Overview
For export wire coils, the packaging process must secure the product against physical damage and moisture while ensuring accurate documentation for customs. A typical automated line handles coils from 30 kg to over 6,500 kg, moving them through unloading, strapping, wrapping, weighing, and labelling stations. The system is designed to maintain coil integrity during sea shipping, where humidity and handling stresses are significant.
What an export wire coil pack needs
A wire coil shipped by sea requires three critical protections. First, straps must keep the individual rings tight while the coil is lifted and shaken during transit. Second, a moisture barrier is essential to prevent rust and water spots during weeks in humid air. Third, correct weight and labeling data are required for the coil to clear the port and reach the correct customer.
Manual packaging relies on a crane, a handheld strapping tool, two people for wrapping, and a separate scale. This approach is slow and inconsistent. An automated line assigns each step to a dedicated station, moving the coil between them on conveyors to ensure uniform quality and higher throughput.
From collecting rack to labelled coil
The process begins with unloading. The coil stands in a vertical collecting rack with upright posts. A manipulator grips the coil and pulls it out as the rack tilts back, then places it on the roller conveyor. This mechanism ensures smooth handling without damaging the coil edges.
Next is strapping. Green PET strap is dispensed from an overhead unit. The strapping head tensions the strap around the coil section and seals it. The coil then indexes to the next position for additional straps if required.
Wrapping follows strapping. Separate paper and film stations wrap the coil through the eye. Each station has its own ring to apply the material. This separation allows for precise application of both protective layers.
Weighing occurs next. A scale integrated into the conveyor weighs the coil. The reading is displayed on a panel, ensuring the weight recorded matches the physical product.
Finally, labelling takes place. A print-and-apply labeller fixes the label with the coil data. The coil then moves to the outfeed for stacking. A signal tower on the control desk shows the line state, and yellow mesh guards cover the moving parts above the strapping and wrapping units for safety.
One boundary matters here: the footage runs from the collecting rack through strapping and the stretch-film wrap, so weighing and labelling are described from the line architecture, not from the clip.
What are the core technical boundaries and line specifications?
The specifications for these lines vary based on the project requirements. The following table outlines the typical range of capabilities. These values are confirmed per project based on the specific coil dimensions and output targets.
| Item | Wire coil packaging line |
|---|---|
| Coil weight | 30 kg to 6,500 kg and more, light to heavy lines |
| Coil OD | 500–1,500 mm |
| Coil ID | 300, 508 or 610 mm |
| Coil width | 20–500 mm |
| Output | 20–40 coils an hour, depending on automation |
| Strapping | up to 35 s per cycle, PET or steel head |
| Wrapping | 20–120 s per coil |
| Wrapping stations | two, film and paper |
| Weighing | automatic, 1/3,000 accuracy |
| Labelling | print and apply |
| Control | Siemens S7-1200 or 1500F PLC, 12–15 in touch screen |
| Contact surfaces | PU-coated rollers and tilters |
Read that table as the modular range of the line family, not as a description of the unit on camera. The footage shows one configured cell — green stretch film, green PET strapping, a roller conveyor and the tilting rack — and does not show a 6,500 kg coil, a paper station, a scale or a labeller. Paper wrapping, heavy-coil configuration, weighing and labelling are added per project, so confirm the combination with the supplier.
Worked example: the slowest station sets the rate
Understanding throughput requires analyzing the time taken at each station. The overall line speed is determined by the slowest station in the sequence. This principle is critical when designing a line to meet specific hourly targets.
Consider a plant that needs to ship 36 coils an hour. On their specific coils, the paper wrap takes 90 seconds, the film wrap takes 60 seconds, and strapping takes 35 seconds. These are illustrative customer figures within the line’s typical wrapping range.
To achieve 36 coils an hour, the plant needs 100 seconds per coil (3,600 seconds ÷ 36). If one wrapping station performed both paper and film wrapping sequentially, it would take 150 seconds (90 + 60). This would limit the line to 24 coils an hour.
By using two separate wrapping stations in a row, coils move through both simultaneously. The paper station takes 90 seconds, and the film station takes 60 seconds. The slowest station, paper at 90 seconds, sets the pace. This allows for 40 coils an hour (3,600 ÷ 90), which exceeds the 36-coil requirement.
Strapping time also affects the rate. If the strapping cycle is 35 seconds per strap, two straps take 70 seconds, which fits within the 100-second budget. Three straps take 105 seconds, which drops the line to 34 coils an hour. In this case, strapping becomes the bottleneck. Adding a second strapping head or reducing the number of straps can resolve this.
The general rule is: coils per hour = 3,600 ÷ (longest station time + t), where t is the transfer time between stations. This transfer time is set in the layout design.
Weighing and labelling for export papers
Accurate documentation is vital for export compliance. The scale weighs each coil on the line, ensuring the weight on the label matches the actual coil. With 1/3,000 accuracy, a scale sized for 3,000 kg resolves to 1 kg increments.
The labeller prints the weight and coil data directly onto the label. The PLC and HMI track the packing data online. This integration allows packing lists and port papers to be generated from the same data source, reducing errors and administrative time.
Site conditions
The quoted operating range is −10 °C to +45 °C, confirmed per project. However, the electrical cabinets require air conditioning at 23 ± 2 °C. This is particularly important in hot, humid port-side plants where heat buildup can affect electronic components.
All contact surfaces that touch the wire, including rollers and tilters, are PU coated. This coating prevents scratching of galvanized or coated wire during handling.
The line also contains pneumatic elements — the manipulator, the strapping head and the safety interlocks — so it needs a clean, dry compressed-air supply. The required working pressure, air consumption and filtration grade are not fixed by the machine type: confirm them with the supplier for the unit you order, and dry and filter the supply at the point of use. Plan the air drop and the cabinet location with the conveyor layout, because both constrain how the line fits the floor.
Safety and EN 415-10
Safety is a primary design consideration. The equipment is built to CE requirements, with EN 415-10 as the reference standard and an ISO 12100 risk assessment. The main hazards include the manipulator, the strapping head, the turning wrapping rings, and the conveyors.
Mesh guards cover the moving parts above the stations. The manipulator and conveyors are fenced, with interlocked gates or light curtains chosen based on the risk assessment. These safety features ensure the line stops if someone enters a hazardous area. The signal tower indicates when the line is in automatic mode.
It is important to note that certification of a delivered machine is confirmed in the project ordering agreement. EN 415-10 serves as a design reference, and ISO 12100 is a risk-assessment method. We do not claim a certificate; rather, we confirm compliance through the agreement.
Selection checklist: what to send us
To receive a configuration that meets your needs, please provide the following data:
- Coil OD, ID, and width, including the smallest and largest dimensions.
- The heaviest coil weight.
- The required coils per hour.
- Strap type: PET or steel, and the number of straps per coil.
- Wrap type: paper, film, or both, and the order of application.
- Label data requirements and the scale capacity needed.
Next step
To get a real configuration, please send your coil sizes, hourly rate, and packing materials to info@fhopepack.com. We reply with a proposal after we confirm the details. This ensures the proposal accurately reflects your specific operational requirements.
