Steel Strip Coil & Wire Coil Wrapping Machine: FPS-300 vs FPW-300 Engineering Selection Guide

Executive summary

An upright coil wrapping packing machine applies protective materials through the eye of a coil while the coil rotates vertically on motorized carrier rollers. Although steel strip coils and wire coils share an annular geometry, their differences in structural rigidity, core dimensions, weight distribution, and outer turn spring-back require distinct mechanical handling systems. The FPS-300 is engineered for rigid, heavy slit steel strip coils (20–1,000 kg; 508–610 mm ID), while the FPW-300 is optimized for non-rigid, lighter wire coils (10–250 kg; 300–700 mm ID).

The FPS-series upright orbital coil packaging system secures cold-rolled slit coils and wire coils on heavy-duty, polyurethane-lagged carrier rollers. The high-speed shuttle ring rotates continuously through the coil eye, wrapping crepe paper, VCI film, or stretch film with constant mechanical tension. Complete with an integrated operator console, stack-light status indicators, and perimeter safety trip devices, the system eliminates coil marking while maintaining continuous throughput.

Table of Contents

Steel Strip Coil vs. Wire Coil: Structural & Handling Differences

Selecting between an FPS and an FPW orbital packaging machine requires evaluating the physical state of the coiled product. Slit strip coils and wire rod bundles exert fundamentally different loads on carrier rollers and shuttle rings:

Critical Parameter Cold-Rolled Slit Steel Strip Coil Drawn Steel / Non-Ferrous Wire Coil
Internal Diameter (ID) Standardized mill bore: 508 mm or 610 mm Variable arbor bore: 300 mm to 700 mm
Structural Rigidity Solid, tightly wound metal block Semi-rigid to loose bundling; susceptible to settling
Turn Behavior Fixed, sharp edge profiles; vulnerable to telescoping Elastic turns; prone to spring-back and strand loosening
Surface Failure Risk Transverse edge cracking, indentations, surface oxidation Inter-strand scuffing, friction fretting, trapped moisture
Carrier Roller Profile Dual cylindrical rollers with fixed radial support Dual rollers with deep lateral guide rollers to arrest splay
Recommended Model FPS-300 FPW-300

A cold-rolled slit coil behaves as a rigid, dense annular disc. The packaging machine must support high linear contact loads on the roller bed while protecting precision edges against shear marks.

Conversely, a wire coil consists of multiple elastic loops bound with strapping. The packaging machine must support variable contact points, maintain radial cohesion, and prevent individual loops from shifting into the ring travel path during rotation.

Kinematics: How the Upright Orbital Wrapper Operates

The machine executes a two-axis coordinated wrapping motion:

  1. Primary Rotation (Orbital Ring): The aluminum-cast orbital ring is driven by heavy-duty friction wheels or reinforced belts. It carries the packaging material spool through the central eye of the coil at controlled rotational speeds (ω).
  2. Secondary Rotation (Workpiece Drive): Two polyurethane-coated carrier rollers support the coil on its outer diameter (OD), rotating it continuously around its horizontal axis.
  3. Kinematic Coordination: As the coil indexes forward, the rotating ring applies spiral-wound wraps through the bore. The wrap overlap ratio is determined by the ratio of carrier roller surface speed to ring rotation speed.
       [ Orbital Shuttle Ring (Through Eye) ]
                  │       ▲
                  ▼       │
           ┌───────────────┐
           │   Coil Eye    │
   ◄───────┤ (508-610 mm)  ├───────►  Horizontal Indexing Axis
           │               │
           └───────┬───────┘
                   │
           [ Carrier Rollers ]  (Dual Polyurethane-Lagged Drive)

Vertical lift drives allow the entire mainframe ring assembly to be adjusted to align with the core center of different coil heights, preventing the film shuttle from striking the inner bore. Mechanical friction brakes or pneumatic dancer bars maintain constant tension across the wrapping film to prevent slack or edge necking.

Engineering Specifications: FPS-300 vs. FPW-300

Technical Specification FPS-300 (Slit Strip Coils) FPW-300 (Wire Coils & Bundles)
Coil Internal Diameter (ID) 508–610 mm 300–700 mm
Coil Outer Diameter (OD) 600–1,200 mm 450–850 mm
Coil Width / Height 100–300 mm 100–300 mm
Maximum Payload Capacity 20–1,000 kg 10–250 kg
Wrapping Material Overlap 10%–90% (Inverter-Controlled) 10%–90% (Inverter-Controlled)
Compatible Packaging Media Crepe paper, PE stretch film, VCI film, woven HDPE PE stretch film, PVC, woven tape, crepe paper
Dispenser Roll Capacity Core ID 50 mm; OD 100–450 mm; Width 100–150 mm Core ID 50 mm; OD 100–250 mm; Width 100–120 mm
Pneumatic Requirements 0.4–0.6 MPa (4–6 bar clean, dry plant air) 0.4–0.6 MPa (confirmed per clamping options)
Installed Power 1.5 kW 1.5 kW
Standard Electrical Service 380V, 50 Hz, 3-Phase (Customized to 460V/480V) 380V, 50 Hz, 3-Phase (Customized to 460V/480V)

Protective Packaging Media: Paper, VCI Film, or Multi-Layer Wraps

Selecting the correct wrapping material depends on storage conditions, shipping mode, and the metallurgic sensitivity of the coil:

  • Reinforced Crepe Paper (70–120 GSM): Provides structural padding over sharp slit edges and absorbs moisture condensation during warehouse transit.
  • LLDPE Stretch Film (25–35 µm): High-elasticity moisture seal. Provides dust-proofing and weather resistance when wrapped with a minimum 50% overlap.
  • VCI (Vapor Corrosion Inhibitor) Film / Paper: Emits corrosion-inhibiting chemical vapors directly onto the steel surface, neutralizing atmospheric moisture for overseas ocean freight.
  • Dual-Layer Co-Wrapping: For maximum barrier defense, machines can be fitted with a dual-dispenser shuttle carriage that applies VCI paper and PE stretch film simultaneously in a single pass.

Engineering Calculation: 880 kg Slit Strip Coil

The following calculation evaluates the packing parameters for a prime slit carbon steel coil:

  • Outer Diameter (OD): 1,100 mm (1.10 m)
  • Inner Diameter (ID): 508 mm (0.508 m)
  • Width (W): 150 mm (0.15 m)
  • Steel Density (ρ): 7,850 kg/m³
  • Material: 150 mm wide crepe paper, set for 50% overlap at the outer circumference.
Cross-Sectional Face Area:
  A_face = (π / 4) × (OD² − ID²)
  A_face = (π / 4) × (1.10² − 0.508²) = (π / 4) × (1.21 − 0.258) ≈ 0.748 m²

Total Coil Volume:
  V = A_face × W = 0.748 m² × 0.15 m ≈ 0.112 m³

Mass Verification:
  M = V × ρ = 0.112 m³ × 7,850 kg/m³ ≈ 879.2 kg (Nominal 880 kg)
  Result: Fits the FPS-300 limit (1,000 kg). Exceeds the FPW-300 capacity (250 kg max).

Radial Wall Thickness:
  T_wall = (OD − ID) / 2 = (1,100 mm − 508 mm) / 2 = 296 mm

Annular Cross-Section Perimeter:
  P_section = 2 × (T_wall + W) = 2 × (296 mm + 150 mm) = 892 mm (0.892 m)

Outer Circumference:
  C_outer = π × OD = π × 1,100 mm ≈ 3,456 mm

Number of Wraps at 50% OD Overlap:
  Linear advance per ring turn = 150 mm × (1 − 0.50) = 75 mm
  N_turns = C_outer / Advance = 3,456 mm / 75 mm ≈ 46.08 → 46 turns

Total Required Material Length (Single Layer):
  L_paper = N_turns × P_section = 46 × 0.892 m ≈ 41.0 m (excluding lead/tail tails)

Overlap Differential at the Inner Core

The 50% overlap is established at the maximum outer diameter (1,100 mm). Because the core circumference is smaller:

Inner Circumference:
  C_inner = π × ID = π × 508 mm ≈ 1,596 mm

Linear Advance per Turn at Inner Bore:
  Advance_ID = 75 mm × (C_inner / C_outer) = 75 mm × (1,596 / 3,456) ≈ 34.6 mm

Resulting Overlap Ratio at the Inner Eye:
  Overlap_ID = (150 mm − 34.6 mm) / 150 mm = 115.4 / 150 ≈ 76.9% (~77%)

Engineering Consequence: Wrap material builds up significantly inside the central eye. Ensure the central hole retains adequate open clearance for overhead C-hook or coil car unloader access.

Pre-Commissioning Technical Checklist

Verify these six plant parameters before completing the machine configuration:

  1. Workpiece Class: Solid slit steel coil, galvanized strip, or loose/bundled wire loops.
  2. Dimension Range: Min/max ID, OD, and axial width.
  3. Coil Mass Envelope: Minimum and maximum weight per unit (kg).
  4. Protective Layer Profile: Single-layer stretch film, woven plastic cloth, or dual-layer paper + PE film.
  5. Cycle Time Requirements: Total target coils per hour (determines required ring RPM and VFD indexing speeds).
  6. Integration Interface: Manual crane loading, coil tilter integration, or powered indexing conveyor linkage.

Safety Standards: EN 415-10 and ISO 12100 Compliance

The FPS and FPW series are engineered under EN 415-10 (Safety of Packaging Machines: General Requirements) and ISO 12100:2010 (Risk Assessment and Reduction):

  • In-Running Nip Point Isolation: Carrier-roller drive hubs and orbital ring tracks are isolated behind safety interlocks with mechanical limit switches.
  • Operator E-Stop Circuit: Monitored dual-channel category-4 E-stop buttons are mounted on the main electrical console and on the machine frame.
  • Entanglement Protection: The rotating orbital zone is rated for strict entanglement zone isolation; light curtains or fixed interlocking perimeter fencing prevent machine start during coil positioning.
  • Roll-Off Restraints: Pneumatically actuated side-guide rollers prevent narrow, tall slit coils from tipping laterally on the carrier rollers during acceleration.

Engineering FAQ

Q: Can one machine wrap both steel strip coils and wire coils? A: Only if both product ranges fit within a single model’s envelope. Heavy slit coils (508 mm core, up to 1,000 kg) require the heavy roller beds and frame of the FPS-300. Light wire bundles (300–700 mm ID, up to 250 kg) operate efficiently on the FPW-300. Cross-running is mechanically limited by minimum core clearance and roller payload capacity.

Q: Why use polyurethane covering on carrier and guide rollers? A: Polyurethane (typically 85–90 Shore A durometer) delivers a high coefficient of friction to rotate the coil without slip while preventing contact marks or edge indentation on critical cold-rolled, polished, or galvanized surfaces.

Q: What compressed air supply is required for pneumatic tensioning? A: Clean, dried plant air at 0.4–0.6 MPa (4–6 bar). Air powers the pneumatic film-cut clamp and the lateral stabilization rollers.

Q: Can paper and stretch film be applied simultaneously? A: Yes. An optional dual-material dispenser carriage mounts both a paper reel and a film roll on the orbital ring, applying a composite protective shell in a single operational cycle.

Direct Technical Inquiry & Proposal Generation

  1. Send Technical Parameters: Email your minimum/maximum coil ID, OD, width, weight, and target cycle time to info@fhopepack.com.
  2. Engineering Review: Our mechanical engineering team verifies ring clearance, drive torque, roller-bed spacing, and material overlaps.
  3. Formal Proposal: Receive a full dimensional layout drawing, mechanical quotation, and electrical schematic within 24 hours.

Reference Standards

  • FHOPE Packaging Machinery Mechanical Documentation: FPS-300 & FPW-300 Series Technical Specifications
  • EN 415-10:2014: Safety of packaging machines — Part 10: General requirements
  • ISO 12100:2010: Safety of machinery — General principles for design — Risk assessment and risk reduction
  • Steel Packaging Technical Association: Best Practice Guide for Cold-Rolled Strip & Wire Rod Corrosion Prevention

Last reviewed: 2026-10-19

Author: Packaging Systems Engineering Group, FHOPE

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