Small Coil Wrapping Machine: Eye-Through Wrapping, FPCA Models and Film Use

Executive summary

Small coil packaging means wrapping cable, wire and tube coils from a few kilograms to several hundred kilograms, quickly and the same way every time. Our compact coil wrappers turn the coil on drive wheels while a ring passes film through the eye, so a coil is sealed in 18–38 s depending on model. This page explains the technology, how to pick a model, how to set overlap and how much film a coil uses.

A small coil lies flat on the wrapper table, supported by drive wheels and a top press rod. The ring passes film through the coil eye while the wheels turn the coil, and the operator initiates each cycle via the foot pedal.

Table of Contents

How eye-through coil wrapping works

Eye-through orbital wrapping seals toroidal products by passing packaging material radially through the open center (eye) while the coil rotates about its horizontal axis. The mechanical wrapping cycle proceeds in four discrete phases:

  1. Load: The operator places the tied coil on the table, centering it around the lower aperture of the rotating ring.
  2. Clamp: Guide rollers centre the coil and a press rod holds it from above.
  3. Wrap: The orbital ring carries the packaging film dispenser through the coil eye. Simultaneously, the base drive wheels rotate the coil so that each consecutive wrap overlaps the preceding layer at a uniform pitch.
  4. Finish: Once the coil completes a 360° rotation, the film is severed, the top press clamp retracts, and the wrapped coil is unloaded.

The overlap ratio is set by the ratio of ring speed to coil turning speed. Inverters let you change either from the panel. Film tension is set on the ring: our standard configuration incorporates a 2.5 kg·m magnetic powder tension controller, so light or soft coils can be wrapped without crushing them. Press-rod force and automatic cut-and-clamp options are confirmed at quote.

Choosing a model by coil size

Selecting the correct wrapper requires matching the physical dimensions and mass of your coil envelope against machine clearance limits. The primary mechanical constraint is the minimum internal diameter: the orbital ring cross-section and film carriage must pass through the coil eye without interference.

Item FPCA100 FPCA-200 FPCA-300
Coil ID 90–250 mm 150–400 mm 250–510 mm
Coil OD 150–400 mm 250–500 mm 400–900 mm
Coil width 50–180 mm 80–200 mm 60–300 mm
Coil weight 2–30 kg 2–50 kg 20–200 kg
Ring speed 10–120 r/min 10–120 r/min 10–90 r/min
Cycle 18–30 s 20–30 s 20–38 s
Overlap 20–90% 20–80% 10–90%
Power 1.8 kW 2.0 kW 2.4 kW
Wrap material PE, stretch film, PVC PE, stretch film, PVC LLDPE, PVC, PE, paper

Note: All specification parameters represent manufacturer baseline ratings [manufacturer rating]. Pick the model whose minimum ID rating is below your smallest coil eye to ensure unobstructed orbital clearance.

Overlap and wrap count

Film overlap is calculated based on the outer perimeter of the coil, where surface speed is highest:

Wraps per coil = π × coil OD ÷ (film width × (1 − overlap))

(The following calculation is an illustrative example only)

For a 400 mm OD coil wrapped with 60 mm wide film at a target 50% overlap:

  • Effective advance per ring revolution = 60 mm × (1 − 0.50) = 30 mm
  • Total outer perimeter = π × 400 mm ≈ 1,257 mm
  • Total wraps required = 1,257 mm ÷ 30 mm ≈ 42 wraps
  • At a ring speed of 120 r/min, total rotational wrapping time is 42 ÷ 120 × 60 s ≈ 21 s, which falls comfortably within the 20–30 s operating cycle of the FPCA-200.

Film use per coil

Linear film consumption per wrap corresponds directly to the cross-sectional perimeter of the toroidal package:

Film per wrap ≈ perimeter of the coil cross-section = 2 × (width + (OD − ID) ÷ 2)

(The following calculation is an illustrative example only)

For a coil with 100 mm width, 400 mm OD, and 200 mm ID:

  • Radial wall thickness = (400 mm − 200 mm) ÷ 2 = 100 mm
  • Film length per wrap = 2 × (100 mm + 100 mm) = 400 mm (0.4 m)
  • Over 42 wraps, total film required = 42 × 0.4 m ≈ 16.8 m of film per coil (unstretched base calculation).

Multiply this linear figure by coils per shift to size film stock and compare film, PVC and paper costs.

Best practices

  • Pre-secure loose turns: Strap or tie the coil prior to loading so individual cable or tube turns do not shift under the top press rod during initial rotation.
  • Reference overlap to outer diameter: Always configure the overlap ratio for the outer diameter (OD). Because linear surface speed is lower at the inner diameter (ID), the eye will naturally receive a higher layer density.
  • Select application-specific media: Use PVC or paper where the coil must breathe, and stretch film where it must stay sealed.
  • Keep the drive wheels clean: Film residue makes the coil slip and leaves gaps in the wrap.
  • Use vertical eye-through wrapping for small, light coils: With supportive guiding rollers, vertical wrapping suits lightweight coils that are awkward to handle [manufacturer rating].

Selection checklist

  1. Dimensional range: Exact minimum and maximum coil ID, OD, width, and gross weight?
  2. Product profile: cable, wire, tube or hose?
  3. Throughput requirements: Required cycle speed or target coils per hour?
  4. Wrap material: stretch film, PVC or paper?
  5. Handling integration: Manual workstation loading or automated infeed/outfeed conveyor transfer?
  6. Downstream operations: labeling or cartoning after wrapping?

Safety

FPCA series wrappers are engineered in compliance with international machinery safety directives:

  • EN ISO 12100:2010: Risk assessment and risk reduction principles.
  • EN 415-10: General safety requirements for packaging machines.
  • EN 60204-1: Electrical safety and operational control systems.

The rotating ring, drive wheels and press rod are the main hazards. Keep hands clear during the cycle, start it only from the pedal or button, and keep the emergency stop in reach.

Engineering FAQ

Q: What is the smallest coil diameter the series can wrap? A: The compact FPCA100 processes coils down to a 90 mm inner diameter (ID) and 150 mm outer diameter (OD).

Q: What is the typical complete machine cycle time? A: Single coil wrapping cycle ranges from 18 to 38 seconds, depending on the selected model frame, coil perimeter, and programmed overlap percentage.

Q: Can it wrap with paper? A: Yes. The FPCA-300 takes paper as well as LLDPE, PVC and PE film.

Q: How is overlap set? A: By the ratio of ring speed to coil turning speed, adjustable from the panel.

Next step

  1. Submit your coil specifications: Send your min/max coil ID, OD, width, mass, and production output targets to info@fhopepack.com.
  2. Technical validation: Our engineering team calculates ring clearance, cycle capacity, and conveyor integration.
  3. Proposal delivery: We reply within 24 hours with a proposal and quotation.

Sources

  • FHOPE product pages: cable coil wrappers FPCA100, FPCA-200 and FPCA-300
  • FHOPE product page: Hose coil wrapper FPH-200
  • EN ISO 12100:2010; EN 415-10; EN 60204-1

Last reviewed: 2026-10-28

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