{"id":1714,"date":"2019-08-29T06:53:35","date_gmt":"2019-08-29T06:53:35","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=1714"},"modified":"2026-10-19T09:37:44","modified_gmt":"2026-10-19T09:37:44","slug":"robot-pallet-wrapping-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/robot-pallet-wrapping-machine\/","title":{"rendered":"Robot pallet wrapping machine"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong><\/p>\n<p>Our robot pallet wrapping machine is a battery-powered wrapper that drives around the load, so it wraps pallets where they stand: in the warehouse, at the loading bay or next to the production line. The operator steers it to the load with a tiller handle, starts the cycle, and the machine circles the load while the film carriage runs up and down the mast. Travel speed, mast height and battery are matched to your loads and confirmed at quote.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/fV6fP7aHmUQ\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<p>We build the machine on a black base with a steering tiller and an on-board battery, a black bumper skirt at the front, and a tall black mast. A red control box with a screen and an emergency stop sits on the mast, and the red film carriage carries the film roll up and down beside the white load.<\/p>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#parts\">Main parts and what they do<\/a><\/li>\n<li><a href=\"#operation\">How to run a wrap cycle<\/a><\/li>\n<li><a href=\"#programs\">Wrap programs<\/a><\/li>\n<li><a href=\"#mast-battery\">Mast height and battery planning<\/a><\/li>\n<li><a href=\"#daily-checks\">Daily checks<\/a><\/li>\n<li><a href=\"#selection-checklist\">Selection checklist<\/a><\/li>\n<li><a href=\"#safety\">Safety: EN 415-6 and ISO 12100<\/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<h2 id=\"parts\">Main parts and what they do<\/h2>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Part<\/th>\n<th style=\"text-align: left\">Function<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Base with drive wheels<\/td>\n<td style=\"text-align: left\">carries the machine around the load<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Steering tiller<\/td>\n<td style=\"text-align: left\">the operator drives the machine to the load and between loads<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">On-board battery<\/td>\n<td style=\"text-align: left\">powers the drive, the carriage and the controls, no cable to trail<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Front bumper skirt<\/td>\n<td style=\"text-align: left\">stops the machine if it touches an obstacle or a person<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Mast<\/td>\n<td style=\"text-align: left\">guides the film carriage from the pallet base to the top of the load<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Film carriage<\/td>\n<td style=\"text-align: left\">holds the film roll and controls film tension<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Control box with screen<\/td>\n<td style=\"text-align: left\">sets the wrap program; red mushroom emergency stop<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"operation\">How to run a wrap cycle<\/h2>\n<ol>\n<li>Steer the machine to a corner of the load with the tiller.<\/li>\n<li>Pull the film from the carriage and tie the tail to the pallet.<\/li>\n<li>Select the wrap program on the screen.<\/li>\n<li>Press start: the machine drives around the load, the carriage starts at the base and climbs. Robot wrappers usually keep their distance from the load with a feeler wheel running against the load face; the guidance and the free space needed around the load are confirmed at quote.<\/li>\n<li>At the end of the program the machine stops at its start point.<\/li>\n<li>Cut the film, press the tail onto the load and steer to the next pallet.<\/li>\n<\/ol>\n<p>The load is not lifted or moved, so the same machine serves several bays in one shift.<\/p>\n<h2 id=\"programs\">Wrap programs<\/h2>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Program<\/th>\n<th style=\"text-align: left\">Use<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Up only<\/td>\n<td style=\"text-align: left\">light, stable loads; fastest cycle<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Up and down<\/td>\n<td style=\"text-align: left\">standard loads; two layers of film<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Extra bottom turns<\/td>\n<td style=\"text-align: left\">locks the load to the pallet, typically 3 turns<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Extra top turns<\/td>\n<td style=\"text-align: left\">holds the top layer, typically 3 turns<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Re-wrap at a set height<\/td>\n<td style=\"text-align: left\">adds film where the load is weakest<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><strong>Example.<\/strong> A program with 3 bottom and 3 top turns adds 6 turns to every load. Set the film tension low for soft cartons and higher for heavy, square loads.<\/p>\n<p>Film on the load for an up-and-down program with a 250 mm pitch per turn, on two typical load sizes from robot wrapper enquiries:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Load (with 150 mm pallet)<\/th>\n<th style=\"text-align: left\">Perimeter<\/th>\n<th style=\"text-align: left\">Turns up and down<\/th>\n<th style=\"text-align: left\">Plus 6 extra turns<\/th>\n<th style=\"text-align: left\">Film on the load<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">1,200 \u00d7 1,200 \u00d7 1,500 mm, wrap height 1,650 mm<\/td>\n<td style=\"text-align: left\">4 \u00d7 1.2 = 4.8 m<\/td>\n<td style=\"text-align: left\">2 \u00d7 (1,650 \u00f7 250) = 13.2<\/td>\n<td style=\"text-align: left\">19.2 turns<\/td>\n<td style=\"text-align: left\">19.2 \u00d7 4.8 = 92 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">1,200 \u00d7 1,200 \u00d7 2,000 mm, wrap height 2,150 mm<\/td>\n<td style=\"text-align: left\">4.8 m<\/td>\n<td style=\"text-align: left\">2 \u00d7 (2,150 \u00f7 250) = 17.2<\/td>\n<td style=\"text-align: left\">23.2 turns<\/td>\n<td style=\"text-align: left\">23.2 \u00d7 4.8 = 111 m<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>The taller load uses about 20% more film and needs a mast that reaches 2,150 mm. These are stretched lengths on the load; the film drawn from the roll is shorter by the pre-stretch ratio of the carriage, which is confirmed at quote.<\/p>\n<h2 id=\"mast-battery\">Mast height and battery planning<\/h2>\n<p><strong>Mast.<\/strong> The top of the film band must pass over the top edge of the load. For a 1,500 mm load on a 150 mm pallet, the wrap must reach 1,500 + 150 = 1,650 mm. With a 500 mm film band, the carriage must lift the bottom of the roll to at least 1,650 \u2212 500 = 1,150 mm.<\/p>\n<p>Lift it a little higher so the top edge of the film rises above the load and folds over the top corners. The mast height is confirmed at quote for your tallest load.<\/p>\n<p><strong>Battery.<\/strong> We plan the battery by shift, not by load:<\/p>\n<p><strong>Loads per charge = usable battery energy \u00f7 energy per load.<\/strong><\/p>\n<p>Energy per load depends on load size, turns and floor. Tell us your largest load and loads per shift and we confirm the battery at quote. Charge the machine between shifts.<\/p>\n<h2 id=\"daily-checks\">Daily checks<\/h2>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Check<\/th>\n<th style=\"text-align: left\">Why<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Battery charge level<\/td>\n<td style=\"text-align: left\">enough charge for the whole shift<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Bumper skirt moves freely and stops the machine<\/td>\n<td style=\"text-align: left\">contact stop must work<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Emergency stop<\/td>\n<td style=\"text-align: left\">must stop all motion<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Wheels and floor path clean<\/td>\n<td style=\"text-align: left\">steady steering around the load<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Film carriage rollers clean<\/td>\n<td style=\"text-align: left\">even film tension<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"selection-checklist\">Selection checklist<\/h2>\n<ol>\n<li>Largest and smallest load, including pallet height.<\/li>\n<li>Loads per shift.<\/li>\n<li>Number of wrapping places.<\/li>\n<li>Floor condition and free space around the load.<\/li>\n<li>Wrap programs needed.<\/li>\n<li>Charging point and shift pattern.<\/li>\n<\/ol>\n<h2 id=\"safety\">Safety: EN 415-6 and ISO 12100<\/h2>\n<p>Pallet wrapping machines are covered by EN 415-6, with the risk assessment to ISO 12100:2010. A robot wrapper has no fence, so the bumper skirt and the emergency stop are the main guards.<\/p>\n<p>The bumper must cut the drive at once on contact. A flashing light and a buzzer during automatic travel warn people nearby; the fitted items are confirmed at quote. The operator keeps the area around the load clear. Mark the floor where loads are wrapped. CE documents are agreed per project.<\/p>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p>Q: Does the load need to be on a turntable?\nA: No. The machine drives around the load where it stands.<\/p>\n<p>Q: How is it moved between loads?\nA: The operator steers it with the tiller handle.<\/p>\n<p>Q: What stops it if it hits something?\nA: The bumper skirt at the front stops the drive on contact, and the red emergency stop on the mast stops all motion.<\/p>\n<p>Q: How tall a load can it wrap?\nA: The mast height is matched to your tallest load, including the pallet, and confirmed at quote.<\/p>\n<p>Q: How many loads per charge?\nA: It depends on load size and program; we confirm it at quote from your shift data.<\/p>\n<h2 id=\"next-step\">Next step<\/h2>\n<ol>\n<li><strong>Send your load sizes, pallet height and loads per shift<\/strong> to info@fhopepack.com.<\/li>\n<li><strong>We set<\/strong> the mast height, battery and wrap programs.<\/li>\n<li><strong>We reply within 24 hours<\/strong> with a proposal and quotation.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/robot-pallet-wrapper\/\">Robot pallet wrapper<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Semi-auto-pallet-wrapping-machine\/Pallet-wrapping-machine-A200.html\">A200 turntable pallet wrapping machine (product)<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/rotary-arm-pallet-wrapping-machine-2\/\">Rotary arm pallet wrapping machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/fhope-r100-rotary-arm-pallet-wrapper-with-film-cutter\/\">R100 rotary arm pallet wrapper with film cutter<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>FHOPE project correspondence on robot wrapper enquiries<\/li>\n<li>EN 415-6; ISO 12100:2010<\/li>\n<li>Our robot pallet wrapping machine shown above<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 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