline powered conveyor.

Engineering FAQ

Q: What are the absolute maximum coil dimensions for the standard FPC-200? A: The standard FPC-200 accepts outer diameters from 600 mm to 1,200 mm, inner diameters from 300 mm to 800 mm, coil widths from 10 mm to 200 mm, and total weights up to 500 kg. The radial cross-section wall (OD − ID) / 2 must not exceed 400 mm.

Q: What is the typical wrap time per copper tube coil? A: Pure wrapping time ranges between 23 s and 50 s depending on coil outer diameter, chosen film overlap (typically 50%), and programmed VFD speed settings.

Q: Where should the overlap percentage be programmed on the HMI? A: Always configure the target overlap at the outer diameter (OD). Because linear surface travel is longest at the OD, securing the correct overlap percentage here ensures the inside diameter (ID) receives full, dense protective coverage.

Q: Can the machine apply paper and stretch film simultaneously? A: Yes. An optional twin-arm dispenser holds one roll of creped VCI anti-corrosion paper and one roll of protective stretch film, applying both layers simultaneously in a single wrapping cycle.

Q: How does the machine prevent scratching and ovalization on annealed copper coils? A: All cradle rollers are clad in non-marking 85 Shore A nitrile rubber, and the rotation ring runs on precision polyurethane guide wheels. Film tension is finely regulated via a friction-brake core holder to eliminate radial squeeze forces on thin-wall tubes.

Next step

We engineer and deliver turnkey packaging solutions for copper tube and wire mills:

  1. Submit Specifications: Email your coil dimensions (OD, ID, width, mass) and floor layout drawings to info@fhopepack.com.
  2. Engineering Proposal within 48 Hours: Receive a comprehensive quotation complete with kinematic cycle time calculations, CAD layout drawings, and utility connection details.
  3. Application Review: Schedule a direct technical consultation with our engineering team to review line integration, safety gating, and automated conveyor handshakes.

Related reading

Sources

Technical Documentation Review: FHOPE Principal Packaging Engineering Group

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