Large Size Bearing Packaging Machine: FPCA-6000 Engineering & Selection Guide

Executive summary

A large size bearing packaging machine wraps a big slewing or wind turbine bearing ring in protective film without lifting it off the line. The bearing lies flat on driven rollers that turn it, while an orbital ring wraps film through the bore and around the section. Our FPCA-6000 takes bearings of 2,900–5,000 mm OD and 500–12,000 kg, and can lay VCI film plus two stretch layers in one pass. A worked example checks a 6.4 t bearing.

Table of Contents

Why big bearings need a dedicated wrapper

Slewing rings and wind turbine bearings are machined to fine tolerances (often within ISO tolerance class P6 or P5) and shipped long distances, frequently via ocean freight. Rust formation or a mechanical scratch on the raceway can instantly scrap a precision part worth tens of thousands of dollars. Manual wrapping of a three-to-five-meter ring requires multiple operators walking in circles with heavy film rolls, inevitably resulting in inconsistent film tension, uneven layer overlap, and unsealed air pockets.

A dedicated orbital wrapping machine rotates the bearing flat on heavy-duty motorized rollers under a synchronized wrapping head. This automation allows a single operator to achieve continuous, hermetic encapsulation with identical film overlap and tension across every single ring.

How our big bearing wrapper works

The heavy bearing lies horizontally flat on a set of heavy-duty polyurethane-faced rollers (85–90 Shore A hardness to protect ground steel surfaces from denting). A variable-frequency drive (VFD) controls the rotation speed of the rollers.

An orbital shuttle ring stands perpendicular across the bearing radial cross-section, passing through the inner bore. As the driven rollers turn the bearing ring horizontally, the orbital carriage rotates around the cross-section, wrapping VCI film and stretch film in a continuous spiral through the bore, over the top, around the outer face, and under the bottom.

Once the bearing completes a full 360° rotation, the automatic pneumatic cutter and clamp unit seals and severs the film, allowing the orbital ring to stop smoothly. The wrapping head features motorized vertical and horizontal positioning to accommodate varying ring diameters and cross-sectional heights.

FPCA-6000 data

Item Technical Specification Engineering Detail
Bearing Outer Diameter (OD) 2,900–5,000 mm Adjustable wrapping head positioning
Bearing Inner Diameter (ID) 2,500–4,200 mm Minimum bore clearance for shuttle pass
Maximum Section Height (OD − ID)/2 ≤ 475 mm (Radial section ≤ 950 mm total) Ring clearance envelope
Bearing Face Width 150–600 mm Height capability of shuttle frame
Bearing Weight Capacity 500–12,000 kg Driven PU roller load rating
Wrapping Cycle Time 60–110 s per bearing 3 layers applied simultaneously in one pass
Line Conveyor Speed 2–4 m/min VFD inverter control
Layer Overlap Ratio 10%–90% adjustable Calibrated based on OD rotation speed
Operator Requirement 1 person Panel operation clear of moving ring
Total Connected Power ≈ 4.5 kW 380V/440V, 50/60Hz 3-Phase
VCI Film Roll Spec Core 50 mm, OD 100–300 mm, width 200 mm Active vapor-phase rust inhibitor
Stretch Film Roll Spec Core 50 mm, OD 100–300 mm, width 300 mm PE stretch film (200% pre-stretch ratio)

Note: Custom frame configurations allow the positioning adjustment to cover extended bearing sizes from 1,000 mm up to 6,500 mm OD.

Worked example: a 6.4 t slewing bearing

Consider an industrial slewing ring: OD 3,200 mm, ID 2,600 mm, width 300 mm, forged steel construction.

Parameter / Check Mathematical Formulation Engineering Result Verification Status
Radial Difference (OD − ID) 3,200 mm − 2,600 mm 600 mm Pass (Radial section = 300 mm ≤ 475 mm limit)
Cross-Section Dimension (3,200 − 2,600) / 2 × 300 mm 300 mm × 300 mm Pass (Fits shuttle clearance envelope)
Solid Steel Section Mass π × 2.9 m × 0.3 m × 0.3 m × 7,850 kg/m³ ≈ 6,430 kg (6.4 t) Pass (Within 12 t roller capacity)
Wraps per Layer (300 mm film @ 50% overlap) π × 3,200 mm ÷ (300 mm × 0.5) ≈ 67 revolutions at OD Nominal wrap calculation
Film Path Distance per Wrap 2 × (300 mm + 300 mm) 1.2 m per shuttle turn Cross-sectional perimeter
Stretch Film Consumed per Layer 67 wraps × 1.2 m ≈ 80.4 m film on bearing Net usage (excluding pre-stretch)

Engineering Analysis: The target bearing falls comfortably within all structural and load limits of the FPCA-6000. Each stretch film layer consumes approximately 80 m of film. Because the inner diameter circumference (π × 2,600 mm = 8.17 m) is smaller than the outer diameter circumference (π × 3,200 mm = 10.05 m), the film overlap percentage automatically increases inside the bore. This provides extra layer thickness directly over the internal raceway, enhancing corrosion and impact resistance where it matters most.

The orbital ring speed (n) is coordinated with roller speed using: n = N ÷ t (where N is total shuttle wraps and t is target wrapping cycle time). Both parameters are programmed via the HMI touchscreen on initial setup.

Layers, oil spraying and loading

  • Three-Layer Single-Pass Encapsulation: The orbital head houses three dedicated material dispensers: an inner VCI anti-rust film roll applied directly against the steel surface, followed by two outer PE stretch film layers for mechanical sealing and structural tightness.
  • Integrated Anti-Rust Oil Spraying: An automated spraying system featuring a fluid tank, diaphragm pump, and atomizing nozzles coats the raceway and outer faces with protective oil during rotation prior to film application.
  • Pneumatic Cut & Hold System: Automatically clamps, cuts, and wipes the film tail at the end of the wrapping cycle, eliminating manual intervention and hazard exposure.

Pre-Quotation Engineering Input: To configure your line correctly, our engineering team requires:

  1. Complete bearing size spectrum (min/max OD, ID, width, weight).
  2. Layering sequence (e.g., VCI + stretch film + woven tape).
  3. Material handling method (overhead crane, C-hook, or inline conveyor). For smaller bearings under 2,000 mm OD, vertical ring wrappers are available for crane or trolley loading.

Selection checklist

  1. Dimensional Profile: Minimum and maximum bearing OD, ID, width, and gross mass.
  2. Material Layer Sequence: Combination of VCI film, LLDPE stretch film, VCI paper, or PE woven tape.
  3. Rust Prevention Requirement: Integrated anti-rust oil misting unit required (Yes/No).
  4. Loading Strategy: Overhead crane with C-hook, forklift manipulator, or motorized roller conveyor.
  5. Throughput Target: Required wrapped units per shift (tact time determination).
  6. Electrical Standards: Plant voltage, frequency, and control voltage (e.g., 400V 50Hz / 480V 60Hz).

Safety: EN 415-10 and ISO 12100

The FPCA-6000 is engineered in compliance with EN 415-10 (Safety of packaging machines – General requirements) and risk-assessed under ISO 12100:2010.

Key hazard mitigation features include:

  • Zero-Access Loading Zone: Bearing loading and unloading occur exclusively while the machine is in a zero-energy state.
  • Remote Operation Interface: Operators initiate and monitor the wrapping cycle from a pedestal-mounted PLC HMI panel outside the hazard zone.
  • Perimeter Safeguarding: Heavy-duty safety fencing with interlocked gate switches or optical safety light curtains prevents access to the driven rollers and rotating orbital ring during operation.
  • E-Stop & LOTO: Category 0 Emergency Stop button and OSHA-compliant Lockout/Tagout (LOTO) energy isolation points for maintenance.

Engineering FAQ

Q: Can one FPCA-6000 wrap both 3 m and 5 m diameter bearings? A: Yes. The motorized wrapping head adjusts vertically and horizontally along linear guides to match any bearing OD within the 2,900–5,000 mm range.

Q: What is the typical wrapping cycle time per bearing? A: Approximately 60–110 seconds per ring, applying VCI film and double stretch film layers in a single continuous pass.

Q: What packaging materials can be used on the shuttle head? A: Standard setup runs VCI film, PE stretch film, and PE woven tape. Spindle tension dispensers are custom-sized to client roll specifications.

Q: Which international machinery standards govern this equipment? A: The machine is designed according to EN 415-10 for packaging equipment safety, with risk assessment conducted under ISO 12100:2010 for CE compliance.

Next step

  1. Submit Specifications: Email your bearing size matrix, weights, and layer requirements to info@fhopepack.com.
  2. Engineering Sizing: Our engineers will configure the heavy-duty frame, PU roller drive, and shuttle ring kinematics.
  3. 24-Hour Proposal Delivery: Receive a comprehensive technical proposal, 3D GA layout drawing, and commercial quotation within 24 hours.

Related reading

Sources

  • FHOPE technical specification datasheet: FPCA-6000 Large Bearing Orbital Wrapping System
  • FHOPE Engineering Application Notes: Heavy Duty Slewing Ring Packaging & Kinematics
  • Factory Acceptance Test (FAT) operational video (featured above)
  • Structural steel density standard (7,850 kg/m³) & bearing kinematics calculations
  • European Machinery Safety Standards: EN 415-10; ISO 12100:2010

Last reviewed: 2026-10-19

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