Robot Pallet Wrapper

Executive summary

A robot pallet wrapper (self-propelled mobile stretch wrapping machine) wraps palletized loads without requiring the cargo to rotate or move. Operating on an autonomous tracked or tracer-wheel guidance system, the machine circles stationary loads on the shop floor while a powered pre-stretch film carriage travels vertically along a structural mast. By eliminating fixed-position turntables, floor anchoring, and dedicated forklift staging cycles, mobile robot wrappers resolve packaging bottlenecks for ultra-heavy, oversized, unstable, or geometrically irregular loads across multi-station warehouse facilities.

Industrial mobile wrapping robots integrate a heavy-duty motorized traction chassis, a structural lifting mast, and a power pre-stretch carriage calibrated for LLDPE film. Engineered for decentralized end-of-line packaging, the self-propelled unit tracks load peripheries directly on industrial concrete floors. Operating parameters—including carriage lift frequency, bottom/top reinforcement turns, travel drive speeds, and dynamic film containment force—are configured via an industrial HMI touchscreen controller powered by an on-board industrial battery bank.

Table of Contents

• Robot wrapper or turntable wrapper?
• How a robot wrapper follows the load
• Film use and travel distance
• Floor, battery and site checks
• Selection checklist
• Safety: EN 415-6 and ISO 12100
• Engineering FAQ
• Next step
• Related reading
• Sources

Robot wrapper or turntable wrapper?

Selecting between a mobile self-propelled wrapper and a stationary turntable platform depends directly on payload weight, structural stability, and internal logistics flow.

Rule. Deploy a self-propelled robot wrapper when payloads exceed 2,500 kg, exhibit unstable/irregular stacked geometries, exceed standard platform dimensions, or require packaging across dispersed staging lanes. Select a stationary turntable wrapper for standardized pallet profiles (e.g., 1,200 × 1,000 mm) consolidated at a single high-throughput packaging point.

How a robot wrapper follows the load

Mobile wrapping units execute coordinated kinematics between linear chassis drive and vertical carriage lift:

1. Cycle Initialization: The operator steers the machine to the corner of the target pallet using manual directional controls, anchors the LLDPE film tail to the pallet timber base, and depresses the cycle start push-button.
2. Perimeter Guidance: The mobile chassis circles the pallet at an electronically controlled offset. Tracking relies on an adjustable mechanical tracer feeler wheel with an integrated shock-absorbing potentiometer running along the cargo face, or non-contact optical/ultrasonic obstacle sensors.
3. Reinforced Containment Spiraling: The motorized film carriage initiates wrapping at the structural pallet stringers (typically 2 to 4 base turns at 15–45 N containment force) to bond payload to pallet. The carriage then ascends the mast via an inverter-driven chain or timing belt, laying overlapping film spirals until an optical photo-eye detects the top load edge.
4. Cycle Completion: After applying pre-set top wraps and down-cycle reinforcement, the machine stops autonomously, cuts the film via an integrated impulse or mechanical blade, and wipes down the film tail, entering stand-by for transit to the next bay.

Because the guidance system references external surfaces, a single machine accommodates standard pallets, oversized machinery crates, and cylindrical containers without mechanical changeover.

Film use and travel distance

Operational throughput and film economy depend on two linked mechanical calculations: actual film tensioned onto the load versus driven chassis path.

• Film on Load = N_turns × P_load
• Chassis Travel Path = N_turns × P_travel
• Raw Film Delivered from Roll = Film on Load ÷ (1 + Pre-stretch Ratio)

Note: Pre-stretch ratios are defined as dynamic elongation (e.g., 200% dynamic stretch equates to 1 m raw film yielding 3 m stretched film on load).

At a standard OEM power pre-stretch ratio of 250% (1 + 2.50 = 3.50 elongation factor), wrapping a 1,200 × 1,000 mm load with 12 spirals consumes approximately 52.8 ÷ 3.50 = 15.1 m of unstretched film from the roll.

Kinematic Result. The mobile chassis traverses approximately 1.8 to 2.0 times the linear perimeter of the wrapped unit due to the outer turning envelope. Total packaging cycle time is derived as:

Cycle Time (sec) = (Driven Travel Path ÷ Travel Velocity) + Carriage Dwell & Cut Time

With variable stepless chassis drive speeds running at 35–70 m/min (0.58–1.16 m/s), a standard 1,200 × 1,000 mm pallet cycle completes in approximately 85 to 110 seconds.

Floor, battery and site checks

Deploying self-propelled wrapping equipment requires systematic evaluation of site physical constraints:

Selection checklist

1. Dimensional Envelope: Minimum and maximum package footprint (L × W × H), verifying mast vertical stroke and tracer arm travel.
2. Payload Integrity & Weight: Unit weight, stack stability, and whether bottom layer pallet clearance allows standard contact tracer feelers.
3. Daily Throughput Target: Peak-hour pallet count and loads required per shift to determine battery pack capacity (AGM vs. fast-charging LiFePO4).
4. Facility Floor & Routing Envelope: Floor flatness, aisle clear passage (≥ 1,100 mm), expansion joints, and warehouse gradient limits.
5. Film Specifications: Micron rating (17–35 µm), cast vs. blown film resin, pre-stretch target (200% fixed gear vs. up to 300% motorized variable stretch).
6. Maintenance & Charging Station: Location of 110V/230V charging outlets and central staging zone for off-shift storage.

Safety: EN 415-6 and ISO 12100

Mobile packaging robots fall under the scope of EN 415-6 (Safety of packaging machines: pallet wrapping machines), with risk assessments conducted in compliance with ISO 12100:2010.

Because self-propelled wrapping machinery operates in un-fenced, pedestrian-shared warehouse aisles, the hazard envelope moves dynamically with the machine chassis. To mitigate crush, shearing, and impact risks, compliant mobile wrappers incorporate:

• Deformable Sensitive Edge Bumper (EN ISO 13856-2 / EN 1760-2): A wraparound safety pressure bumper surrounding the drive carriage. Contact with any physical obstacle activates an instantaneous emergency stop circuit (braking distance ≤ 150 mm).
• Control Reliability: Safety circuits, including dual-channel E-stops, emergency belly switches on steering tillers, and bumper interlocks, adhere to ISO 13849-1 Category 3 / PL d.
• Visual & Acoustic Indicators: Integrated 85 dB audible sirens and 360-degree high-intensity flashing LED beacons alert surrounding personnel whenever the drive motors are energized.
• Workzone Delineation: Operators must maintain a clear zone, with high-traffic packaging bays designated by yellow floor safety striping. Full CE compliance declarations and technical construction files are delivered with each unit.

Engineering FAQ

Q: Can a mobile robot wrapper stabilize loads that are dangerous to rotate on a turntable? A: Yes. Because the pallet remains completely stationary on the floor, zero centrifugal force is exerted on the cargo. This makes it ideal for tall, unstable, extremely light, or heavy unbalanced items (e.g., stacked beverage cans, un-banded barrels, heavy machinery).

Q: Does the unit require floor tracks, magnetic tape, or laser navigation grids? A: No. Standard industrial mobile wrappers use a mechanical tracking feeler wheel running against the cargo face, requiring zero civil works or floor modifications. Laser or ultrasonic guide configurations are available for sensitive or compressible loads.

Q: What is the average cycle time for a standard Euro-pallet (1,200 × 800 mm)? A: With chassis travel speed set to 50 m/min, applying 3 base wraps, spiral ascent, 3 top wraps, and spiral descent, the total floor cycle runs between 75 and 90 seconds.

Q: How many pallets can the machine wrap on a single battery charge? A: A standard 24V/110Ah battery configuration wraps approximately 200 to 250 standard pallets (12 turns per load). Upgrading to a lithium pack provides continuous shift operation with short opportunity charges during operator breaks.

Q: Can the robot wrap irregular, octagonal, or non-palletized machinery crates? A: Yes. The flexible feeler arm system follows non-standard contours, octagonal bulk bins, long bundles, and extra-long structural profiles without requiring software reprogramming.

Next step

1. Submit Payload Parameters: Send your maximum and minimum load dimensions (L × W × H), maximum gross weight, and shifts-per-day throughput targets to info@fhopepack.com.
2. Kinematic & Engineering Review: Our technical engineering team verifies tracking clearance, recommends ideal film carriage pre-stretch ratios, and models your cycle time.
3. Turnkey Technical Quotation: Receive a comprehensive proposal, dimensional layout drawings, and full CE-compliance documentation within 24 hours.

Related reading

• Robot pallet wrapping machine
• Robotic arm semi-automatic pallet wrapper
• R100 rotary arm pallet wrapper with film cutter
• Automatic pallet wrapping machine
• Pallet wrapping machine
• A200 turntable pallet wrapping machine (product)
• B200 automatic pallet wrapping machine (product)

Sources

• FHOPEPACK Mobile Stretch Wrapper Technical Engineering Archive (Model Series R-Mobile)
• European Standard EN 415-6: Safety of packaging machines – Part 6: Pallet wrapping machines
• International Standard ISO 12100:2010: Safety of machinery – General principles for design – Risk assessment and risk reduction
• ISO 13849-1: Safety of machinery – Safety-related parts of control systems
• Technical performance benchmarks for self-propelled industrial packaging machinery

Last reviewed: 2026-10-19