{"id":1351,"date":"2018-07-27T07:14:49","date_gmt":"2018-07-27T07:14:49","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=1351"},"modified":"2026-10-27T08:13:48","modified_gmt":"2026-10-27T08:13:48","slug":"auto-pallet-strapping-machine-packaging-machine-2","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/auto-pallet-strapping-machine-packaging-machine-2\/","title":{"rendered":"Automatic Pallet Strapping &#038; Rotary Arm Wrapping Systems: Heavy-Load Packaging Engineering Guide"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nHeavy, dense pallet loads\u2014such as concrete masonry units, refractory bricks, and heavy bagged minerals\u2014require a dual-stage stabilization system: high-tension vertical strapping to anchor the cargo directly to the pallet skids, followed by continuous pre-stretch wrapping to seal against moisture and resist transit shear forces.\nThe automated packaging cell highlighted here coordinates heavy-duty infeed roller conveyors, automated strapping integration, and an overhead rotary arm stretch wrapper equipped with an automatic pneumatic clamp-and-cut tail treatment system. This design eliminates manual handling, secures loads up to 2,000 kg, and maintains continuous 24\/7 end-of-line throughput.<\/p>\n<\/blockquote>\n<hr \/>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#video\">What the video shows: Integrated line kinematics<\/a><\/li>\n<li><a href=\"#how-it-works\">How the pallet strapping and wrapping cycle works<\/a><\/li>\n<li><a href=\"#strap\">Strap consumption and yield per pallet<\/a><\/li>\n<li><a href=\"#when\">When to strap as well as wrap: Engineering justification<\/a><\/li>\n<li><a href=\"#safety\">Controls, interlocks, and CE machinery safety<\/a><\/li>\n<li><a href=\"#selection-checklist\">Selection checklist for an automatic pallet strapping line<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step\">Next step: Request engineering layout &amp; specification review<\/a><\/li>\n<li><a href=\"#related-reading\">Related reading<\/a><\/li>\n<li><a href=\"#sources\">Sources &amp; reference standards<\/a><\/li>\n<\/ul>\n<h2 id=\"video\">What the video shows: Integrated line kinematics<\/h2>\n<p>The production sequence captures an automated, in-line pallet containment sequence for high-density stacked blocks inside an interlocked safety enclosure:<\/p>\n<ol>\n<li><strong>Payload Infeed &amp; Conveyor Centering<\/strong>: A reinforced polymer pallet laden with heavy blockwork enters via a heavy-duty powered roller conveyor and halts at the zero-datum station.<\/li>\n<li><strong>Pre-Strapped Stability<\/strong>: The block stack enters having already received two longitudinal high-tension PET bands, which rigidly bind the layered blocks through the fork entry voids of the pallet base.<\/li>\n<li><strong>Rotary Arm Pre-Stretch Wrapping<\/strong>: Rather than rotating the fragile or heavy stack (which risks centrifugal load shifting on conventional turntables), a counterbalanced yellow overhead rotary arm revolves around the stationary pallet at speeds up to 20\u201325 RPM. The carriage applies power-pre-stretched film (stretched between 200% and 300%) under closed-loop load-cell tension control.<\/li>\n<li><strong>Pneumatic Clamp, Cut, and Wipe Execution<\/strong>: At the end of the wrap cycle, an automated side-mounted pneumatic assembly extends. A mechanical gripping jaw holds the film web, a solid-state thermal wire severs the film, and an integrated trailing brush\/pad wipes the film tail firmly against the pallet side, ensuring no loose tail unravels during conveyor transfer or automated storage and retrieval systems (ASRS) intake.<\/li>\n<\/ol>\n<h2 id=\"how-it-works\">How the pallet strapping and wrapping cycle works<\/h2>\n<p>Combining strapping with rotary arm wrapping resolves both vertical shear failure and horizontal moisture penetration. The automated sequence runs as follows:<\/p>\n<table>\n<thead>\n<tr>\n<th>Process Step<\/th>\n<th>Mechanism &amp; Motion<\/th>\n<th>Engineering Function<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>1. Infeed &amp; Positioning<\/strong><\/td>\n<td>Powered chain\/roller conveyor; photo-eye array stops payload at target datum (\u00b110 mm tolerance).<\/td>\n<td>Prevents shock loads and verifies payload clearance envelope before packaging begins.<\/td>\n<\/tr>\n<tr>\n<td><strong>2. Primary Vertical Strapping<\/strong><\/td>\n<td>Sword-type strapping head indexes through pallet fork voids; feeds, tensions, and friction-welds PET\/PP bands.<\/td>\n<td>Generates 1,500\u20132,500 N vertical clamping force, locking masonry units directly to the structural pallet base.<\/td>\n<\/tr>\n<tr>\n<td><strong>3. Conveyance to Wrapper<\/strong><\/td>\n<td>Downstream transfer section advances unit load directly into the rotary arm wrapper zone.<\/td>\n<td>Eliminates interim forklift transit, maintaining structural stack integrity.<\/td>\n<\/tr>\n<tr>\n<td><strong>4. Overhead Arm Rotation<\/strong><\/td>\n<td>Balanced structural mast revolves horizontally around the static pallet while the carriage traverses vertically.<\/td>\n<td>Delivers multi-layer containment force without subjecting the heavy or unstable stack to centrifugal forces.<\/td>\n<\/tr>\n<tr>\n<td><strong>5. Automatic Clamp &amp; Cut<\/strong><\/td>\n<td>Pneumatic cylinder drives gripper arm to capture film web; heated impulse wire severs film; silicone wipe pad seals tail.<\/td>\n<td>Fully automates film completion; zero operator intervention required inside the active safety perimeter.<\/td>\n<\/tr>\n<tr>\n<td><strong>6. Discharge<\/strong><\/td>\n<td>Motorized conveyor transfers secured pallet to pick-up buffer or downstream automated warehouse.<\/td>\n<td>Clear permissive signal transmitted to factory PLC via standard Ethernet\/IP or PROFINET interface.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Strapping directly on the flow line eliminates dedicated forklift transfer stages between primary securing and weatherproofing. For plants seeking high-capacity wrapping integration, explore our <a href=\"https:\/\/www.fhopepack.com\/videos\/fully-automatic-pallet-wrapping-machinery-line\/\">fully automatic pallet wrapping machinery line<\/a>.<\/p>\n<h2 id=\"strap\">Strap consumption and yield per pallet<\/h2>\n<p>To calculate accurate strap consumption per pallet cycle, account for perimeter geometry, seal overlap, and feeder track accumulator waste.<\/p>\n<h3>Engineering Sizing Example<\/h3>\n<p>For a standard industrial pallet handling refractory bricks:<\/p>\n<ul>\n<li>Pallet dimension: 1,000 mm (W) \u00d7 1,200 mm (L)<\/li>\n<li>Stack height (including pallet structure): 1,800 mm (H)<\/li>\n<\/ul>\n<table>\n<thead>\n<tr>\n<th>Calculation Parameter<\/th>\n<th>Formula \/ Input<\/th>\n<th>Value<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Load Width (W)<\/strong><\/td>\n<td>Cross-section transverse width<\/td>\n<td>1,000 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Combined Height (H)<\/strong><\/td>\n<td>Pallet deck + product stack<\/td>\n<td>1,800 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Single Band Perimeter<\/strong><\/td>\n<td>2 \u00d7 (W + H)<\/td>\n<td>5,600 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Seal Overlap &amp; Joint Allowance<\/strong><\/td>\n<td>Friction weld take-up + chute offset<\/td>\n<td>150 mm<\/td>\n<\/tr>\n<tr>\n<td><strong>Gross Length per Band<\/strong><\/td>\n<td>Perimeter + Joint Allowance<\/td>\n<td>5,750 mm (5.75 m)<\/td>\n<\/tr>\n<tr>\n<td><strong>Bands per Pallet<\/strong><\/td>\n<td>2 vertical parallel straps<\/td>\n<td>2<\/td>\n<\/tr>\n<tr>\n<td><strong>Total Strap Required per Pallet<\/strong><\/td>\n<td>2 \u00d7 5.75 m<\/td>\n<td><strong>11.50 m<\/strong><\/td>\n<\/tr>\n<tr>\n<td><strong>Coil Yield (PET 16 \u00d7 0.8 mm, 1,500 m coil)<\/strong><\/td>\n<td>1,500 m \/ 11.5 m<\/td>\n<td><strong>~130 pallets \/ coil<\/strong><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: Always specify high-tensile polyester (PET) strapping with an elongation recovery rate \u2265 70% for dense, settling masonry blocks rather than polypropylene (PP) to maintain residual tension over extended transit periods.<\/em><\/p>\n<h2 id=\"when\">When to strap as well as wrap: Engineering justification<\/h2>\n<p>Stretch film provides exceptional horizontal containment, dust resistance, and rain shielding, but stretch film alone cannot deliver vertical tensile retention through open pallet runner gaps.<\/p>\n<table>\n<thead>\n<tr>\n<th>Payload Dynamic \/ Category<\/th>\n<th>Failure Risk (Film Only)<\/th>\n<th>Engineering Benefit of Dual Packaging (Strap + Wrap)<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Concrete Blocks &amp; Clay Bricks<\/strong><\/td>\n<td>Interlayer sliding; separation of top layers from wood skids during forklift tilting.<\/td>\n<td>High-tension vertical bands anchor the foundation layers to the pallet runners; film holds loose chipping.<\/td>\n<\/tr>\n<tr>\n<td><strong>Long-Haul Road &amp; Rail Freight<\/strong><\/td>\n<td>Sustained vibration and emergency braking cause high G-force lateral shift.<\/td>\n<td>Straps absorb primary longitudinal momentum; elastic film maintains containment memory.<\/td>\n<\/tr>\n<tr>\n<td><strong>Top-Heavy, Tall Stacks (&gt;1.6 m)<\/strong><\/td>\n<td>Columnar buckling and shifting of upper tiers during conveyor transfers.<\/td>\n<td>Straps compress columns into a solid structural prism; film shields edges against corner crushing.<\/td>\n<\/tr>\n<tr>\n<td><strong>High-Density Irregular Loads<\/strong><\/td>\n<td>Sharp masonry corners rupture stretch film under point tension.<\/td>\n<td>Rigid plastic or steel strapping takes initial structural load; multi-layer film seals punctured zones.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>For lightweight, uniform distribution center cartons, a stand-alone stretch wrapping approach is typically sufficient. See our <a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-pallet-stretch-wrapping-machine-with-film-cutter\/\">automatic pallet stretch wrapping machine with film cutter<\/a> for standard cartoned SKUs.<\/p>\n<h2 id=\"safety\">Controls, interlocks, and CE machinery safety<\/h2>\n<p>Integrated packaging cells combining motorized conveyors, high-speed rotary arms (20+ RPM), and automated high-tension strap feeders fall under strict European Machinery Directive and OSHA guidelines.<\/p>\n<ul>\n<li><strong>Physical Perimeter Guarding<\/strong>: The entire mechanical zone is enclosed by 2,000 mm high steel mesh fencing finished in safety yellow (RAL 1021), installed at distances conforming to ISO 13857 reach-distance tables.<\/li>\n<li><strong>Access Interlocks<\/strong>: Access doors are equipped with dual-channel Category 4 \/ PLe safety interlock switches with trapped-key solenoid locking. Entry is prohibited until the rotary arm has come to a zero-speed safe standstill and the strapping head accumulator has discharged pneumatic pressure.<\/li>\n<li><strong>Infeed \/ Discharge Light Curtains<\/strong>: Muting light curtains differentiate between valid exiting pallet profiles and personnel intrusion, tripping instantaneous Safe Torque Off (STO) if violated by an unauthorized body.<\/li>\n<li><strong>Applicable Technical Standards<\/strong>:\n<ul>\n<li><strong>ISO 12100:2010<\/strong>: Basic concepts and general principles for risk assessment and risk reduction.<\/li>\n<li><strong>EN 415-6:2013<\/strong>: Safety requirements for pallet wrapping machines.<\/li>\n<li><strong>EN 415-10:2014<\/strong>: General safety requirements for integrated packaging machinery systems.<\/li>\n<\/ul><\/li>\n<\/ul>\n<h2 id=\"selection-checklist\">Selection checklist for an automatic pallet strapping line<\/h2>\n<p>Review these engineering variables before finalizing your equipment specification:<\/p>\n<ul>\n<li><strong>Pallet Profile<\/strong>: Footprint (L \u00d7 W), total height including runners (H), and runner clearance dimensions for strap sword insertion.<\/li>\n<li><strong>Maximum Mass &amp; Dynamic Stability<\/strong>: Peak unit weight (e.g., 500 kg to 2,000 kg) and center-of-gravity elevation.<\/li>\n<li><strong>Strapping Configuration<\/strong>: Number of parallel vertical bands (typically 2 or 4), cross-strapping requirement (turntable index needed?), and edge-protector applicator necessity.<\/li>\n<li><strong>Consumable Sizing<\/strong>: PET vs. PP strap material, strap width (9 mm, 12 mm, 15 mm, or 19 mm), and core inner diameter (typically 406 mm).<\/li>\n<li><strong>Line Speed &amp; Cycle Time<\/strong>: Target pallets per hour (PPH) required to match continuous furnace, kiln, or production line output.<\/li>\n<li><strong>Conveyor Geometry<\/strong>: Roller pitch, top-of-roller (TOR) elevation, drive chain specifications, and available floor space envelope.<\/li>\n<\/ul>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: Why strap a payload that is already slated for stretch wrapping?<\/strong>\nA: Strapping and stretch wrapping serve distinct mechanical roles. Strapping creates high vertical compressive anchoring force (typically 1,500\u20132,500 N per band), mechanically clamping the load to the pallet stringers so it cannot lift off during transit. Stretch film provides multi-axis dust and weatherproofing while locking adjacent tiers together horizontally to prevent shifting under braking.<\/p>\n<p><strong>Q: How much strap does a typical 1,000 mm \u00d7 1,200 mm pallet consume?<\/strong>\nA: For a 1,800 mm high load using two vertical straps, consumption is approximately 11.5 meters per pallet (accounting for the 5.6 m nominal path plus joint overlaps and feed margins). A standard 1,500 m coil yields roughly 130 pallets.<\/p>\n<p><strong>Q: Why choose an overhead rotary arm wrapper instead of a standard turntable wrapper for brick lines?<\/strong>\nA: Turntable wrappers rotate the entire load. Heavy, brittle, or stacked unbonded brick loads subjected to rotation can destabilize due to centrifugal acceleration. A rotary arm keeps the load completely stationary on the conveyor, spinning only the counterbalanced arm and film carriage around the load.<\/p>\n<p><strong>Q: What type of strap joint is used in these automatic packaging systems?<\/strong>\nA: Automated heavy-load pallet strapping machines typically utilize vibration friction welding (or high-efficiency thermal seal heads), providing a joint seal efficiency exceeding 80% to 85% of the nominal breaking strength of high-tensile polyester (PET).<\/p>\n<p><strong>Q: Can the automated line handle variable height pallet loads on the fly?<\/strong>\nA: Yes. An integrated retroreflective optical sensor on the wrapping carriage and strapping lance automatically detects top-of-load boundaries, allowing the machine to adjust strap take-up stroke and film carriage reversing points dynamically without manual recipe reprogramming.<\/p>\n<h2 id=\"next-step\">Next step: Request engineering layout &amp; specification review<\/h2>\n<p>We engineer turnkey pallet strapping and stretch wrapping automation tailored to your line footprint and loading profiles:<\/p>\n<ol>\n<li><strong>Submit Your Layout Parameters<\/strong>: Provide pallet dimensions, maximum load weights, line elevation, and target throughput (PPH) to our application team at <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Receive 3D System Layout &amp; Proposal (48 Hours)<\/strong>: We will issue an integration layout showing conveyor indexing, safety fencing boundaries, cycle timing diagrams, and exact consumable consumption rates.<\/li>\n<li><strong>Line Integration &amp; Acceptance<\/strong>: Our field engineering team coordinates line commissioning, PLC handshake integration, and on-site CE\/OSHA safety validation.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-Strapping-Machine\/\">Automatic Strapping Machines Portfolio<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/bottle-pallet-strapping-machine\/\">Video: Automatic Bottle &amp; Can Pallet Strapping Systems<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/horizontal-orbital-stretch-wrapper-for-pallet-strapping-and-wrapping\/\">Video: Horizontal Orbital Stretch Wrapper for Industrial Pallet Profiles<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources &amp; reference standards<\/h2>\n<ul>\n<li>Operational Analysis: FHOPE Machine Automation Engineering Team, technical review date: 2026-10-04<\/li>\n<li>Kinematics &amp; Consumption Model: FHOPE Packaging Systems Engineering Core Handbook<\/li>\n<li>International Safety Specifications: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Safety of Machinery<\/a><\/li>\n<li>Packaging Machinery Specifics: <a href=\"https:\/\/www.en-standard.eu\/csn-en-415-6-safety-of-packaging-machines-part-6-pallet-wrapping-machines\/\">EN 415-6:2013 Pallet Wrapping Machines<\/a> &amp; <a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 General Requirements<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-04<\/p>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/LyXe6x-KfHM\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>","protected":false},"excerpt":{"rendered":"<p>Executive summary Heavy, dense pallet loads\u2014such as concrete masonry units, refractory bricks, and heavy bagged minerals\u2014require a dual-stage stabilization system: high-tension vertical strapping to anchor the cargo directly to the pallet skids, followed by continuous [&hellip;]<\/p>","protected":false},"author":1,"featured_media":5800,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Automatic Pallet Strapping Machine on a Roller Conveyor Line","_seopress_titles_desc":"How our automatic pallet strapping machine centres a pallet on the roller conveyor, lowers its arm and bands the load, and how to estimate strap per 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