{"id":151,"date":"2018-04-17T09:15:29","date_gmt":"2018-04-17T09:15:29","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=151"},"modified":"2026-11-06T09:54:11","modified_gmt":"2026-11-06T09:54:11","slug":"automatic-bar-wrapping-machine-and-small-orbital-wrapper","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-bar-wrapping-machine-and-small-orbital-wrapper\/","title":{"rendered":"Bar Wrapping Machine and Small Orbital Wrapper: S200 Data and Film Pitch"},"content":{"rendered":"<blockquote>\n<p><strong>Executive Summary:<\/strong> A bar wrapping machine secures longitudinal products by rotating an orbital film carriage in a vertical plane around a horizontally advancing, non-rotating workpiece. The FHOPE S200 small orbital wrapper processes precision single bars and light rigid bundles with a cross-section of 10\u2013200 mm (diagonal envelope), minimum length of 300 mm, and unit weights from 10 to 100 kg. Powered by a 2.1 kW drive system, it operates at variable ring speeds of 20\u2013120 r\/min and conveying speeds of 4\u201312 m\/min. For fully automated packaging lines handling pieces exceeding 1000 mm, the E200 platform introduces automatic film clamping and cutting. Both platforms govern spiral film distribution through strict kinematics: <code>Pitch (mm) = Conveying Velocity (mm\/min) \/ Ring Speed (r\/min)<\/code>.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" src=\"https:\/\/www.youtube.com\/embed\/J4aj2NQkTwo\" width=\"854\" height=\"480\" frameborder=\"0\" allowfullscreen=\"allowfullscreen\"><\/iframe>\n<hr \/>\n<h2>Table of Contents<\/h2>\n<ul>\n<li><a href=\"#two-machines\">Two machines, one decision<\/a><\/li>\n<li><a href=\"#bar-does-not-rotate\">Why the bar never rotates<\/a><\/li>\n<li><a href=\"#film-pitch\">Film pitch: the three-number method<\/a><\/li>\n<li><a href=\"#pitch-boundary\">Pitch bounded by film width<\/a><\/li>\n<li><a href=\"#length-and-conveyors\">Length and conveyor bridging<\/a><\/li>\n<li><a href=\"#centring-and-tension\">Centring and tension<\/a><\/li>\n<li><a href=\"#film-materials\">Film materials<\/a><\/li>\n<li><a href=\"#controls\">Controls<\/a><\/li>\n<li><a href=\"#safety\">Safety<\/a><\/li>\n<li><a href=\"#selection-checklist\">Checklist<\/a><\/li>\n<li><a href=\"#engineering-faq\">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<hr \/>\n<h2 id=\"two-machines\">Two machines, one decision<\/h2>\n<p>Horizontal orbital stretch wrapping is determined by three physical parameters: cross-sectional envelope (outer diagonal), workpiece length, and bundle weight. Within FHOPE&#8217;s orbital wrapping portfolio\u2014comprising 5 semi-automatic, 10 fully automatic, and 14 custom-engineered models\u2014precision bars and industrial rods are routed primarily through two standard platforms, with oversized profiles directed to custom structural frames.<\/p>\n<p>The <strong>S200 Semi-Automatic Horizontal Wrapper<\/strong> serves short-to-medium runs, sensitive profiles, and short bars. The <strong>E200 Automatic Horizontal Stretch Wrapper<\/strong> is engineered for high-throughput automated lines requiring integrated pneumatic clamping, automatic hot-blade or mechanical shear film cutting, and continuous conveyor cycling.<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Engineering Parameter<\/th>\n<th style=\"text-align: left\">S200 Semi-Automatic Orbital Wrapper<\/th>\n<th style=\"text-align: left\">E200 Automatic Horizontal Stretch Wrapper<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Target Workpiece Section (OD \/ Diagonal)<\/strong><\/td>\n<td style=\"text-align: left\">10\u2013200 mm<\/td>\n<td style=\"text-align: left\">50\u2013200 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Minimum Workpiece Length<\/strong><\/td>\n<td style=\"text-align: left\">300 mm<\/td>\n<td style=\"text-align: left\">1000 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Payload Capacity Range<\/strong><\/td>\n<td style=\"text-align: left\">10\u2013100 kg<\/td>\n<td style=\"text-align: left\">8\u2013100 kg<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Infeed \/ Outfeed Powered Conveyors<\/strong><\/td>\n<td style=\"text-align: left\">2000 mm + 2000 mm (Standard motorized)<\/td>\n<td style=\"text-align: left\">2000 mm + 2000 mm (Standard motorized)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Conveying Linear Speed<\/strong><\/td>\n<td style=\"text-align: left\">4\u201312 m\/min<\/td>\n<td style=\"text-align: left\">6\u201312 m\/min<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Ring Rotation \/ Drive Speed<\/strong><\/td>\n<td style=\"text-align: left\">20\u2013120 r\/min<\/td>\n<td style=\"text-align: left\">5\u201315 m\/min (Carriage surface speed)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Installed Drive Power<\/strong><\/td>\n<td style=\"text-align: left\">Approximately 2.1 kW<\/td>\n<td style=\"text-align: left\">Approximately 2.5 kW<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Electrical Utility Supply<\/strong><\/td>\n<td style=\"text-align: left\">380V, 3-Phase, 60Hz<\/td>\n<td style=\"text-align: left\">380V, 3-Phase, 60Hz<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Roll Dimensional Envelope<\/strong><\/td>\n<td style=\"text-align: left\">Width: 120\u2013200 mm; OD: 150\u2013200 mm; Core ID: 50 mm<\/td>\n<td style=\"text-align: left\">Width: 100\u2013200 mm; OD: 100\u2013200 mm; Core ID: 50 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Automation Level<\/strong><\/td>\n<td style=\"text-align: left\">Semi-automatic (Manual film tie\/tuck, push-button\/pedal run)<\/td>\n<td style=\"text-align: left\">Fully automatic (Optical auto-start, clamp, cut, wipe)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: For bundles exceeding 200 mm in outer diameter or 100 kg total mass, applications transition to heavy-duty custom rod wrapping platforms accommodating cross-sections up to 500\u20132000 mm and weights up to 4000 kg.<\/em><\/p>\n<hr \/>\n<h2 id=\"bar-does-not-rotate\">Why the bar never rotates<\/h2>\n<p>In orbital packaging, the bar travels strictly along a horizontal axis while the orbital ring revolves around it in the vertical plane. Rotating long or slender stock along its own longitudinal axis creates severe mechanical complications:<\/p>\n<ol>\n<li><strong>Elimination of Dynamic Whipping<\/strong>: Rotating a slender 6000 mm steel rod or extruded profile at wrapping speeds causes centrifugal deflection, dynamic whipping, and equipment vibration. Pure linear feed preserves dynamic stability.<\/li>\n<li><strong>Surface Defect Prevention<\/strong>: Polished steel, ground rod stock, and architectural anodized aluminum suffer scuffing, roller burnish, and tool marks if forced to rotate within stationary clamps or spinning driving beds.<\/li>\n<li><strong>Consistent Containment Force<\/strong>: Maintaining the product on a fixed centerline allows the pre-stretch carriage to apply continuous, uniform hoop tension across the profile&#8217;s perimeter without eccentric pull.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"film-pitch\">Film pitch: the three-number method<\/h2>\n<p>Pitch is how far the conveyor advances during one ring revolution: conveying speed in m\/min times 1,000, divided by ring speed in r\/min. Overlap is then 1 minus pitch over film width.<\/p>\n<p>Three numbers set the machine:<\/p>\n<ol>\n<li><strong>Overlap first:<\/strong> 50% overlap on 200 mm film means a target pitch of 200 \u00d7 0.5 = 100 mm.<\/li>\n<li><strong>Then the ratio:<\/strong> a 100 mm pitch is a 10:1 ratio between linear advance and ring speed. On the S200, 4 m\/min needs 40 r\/min, 6 m\/min needs 60 r\/min, and the 12 m\/min maximum uses the full 120 r\/min.<\/li>\n<li><strong>Then transit:<\/strong> pass-through in seconds is length in metres \u00f7 speed in m\/min \u00d7 60 \u2014 a 6 m bundle at 12 m\/min crosses in 30 s.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"pitch-boundary\">Pitch bounded by film width<\/h2>\n<p>Pitch must never exceed the active film width. Push past it \u2014 210 mm pitch on a 200 mm roll \u2014 and overlap goes negative: successive loops no longer touch, leaving a helical gap of bare metal exposed to moisture, cutting oil and scuffing, with no mechanical connection between turns.<\/p>\n<p>Practical floors: at least 30% overlap for rigid bundle containment, and at least 50% where dust and transit protection matter.<\/p>\n<hr \/>\n<h2 id=\"length-and-conveyors\">Length and conveyor bridging<\/h2>\n<p>A bar has to bridge the throat between the infeed and outfeed beds across the ring plane, so minimum length is the throat gap plus twice the support margin.<\/p>\n<ul>\n<li><strong>S200, over 300 mm:<\/strong> close-coupled cantilevered rollers keep the throat to a minimum, so short components transfer down to 300 mm without transfer plates.<\/li>\n<li><strong>E200, over 1,000 mm:<\/strong> clamping jaws, photocells and a motorised cutter need clearance across the wrapping centreline, so the minimum stable length is 1,000 mm.<\/li>\n<li><strong>Conveyors:<\/strong> both platforms come with 2,000 mm powered infeed and outfeed beds; 6 m bundles use modular idler tables to stop cantilever sag.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"centring-and-tension\">Centring and tension<\/h2>\n<p>The throat diameter must exceed the bundle diagonal plus twice a dynamic clearance of at least 50 mm from the spinning carriage.<\/p>\n<ul>\n<li><strong>Hold-down:<\/strong> thin stock of 10\u201320 mm has little torsional rigidity, and film pull can lift a light bar off the rollers; adjustable pneumatic hold-down wheels apply regulated downforce to keep it seated.<\/li>\n<li><strong>Tension:<\/strong> a spring-loaded friction plate at the spindle sets film tension, so layers stay tight without necking a hollow profile.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"film-materials\">Film materials<\/h2>\n<p>The S200 and E200 run standard packaging films matched to spindle dimensions:<\/p>\n<ul>\n<li><strong>S200:<\/strong> LLDPE stretch film, 120\u2013200 mm wide, roll OD 150\u2013200 mm, 50 mm core.<\/li>\n<li><strong>E200:<\/strong> LLDPE or PE film, 100\u2013200 mm wide, roll OD 100\u2013200 mm, 50 mm core.<\/li>\n<li><strong>Corrosion duty:<\/strong> raw steel or yard-stored rod is usually wrapped with VCI paper or heavy woven HDPE rather than plain stretch film.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"controls\">Controls<\/h2>\n<p>A PLC with a touchscreen runs the machine:<\/p>\n<ul>\n<li><strong>Tracking:<\/strong> retroreflective photocells find the leading edge and start the ramps; the trailing edge starts deceleration and the tail reinforcement turns.<\/li>\n<li><strong>Drives:<\/strong> independent VFDs run the conveyor gearmotors and the ring friction wheels on coordinated S-curves, so nothing slips.<\/li>\n<li><strong>Integration:<\/strong> dry contacts and Ethernet let the cabinet interlock with upstream saws or downstream stackers.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"safety\">Safety<\/h2>\n<p>A ring carries pinch and entanglement risk, so the envelope has to be closed:<\/p>\n<ul>\n<li><strong>Guarding:<\/strong> welded mesh encloses the ring perimeter and keeps operator reach out of the rotation envelope.<\/li>\n<li><strong>Design basis:<\/strong> risk assessment to ISO 12100, the EN 415-6 wrapping-machinery framework, and electrical construction to EN 60204-1, with dual-channel safety relays on the interlocked doors. The required performance level for each guard follows the site risk assessment.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"selection-checklist\">Checklist<\/h2>\n<ul>\n<li><strong>Section:<\/strong> outside diameter or diagonal inside 10\u2013200 mm, otherwise a custom ring.<\/li>\n<li><strong>Length:<\/strong> under 1,000 mm and down to 300 mm goes to the S200; automated runs over 1,000 mm go to the E200.<\/li>\n<li><strong>Weight:<\/strong> pack mass within the 8\u2013100 kg platform limit.<\/li>\n<li><strong>Throughput:<\/strong> conveyor 4\u201312 m\/min matched to ring 20\u2013120 r\/min.<\/li>\n<li><strong>Film:<\/strong> LLDPE on a 50 mm core, 120\u2013200 mm wide (S200) or 100\u2013200 mm (E200).<\/li>\n<li><strong>Finish:<\/strong> coated rollers for anodised, ground or bare steel surfaces.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"engineering-faq\">FAQ<\/h2>\n<p><strong>Q: Can the S200 wrap bars under 300 mm?<\/strong>\nA: Not on the standard bed \u2014 shorter parts drop into the throat between the powered rollers, so they need auxiliary transfer plates.<\/p>\n<p><strong>Q: Why the 20\u2013120 r\/min range?<\/strong>\nA: It holds a constant pitch at any conveyor speed: 4 m\/min needs 40 r\/min for a 100 mm pitch, and 12 m\/min needs the full 120 r\/min.<\/p>\n<p><strong>Q: What makes thin aluminium bow during wrapping?<\/strong>\nA: Too much spindle brake tension with no hold-down pressure. Set hold-down at 0.2\u20130.4 MPa and ease the friction nut until the bundle is held without deflecting the walls.<\/p>\n<p><strong>Q: When does the E200 make sense?<\/strong>\nA: When parts consistently exceed 1,000 mm and the volume justifies a fully automatic cycle instead of manual clamping, cutting and transfer.<\/p>\n<hr \/>\n<h2 id=\"next-step\">Next step<\/h2>\n<p>Contact FHOPE&#8217;s engineering division to validate cycle calculations or discuss custom machinery:<\/p>\n<ol>\n<li><strong>Specification Review<\/strong>: Send profile dimensions, length ranges, bundle weights, and target line speeds to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>48-Hour Technical Proposal<\/strong>: Receive a complete technical evaluation, including conveyor speed synchronization tables, overlap pitch derivations, and layout drawings.<\/li>\n<li><strong>Factory Acceptance Testing (FAT)<\/strong>: Ship sample profiles to our engineering center for trial wrapping, film yield testing, and high-speed motion validation prior to line commissioning.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-wrapper\/S200-semiauto-horizontal-orbital-wrapper.html\">Semi-Auto Horizontal Orbital Wrapper S200 Technical Specifications<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-wrapper\/E200-horizontal-stretch-wrapper.html\">Automatic Horizontal Stretch Wrapper E200 Overview<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/orbital-stretch-wrapper\/\">Complete Orbital Stretch Wrapper Product Family<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Semiauto-horizontal-wrapper\/\">Semi-Auto Horizontal Wrapper Line Overview<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/\">Automatic Horizontal Stretch Wrapping Machines<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/\">Custom Heavy-Duty Rod Wrapping Systems<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>ISO Standard: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Safety of Machinery \u2014 General Principles for Design<\/a><\/li>\n<li>European Harmonized Standard: <a href=\"https:\/\/standards.iteh.ai\/catalog\/standards\/cen\/b00b7310-8bdf-4cb2-87fc-5b72e505872c\/en-415-6-2013\">EN 415-6:2013 Safety of Packaging Machines \u2014 Pallet and Product Wrapping Machines<\/a><\/li>\n<li>Electrical Standard: <a href=\"https:\/\/webstore.iec.ch\/publication\/26217\">EN 60204-1 Safety of Machinery \u2014 Electrical Equipment of Machines<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-11-05<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive Summary: A bar wrapping machine secures longitudinal products by rotating an orbital film carriage in a vertical plane around a horizontally advancing, non-rotating workpiece. The FHOPE S200 small orbital wrapper processes precision single bars [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2252,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Bar Wrapping Machine and Small Orbital Wrapper: Specs","_seopress_titles_desc":"Choose between our small orbital wrapper and rod wrapping machine for bars: OD, length and weight ranges, ring and conveyor speed, and how to set film 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