{"id":1162,"date":"2018-06-14T07:54:03","date_gmt":"2018-06-14T07:54:03","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=1162"},"modified":"2026-10-27T06:20:26","modified_gmt":"2026-10-27T06:20:26","slug":"manual-orbital-stretch-wrapper","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/manual-orbital-stretch-wrapper\/","title":{"rendered":"Manual orbital stretch wrapper"},"content":{"rendered":"
> **Executive Summary**\n> The FHOPE economic horizontal orbital stretch wrapper is an entry-level, operator-assisted ring-wrapping solution engineered for small-to-medium bundle packaging. Designed for rigid linear profiles—including timber battens, plastic extrusions, and aluminum channels—it accommodates cross-sectional profiles up to 200 mm equivalent envelope diameter and continuous lengths exceeding 1,500 mm. By pairing driven polyurethane (PU) infeed and outfeed roller conveyors with a variable-frequency driven rotary ring, this machine bridges the gap between labor-intensive hand wrapping and high-CAPEX automated cells. This technical guide outlines kinematic sizing calculations, cycle-time kinematics, and operational safety criteria under EN 415-10.\n\n---\n\n<h2 id="table-of-contents">Table of Contents<\/h2>\n\n<ul>\n<li><a href="#manual">What "manual" means on this wrapper<\/a><\/li>\n<li><a href="#operator">The operator's part of the cycle<\/a><\/li>\n<li><a href="#machine">What the machine does on its own<\/a><\/li>\n<li><a href="#specs">Economic orbital wrapper specifications<\/a><\/li>\n<li><a href="#example">Worked example: will a rectangular bundle fit, and how fast to run<\/a><\/li>\n<li><a href="#when-to-step-up">When to step up to the S300<\/a><\/li>\n<li><a href="#selection-checklist">Selection checklist: what to send us<\/a><\/li>\n<li><a href="#safety">Safety and EN 415-10<\/a><\/li>\n<li><a href="#engineering-faq">Engineering FAQ<\/a><\/li>\n<li><a href="#next-step">Next step<\/a><\/li>\n<li><a href="#related-reading">Related reading<\/a><\/li>\n<li><a href="#sources">Sources<\/a><\/li>\n<\/ul>\n\n<h2 id="manual">What "manual" means on this wrapper<\/h2>\n\nOn a fully automated horizontal packaging line, bundle positioning, film clamping, hot-wire cutting, and transfer are executed autonomously via PLC and optical beam sensing. On this economic horizontal wrapper, the system operates on a semi-automatic, operator-assisted cycle. An operator stations at the infeed conveyor to load, index, and finish the package.\n\nOnce engaged, the rotary ring and the motorized conveyor beds execute the continuous spiral stretch-wrapping cycle automatically. By omitting pneumatic automatic clamp-and-cut mechanisms and motorized overhead stabilizing clamps, this architecture reduces capital expenditure (CAPEX), lowers mechanical complexity, and eliminates pneumatic supply requirements. It provides an optimal ROI for fabrication shops, distribution yards, and secondary processing lines handling 50 to 300 cycles per shift.\n\n<h2 id="operator">The operator's part of the cycle<\/h2>\n\nThe operator manages four operational touchpoints during the wrapping sequence:\n\n1. **Load.** Place the bundled profiles onto the driven infeed roller conveyor, centering the load against the adjustable lateral guide fence to align the bundle axis perpendicular to the ring center.\n2. **Guide.** Advance the leading edge into the rotating ring throat. The operator steadies long, light bundles to suppress cantilever vibration until the forward PU drive rollers take positive traction.\n3. **Start the film.** Manually pull the film tail from the carriage and anchor it between bundle profiles or fix it to the leading end before engaging the foot pedal \/ start push-button.\n4. **Finish.** Once the bundle's trailing edge exits the wrapping ring, the operator cuts the film web manually using a safety safety knife and presses the film tail against the bound surface to activate the cling layer.\n\nBecause this unit does not integrate an automated mechanical cut-and-wipe unit, the cycle relies on manual cutting. Facilities requiring continuous, hands-free end-of-arm cutting should consider the automated S300 platform detailed below.\n\n<h2 id="machine">What the machine does on its own<\/h2>\n\nThe orbital ring assembly is engineered for continuous spiral packaging:\n\n- **Ring Drive:** Powered by a gear-motor driving high-traction polyurethane friction wheels. A variable-frequency inverter (VFD) controls acceleration, deceleration, and rotational speeds from 20 to 100 r\/min, eliminating sudden torque spikes.\n- **Home Position Indexing:** The drive system incorporates proximity sensors to bring the film carriage to an indexed stop position at cycle termination, providing repeatable operator access for roll changeovers.\n- **Tension Regulation:** The rotating carriage houses a mechanical friction brake hub that accepts core-braked stretch film rolls, allowing fine-tuning of film pre-stretch and containment force without crushing delicate product corners.\n- **Conveyor Synchronization:** Entrance and exit conveyors (1,000 mm standard bed length each) are powered by independent worm-gear motors coordinated via inverter control. Rollers are coated in 5 mm vulcanized polyurethane (PU) to protect high-gloss wood finishes, coated aluminum, or plastic extrusions from scratching.\n\nBy synchronizing the ring rotation with conveyor linear feed rates, the equipment maintains an overlap ratio adjustable between 10% and 90%.\n\n<h2 id="specs">Economic orbital wrapper specifications<\/h2>\n\n| Technical Parameter | Specification \/ Tolerance |\n| :--- | :--- |\n| Max Bundle Outer Diameter (OD) | 50–200 mm (diagonal envelope clearance) |\n| Bundle Length Range | Minimum 1,500 mm (shorter profiles require custom roller pitch) |\n| Infeed Conveyor Length | 1,000 mm (motorized, PU-sleeved rollers) |\n| Outfeed Conveyor Length | 1,000 mm (motorized, PU-sleeved rollers) |\n| Conveyor Linear Speed | 4–15 m\/min (infinitely variable via VFD) |\n| Ring Rotational Speed | 20–100 r\/min (infinitely variable via VFD) |\n| Film Overlap Ratio | 10%–90% (programmable via ring\/conveyor speed ratio) |\n| Installed Power | 1.5 kW, AC 380 V, 3-Phase, 50\/60 Hz |\n| Packaging Consumables | LLDPE stretch film (17–35 µm), PE banding tape, woven HDPE |\n\n<h2 id="example">Worked example: will a rectangular bundle fit, and how fast to run<\/h2>\n\nConsider a production batch of kiln-dried timber battens assembled into a bundle 140 mm wide (W), 120 mm high (H), and 2,400 mm long (L). We specify a standard 120 mm film roll width on a 50 mm core.\n\n### 1. Geometric Fit and Clearance Verification\nThe bundle must traverse the rotating ring without encroaching on the rotating film carriage envelope or side rollers. The limiting constraint is the maximum cross-sectional diagonal (D_diag), not the individual width or height:\n\n`D_diag = √(W² + H²) = √(140² + 120²) = √(19,600 + 14,400) = √34,000 ≈ 184.4 mm`\n\nWith the maximum throat clearance of 200 mm, a 184.4 mm diagonal leaves 15.6 mm of total diametral clearance (approx. 7.8 mm per side). This envelope fits within allowable running tolerances, provided the profile bundle remains aligned via the guide plates. Conversely, a 160 mm × 140 mm bundle yields a diagonal of 212.6 mm, exceeding machine limits and risking collision with the orbital mechanism.\n\n### 2. Kinematic Overlap and Conveyor Speed\nThe linear pitch (P) advanced per ring rotation dictates the overlap ratio (OL):\n\n`P = Film_Width × (1 - OL)`\n\nAt a target 50% overlap using 120 mm film:\n`P = 120 mm × (1 - 0.50) = 60 mm\/rev = 0.06 m\/rev`\n\nTo maintain this overlap at the maximum ring speed of 100 r\/min:\n`Conveyor Speed = 100 r\/min × 0.06 m\/rev = 6.0 m\/min`\n\nBecause the conveyor operating range is 4 to 15 m\/min, 6.0 m\/min sits comfortably inside the VFD operating window. If the conveyor is run at its minimum stable threshold of 4.0 m\/min, the ring must rotate at:\n\n`Ring Speed = 4.0 m\/min ÷ 0.06 m\/rev = 66.7 r\/min`\n\n| Overlap Ratio | Linear Advance per Ring Turn | Required Conveyor Speed at 100 r\/min Ring Speed | Feasibility Status |\n| :--- | :--- | :--- | :--- |\n| **30%** | 84 mm (0.084 m) | 8.4 m\/min | Fully feasible (mid VFD range) |\n| **50%** | 60 mm (0.060 m) | 6.0 m\/min | Ideal operational point |\n| **70%** | 36 mm (0.036 m) | 3.6 m\/min | Exceeds lower drive limit (ring must throttle down) |\n\n*Note: Achieving 70% overlap requires running the ring at 100 r\/min while driving the conveyor below its rated 4.0 m\/min baseline, which can induce motor overheating unless auxiliary fan cooling or alternative gear ratios are deployed. For standard gearboxes, a 40% to 60% overlap represents the optimal kinematic window.*\n\n### 3. Cycle Time and Film Consumption\nAt a conveyor feed rate of 6 m\/min, the 2,400 mm (2.4 m) bundle clears the active wrapping zone in:\n\n`Wrapping Time = 2.4 m ÷ 6.0 m\/min = 0.4 min = 24 seconds`\n\nTotal ring revolutions over the bundle span:\n`Total Revolutions = 24 s × (100 r\/min ÷ 60 s) = 40 revolutions`\n\nThe cross-sectional perimeter is:\n`Perimeter = 2 × (140 mm + 120 mm) = 520 mm (0.52 m)`\n\nTheoretical single-layer film consumption along the span:\n`Film Consumed = 40 turns × 0.52 m = 20.8 m`\n\nAllowing for 3 manual reinforced turns at the leading edge and 3 turns at the trailing edge, total active film usage equals approximately 23.9 m per bundle (excluding carriage pre-stretch ratios). Total operator-paced floor-to-floor cycle time averages 40 to 50 seconds per bundle, including positioning and manual cutting.\n\n<h2 id="when-to-step-up">When to step up to the S300<\/h2>\n\nWhile the economic wrapper delivers superior value for modest batch runs, specific application constraints necessitate stepping up to the FHOPE S300 semi-automatic platform:\n\n- **Larger Diagonal Profiles:** The S300 accommodates bundle diameters up to 300 mm (handling up to 220 mm × 200 mm cross sections) and profiles down to 1,000 mm in length.\n- **Automated Pneumatic Cut & Clamp:** The S300 integrates an automated pneumatic scissor cutter and film clamp, eliminating the manual blade cut and freeing the operator to prepare the next bundle during the cycle.\n- **Overhead Pneumatic Stabilization:** Incorporates vertical pneumatically actuated top-press rollers and lateral side-guide rollers to prevent lightweight bundles from twisting, lifting, or fanning out under high-speed wrapping centrifugal force.\n- **PLC & HMI Automation:** Siemens\/Delta PLC with full-color touch screen stores wrap programs, enabling automatic edge reinforcing wraps and digital conveyor-ring synchronization.\n\n<h2 id="selection-checklist">Selection checklist: what to send us<\/h2>\n\nTo ensure exact gearbox ratio calculation and carriage clearance, prepare the following specifications for review:\n\n1. **Bundle Dimensions:** Minimum and maximum cross-sectional width, height, or solid outer diameter (OD).\n2. **Length Parameters:** Minimum and maximum individual profile length.\n3. **Mass Distribution:** Weight per linear meter and maximum total bundle weight.\n4. **Packaging Substrate:** Stretch film specifications (roll width, outer diameter, core ID, gauge in µm) or alternative media (PE\/HDPE strip).\n5. **Throughput Target:** Required bundles per hour or target shift output.\n6. **Electrical Infrastructure:** Line voltage, frequency, and phasing (e.g., 380 V 50 Hz, 480 V 60 Hz).\n\n<h2 id="safety">Safety and EN 415-10<\/h2>\n\nThe machine is engineered in strict compliance with **EN 415-10** (Safety of Packaging Machines: General Requirements) and verified via **ISO 12100:2010** risk assessment procedures:\n\n- **Orbital Hazard Zonal Enclosure:** The high-speed rotating ring and film carriage assembly are protected by heavy-duty sheet steel outer cowlings and fixed perimeter mechanical guard tunnels to eliminate nip points during orbital rotation.\n- **In-Running Roller Protection:** Gaps between the motorized PU rollers and frame chassis comply with ISO 13857 reach-distance safety limits, mitigating finger-entanglement hazards.\n- **Safety Interlocks & Emergency Stops:** Integrated dual-channel emergency stop buttons (E-stops) and a safety foot pedal comply with EN ISO 13849-1 (Category 3 \/ PL d). Ring power is de-energized instantaneously via regenerative braking resistor circuits if an E-stop is tripped.\n- **Safe Manual Guidance Protocol:** Operators must keep hands positioned outside the fixed safety tunnel periphery at all times while the foot pedal is engaged and the ring is in motion.\n\n<h2 id="engineering-faq">Engineering FAQ<\/h2>\n\n**Q: Can a single line operator sustain full-capacity production on this unit?**\nA: Yes. The layout is optimized for single-operator execution. The worker loads the infeed, initiates ring rotation via the foot switch, and performs the manual cut at the outfeed exit without traversing around the frame.\n\n**Q: Will the polyurethane conveyor rollers mark soft timber or architectural coatings?**\nA: No. Rollers are clad in high-grade 85 Shore A vulcanized polyurethane (PU). This non-marking elastomeric contact surface prevents abrasive damage to pre-finished timber, PVCu extrusions, and anodized aluminum profiles.\n\n**Q: Can this wrapper apply non-stretch barrier films such as HDPE or VCI paper?**\nA: Yes. The orbital carriage features an adjustable friction core spindle capable of running standard LLDPE film, micro-perforated PE, anti-corrosion VCI film, or reinforced woven HDPE tape without mechanical modification.\n\n**Q: Which global safety certifications are supplied with the equipment?**\nA: Export machines comply with EU Machinery Directive 2006\/42\/EC, harmonized standard EN 415-10, and ISO 12100:2010. Electrical enclosures comply with EN 60204-1 standards with optional UL508A certified panels for North American compliance.\n\n<h2 id="next-step">Next step<\/h2>\n\n1. **Submit Application Data:** Send your cross-sectional bundle profiles, weight limits, and target shift volume to **info@fhopepack.com**.\n2. **Kinematic & Mechanical Review:** Our engineering team will return a customized proposal within 24 hours, verifying envelope clearance, overlap gearing, and cycle rate.\n3. **General Arrangement Drawing:** We supply a 2D\/3D footprint layout detailing roller centerline heights, conveyor lengths, and electrical drop requirements for your workshop integration.\n\n<h2 id="related-reading">Related reading<\/h2>\n\n- [Economic Horizontal Orbital Stretch Wrapper Overview](https:\/\/www.fhopepack.com\/Semiauto-horizontal-wrapper\/semi-auto-orbital-wrapper.html)\n- [Semi-Auto Orbital Wrapping Machine S300 Specification](https:\/\/www.fhopepack.com\/Semiauto-horizontal-wrapper\/Semiauto-orbital-wrapping-machine-S300.html)\n- [Industrial Horizontal Profile Wrapping Solutions](https:\/\/www.fhopepack.com\/videos\/semiauto-stretch-orbital-wrapping-machine\/)\n- [FHOPE Heavy-Duty Orbital Packaging Systems](https:\/\/www.fhopepack.com\/videos\/fhope-semi-auto-orbital-wrapper\/)\n\n<h2 id="sources">Sources<\/h2>\n\n- FHOPEPACK Engineering Technical Documentation: Economic Horizontal Orbital Wrapper Platform Data Sheet\n- FHOPE Semi-Automatic S300 Horizontal Wrapping Specifications\n- Packaging Machinery Safety Verification: EN 415-10:2014 & ISO 12100:2010 Assessment Guidelines\n- Machinery Safety: EN 60204-1:2018 (Safety of Machinery - Electrical Equipment of Machines)\n\n<p><strong>Last reviewed:<\/strong> 2026-10-17<\/p><\/code><\/pre>\n