Heavy-Duty Turntable Coil Wrapping Machine: Engineering Selection & Load Calculations

Executive summary

A pallet wrapping machine designed for heavy cylindrical loads secures coils on a reinforced turntable with a dual-roller cradle while a vertical film carriage dispenses pre-stretched film around the outer circumference. Our heavy-duty model, the A200B, supports loads up to 5,000 kg on a 1,650 mm turntable, operates at rotational speeds up to 12 rpm, and delivers a 250% powered pre-stretch ratio. This engineering whitepaper outlines load verification formulas, mechanical centring constraints, stretch film consumption calculations, and comparative criteria for choosing between a turntable wrapper and an eye-through wrapping system.

Table of Contents

Why a turntable wrapper for coils

A turntable coil wrapper applies protective stretch film to the outer cylindrical surface of heavy coils to prevent dust accumulation, moisture ingress, and handling damage during transport. By rotating the coil horizontally on a turntable without passing film through the inner core (bore), the bore and side edges remain accessible for standard handling equipment.

This configuration offers a cost-effective packaging solution for indoor storage, domestic trucking, and interim buffer warehousing. For long-distance ocean transport or severe weather exposure requiring full moisture barrier sealing through the bore, an eye-through orbital wrapping system is recommended.

Heavy-duty turntable data

Technical Parameter Specification (Model A200B)
Operation Mode Semi-automatic / PLC controlled
Throughput Capacity Up to 35 coils/hour (depending on wrap pattern)
Maximum Load Weight 5,000 kg
Turntable Structure 1,650 mm diameter, 80 mm profile height, 10 mm reinforced top plate
Maximum Turning Envelope 2,000 mm diagonal clearance
Drive & Support Heavy-duty slewing support bearing, VFD soft start/stop
Rotation Speed 0 to 12 rpm (variable frequency drive)
Maximum Load Dimensions L 1,200 × W 1,200 × H 2,100 mm (custom sizes available)
Film Specification LLDPE stretch film, 0.025 mm thickness, 500 mm width, 76 mm paper core
Pre-Stretch System 250% fixed powered pre-stretch (100% to 300% gear options)
Carriage Elevating Speed 2.9 m/min (variable speed control)
Drive Motors Turntable: 1.0 kW Carriage: 0.37 kW Pre-stretch: 0.25 kW
Machine Weight / Mobility Approx. 700 kg; dual-direction forklift transport pockets
Power Supply AC 220 V, 1-phase / 3-phase, 50/60 Hz

Check the coil weight first

Before placing a metal coil on the turntable, calculate its nominal mass to ensure it operates within the 5,000 kg structural limit.

Mass Calculation Formula: m = (π / 4) × (OD² - ID²) × W × ρ

Where:

  • OD = Outer diameter of the coil (m)
  • ID = Inner diameter / bore size (m)
  • W = Coil width / face height (m)
  • ρ = Material density (Steel: 7,850 kg/m³, Copper: 8,960 kg/m³, Aluminium: 2,700 kg/m³)

Weight Verification Table for Steel Coils

Coil Dimensions (OD × ID × Width) Mathematical Expansion Calculated Mass 5,000 kg Limit Check
1,200 mm × 508 mm × 600 mm 0.7854 × (1.44 – 0.258) m² × 0.6 m × 7,850 kg/m³ ≈ 4,370 kg PASS (Fits within load rating)
1,200 mm × 508 mm × 1,000 mm 0.7854 × (1.44 – 0.258) m² × 1.0 m × 7,850 kg/m³ ≈ 7,280 kg OVERLOAD (Requires heavy-duty rating)

Note: Paper rolls, non-woven fabric reels, and plastic coils exhibit significantly lower density, meaning physical volume rather than mass usually dictates machine selection.

Centring and the cradle

Coils loaded in the horizontal axis (“eye-to-wall”) require mechanical restraint to prevent rolling during turntable rotation. The A200B turntable incorporates an integrated dual-roller V-cradle built directly into the rotating structure to center and cradle the payload.

       [ Outer Cylindrical Surface ]
                 /       \
                /  Coil   \
               (   Axis    )
                \         /
                 \_______/
               /           \
      [ Roller 1 ]       [ Roller 2 ]
     ================================= (Turntable Top Plate)

Centring Requirements & Motion Envelope

  1. Dynamic Centring: The center of gravity of the coil must align with the rotational axis of the turntable. An off-center offset generates eccentric moments, subjecting the slewing bearing to uneven radial fatigue and causing film tension fluctuation.

  2. Turning Diameter Envelope: The diagonal in plan view must not exceed the 2,000 mm maximum clearance envelope:

    D_plan = √(OD² + W²)

    For a coil measuring 1,200 mm OD by 600 mm width:

    D_plan = √(1.2² + 0.6²) = √(1.44 + 0.36) = √1.80 ≈ 1.342 m (1,342 mm)

    Since 1,342 mm is well below 2,000 mm, the film carriage maintains safe operating clearance.

Film per coil

Calculating stretch film usage per cycle ensures precise packaging cost forecasting.

Operating Parameters:

  • Coil size: 1,200 mm OD × 600 mm width (standing in V-cradle)
  • Wrapping cycle: 3 bottom reinforcement layers, 3 top reinforcement layers
  • Turntable speed: 12 rpm (5.0 seconds per revolution)
  • Carriage elevation speed: 2.9 m/min (48.3 mm/s)
Calculation Step Formula / Method Quantitative Result
Total Vertical Travel Standing OD height to cover 1,200 mm
Traverse Wrap Revolutions 2 × (1,200 mm ÷ 48.3 mm/s) ÷ 5.0 s/rev 10 revolutions
Total Wrap Revolutions 10 traverse turns + 3 bottom turns + 3 top turns 16 total revolutions
Applied Film Path / Turn 2 × (1.2 m + 0.6 m) 3.6 m per revolution
Total Film Wrapped on Coil 16 revolutions × 3.6 m ≈ 57.6 m
Raw Film Consumed from Roll 57.6 m ÷ (1 + 2.50 pre-stretch ratio) ≈ 16.5 m
Coils Wrapped per 1,500 m Roll 1,500 m ÷ 16.5 m ≈ 90 coils per roll

Turntable wrapper or eye-through wrapper?

Packaging Requirement Turntable Wrapper (A200B) Eye-Through Orbital Wrapper
Outer Surface Protection Excellent (Full circumferential cover) Excellent
Bore / Eye & Edge Sealing Open (No coverage through center) Complete 360° axial seal
Ocean Freight & Anti-Corrosion Requires supplementary VCI bag Direct VCI film through eye
Load Capacity Limit Standard up to 5,000 kg Custom engineered (up to 30,000 kg)
Capital Investment & Footprint Low cost, compact floor footprint Higher investment, larger footprint

Selection checklist

When specifying a coil wrapping system, confirm the following technical parameters:

  1. Coil Geometry: Minimum and maximum Outer Diameter (OD), Inner Diameter (ID), and Width (W).
  2. Mass Specification: Maximum weight per coil and material density type.
  3. Target Throughput: Required coils per hour and daily operational duty cycle.
  4. Environmental Exposure: Dust/scratch protection only vs. waterproof sea-freight barrier.
  5. Material Handling Integration: Overhead crane, forklift, or C-hook loading.
  6. Electrical Infrastructure: Available voltage, frequency, and phase configuration.

Safety

The A200B coil wrapping machine is engineered in compliance with international industrial safety directives:

  • EN 415-6: Safety of packaging machines (Pallet wrapping machines)
  • EN ISO 12100:2010: Safety of machinery — General principles for design — Risk assessment
  • EN 60204-1: Safety of machinery — Electrical equipment of machines

Because a 5,000 kg rotating mass creates high rotational inertia, safety perimeter fencing with interlocked light curtains or access gates must be installed around the operating zone. The control panel includes an IEC-compliant emergency stop button and a lockable main power isolator switch.

Engineering FAQ

Q: What is the maximum load capacity of the A200B turntable?

A: The standard A200B supports up to 5,000 kg. Custom structural designs can accommodate higher payloads upon request.

Q: Does the stretch film pass through the coil eye?

A: No. The turntable machine wraps the outer circumferential face. For complete encapsulation through the eye, select an orbital eye-through wrapping machine.

Q: How is heavy coil loading executed?

A: Coils can be placed directly onto the 80 mm low-profile turntable cradle using a forklift or overhead crane equipped with a C-hook or sling.

Q: Can the machine be relocated within the facility?

A: Yes. The base frame includes built-in forklift pockets accessible from both the front and rear for rapid relocation.

Q: Is the machine suitable for non-metallic rolls?

A: Yes. It effectively wraps paper reels, film rolls, and textile coils, provided their dimensions stay within the 2,000 mm turning envelope.

Next step

  1. Submit your coil specifications (OD, ID, width, weight, and hourly target) to info@fhopepack.com.
  2. Receive engineering evaluation to verify turntable cradles versus eye-through system requirements.
  3. Obtain a formal proposal complete with technical drawings and pricing within 24 hours.

Sources

  • FHOPE Engineering Specification: A200B Heavy-Duty Coil Turntable Wrapper (5000 kg rating)
  • Machinery Safety Standards: EN 415-6, EN ISO 12100:2010, EN 60204-1
  • Factory Acceptance Test (FAT) Operational Logs — Heavy Coil Packaging Division

Last reviewed: 2026-10-19

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