Executive summary
An online auto cable winding and wrapping machine sits at the end of a cable extrusion line. It counts the cable length, winds it into a coil, cuts it, and passes the coil to a ring wrapper that films it through the eye. Our coiler runs with line speeds up to 200 m/min and makes 2–2.5 coils per minute. A worked example sizes a 100 m coil and checks the coiler and wrapper keep pace with the line.
Table of Contents
- Why coil and wrap online
- The line, station by station
- Coiler and wrapper data
- Worked example: 100 m coils at 200 m/min
- Wrapping, strapping or shrinking
- Selection checklist
- Safety: EN 415-10 and ISO 12100
- Engineering FAQ
- Next step
- Related reading
- Sources
Why coil and wrap online
An extrusion line makes cable continuously, so whatever follows it has to keep pace. When coiling is done offline, the cable first goes onto large reels and is rewound later, which doubles the handling. Online coiling takes the cable straight from the line, so each coil is counted, cut, wrapped and ready to ship as it is made.
The line, station by station
- Cooling and pay-in. The cable leaves the cooling trough and runs over guide pulleys into the coiler.
- Length count. A meter counter measures each coil. The length is set in 0.01 m steps, up to 500 m.
- Coiling. The coiler winds the cable on a fixed-size coiling head and cuts it at the set length. The finished coil is held and transferred to the next station.
- Wrapping. A ring wrapper passes film through the coil eye and around the coil.
- Out-feed. Wrapped coils roll out on a roller conveyor for labelling and packing.
The cable keeps coming while each coil is cut and moved on. How the line buffers that short gap is matched to your line speed and set out in the layout.
Settings are made through the PLC program, and the blue mesh fencing closes off the moving parts. The control panel stands at the coiler.
Coiler and wrapper data
| Item | Coiler | FPCA-200 wrapper |
|---|---|---|
| Cable diameter | 2–20 mm | — |
| Coil ID | 140–250 mm (fixed per head) | 150–400 mm |
| Coil OD | 200–600 mm | 250–500 mm |
| Coil height / width | 60–180 mm | 80–200 mm |
| Coil weight | — | 2–50 kg |
| Line speed | up to 200 m/min | — |
| Rate | 2–2.5 coils/min | 20–30 s per coil |
| Length count | 0.01–500 m | — |
| Ring speed / overlap | — | 10–120 r/min / 20–80% |
| Material | — | PE stretch film, PVC |
| Air / power | 6 bar; AC 380 V 50 Hz 3 ph | 2.0 kW |
When the coiler is paired with the FPCA-200, the wrapper sets the outer limits: coils up to 500 mm OD and at least 80 mm high. Larger coils, up to the coiler’s 600 mm OD, need a larger wrapper ring, which we size to the coil.
Worked example: 100 m coils at 200 m/min
Illustrative job: 6 mm cable, 100 m coils, 200 mm ID, 100 mm coil height, line speed 200 m/min. We take the cable as packing into a square grid, so each metre fills d² of coil section.
| Check | Calculation | Result |
|---|---|---|
| Coil volume | 100 × 0.006² | 0.0036 m³ |
| Section area at 100 mm height | 0.0036 ÷ 0.1 | 0.036 m² |
| Coil OD | √(0.036 × 4 ÷ π + 0.2²) | ≈ 293 mm |
| Coils per minute from the line | 200 ÷ 100 | 2 |
| Time per coil | 60 ÷ 2 | 30 s |
| Shortest coil the coiler can keep up with | 200 ÷ 2.5 | 80 m |
Result. A 100 m coil comes out about 293 mm OD, inside both the coiler range and the FPCA-200 range. The line feeds 2 coils per minute, within the coiler’s 2–2.5. Each coil gives the wrapper 30 s, the top of its 20–30 s range, so the wrapper must run near full speed. Coils shorter than 80 m at this line speed would outrun the coiler.
Wrapping, strapping or shrinking
We build two families of online cable packing:
- Coiling and wrapping, as here, with an optional label device.
- Coiling, strapping and shrinking, where the coil is tied with PP strap and then shrink-wrapped. Labelling can be added.
Film wrapping through the eye seals the whole coil. Strapping and shrinking give a firm, tidy coil for retail sale.
Selection checklist
- Cable diameter and line speed.
- Coil length, ID, OD and height.
- Online after extrusion or offline from reels.
- Wrapping, or strapping and shrinking.
- Labelling and boxing after packing.
Safety: EN 415-10 and ISO 12100
We design the line to EN 415-10 and assess its risks to ISO 12100. The main hazards are the turning coiling head, the cutter and the wrapping ring. Mesh fencing closes off the moving parts, and the control panel carries an emergency stop.
Engineering FAQ
Q: Can it run offline? A: Yes. Online and offline versions are available. Offline, the cable is paid off from a large reel instead of coming straight from the extruder.
Q: How accurate is the length? A: The length is set in 0.01 m steps. The measuring tolerance depends on the cable and is confirmed at quote.
Q: What limits the rate? A: The shorter of the line feed time and the coiler and wrapper times. Very short coils at high line speed outrun the coiler.
Q: Which standard applies? A: EN 415-10 for the machine, and ISO 12100 for the risk assessment.
Next step
- Send cable size, coil length and line speed to info@fhopepack.com.
- We check the coil size and the station times.
- We reply within 24 hours with a proposal and quotation.
Related reading
- Automatic cable winding and packing machine (product)
- Cable coil wrapping machine FPCA-200 (product)
- Online auto cable coiling and wrapping machine
- Cable coil packing machine and wire packing machine
- Auto cable packing line: coiling, strapping, shrinking, labeling
Sources
- FHOPE product pages: automatic cable winding and packing machine; automatic cable winding machine; cable coil wrapping machine FPCA-200
- FHOPE project notes on online cable packing solutions
- Our online cable line shown above
- Worked example: illustrative figures
- Standards: EN 415-10; ISO 12100:2010
Last reviewed: 2026-10-19
