{"id":2066,"date":"2020-03-03T04:10:30","date_gmt":"2020-03-03T04:10:30","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=2066"},"modified":"2026-10-27T14:03:11","modified_gmt":"2026-10-27T14:03:11","slug":"combined-machine-for-six-sides-wrapping","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/combined-machine-for-six-sides-wrapping\/","title":{"rendered":"Fully Automated Six-Side Board Stretch Wrapping Line: Engineering Guide &#038; Kinematic Process"},"content":{"rendered":"<blockquote>\n<p><strong>Executive Summary<\/strong>\nConventional horizontal orbital wrappers enclose only the four longitudinal faces of a board stack, leaving both ends exposed to moisture penetration, edge crushing, and airborne contaminants during storage and overseas transit. A true six-side wrapping system integrates longitudinal multi-axis wrapping with dedicated end-encapsulation stations along an automated powered roller conveyor. This technical guide outlines the operational kinematics, protective advantages, engineering safety standards (ISO 12100 \/ EN 415-10), and an exact mathematical model for calculating stretch film consumption per stack under specified overlap and pre-stretch ratios.<\/p>\n<\/blockquote>\n<hr \/>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/hFaWQd7c9mQ?rel=0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<h2>Table of Contents<\/h2>\n<ul>\n<li><a href=\"#what-the-video-shows\">What the Video Shows: Station Architecture &amp; Process Flow<\/a><\/li>\n<li><a href=\"#how-it-works\">How Six-Side Wrapping Works: Kinematic Sequence<\/a><\/li>\n<li><a href=\"#film\">Planning Film Consumption per Stack: Mathematical Model<\/a><\/li>\n<li><a href=\"#why\">Why Close All Six Sides: Industrial Vulnerability Matrix<\/a><\/li>\n<li><a href=\"#safety\">Controls and Safety Engineering<\/a><\/li>\n<li><a href=\"#selection-checklist\">Selection Checklist for a Six-Side Wrapping Line<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step\">Next Step: 48-Hour Engineering Proposal<\/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=\"what-the-video-shows\">What the Video Shows: Station Architecture &amp; Process Flow<\/h2>\n<p>The operational footage documents a complete industrial packaging sequence engineered for rigid board stacks, such as gypsum wallboards, PIR\/PUR sandwich panels, and decorative architectural sheets:<\/p>\n<ol>\n<li><strong>Infeed &amp; Alignment<\/strong>: The incoming stack advances along heavy-duty motorized zinc-plated roller conveyors. Side-guiding rollers align the stack along the conveyor centerline to prevent lateral skewing.<\/li>\n<li><strong>Longitudinal Core Wrapping<\/strong>: The stack transitions across a robust intermediate transfer bed. A motorized rotating ring or rotating carriage applies high-tension LLDPE stretch film continuously around the top, bottom, and lateral surfaces.<\/li>\n<li><strong>Perpendicular End-Sealing Station<\/strong>: Downstream, the stack enters a perimeter-guarded vertical wrapping tower. This unit rotates or deploys transversal film carriage strokes across the leading and trailing ends, completely encapsulating both open stack faces.<\/li>\n<li><strong>Outfeed Discharge<\/strong>: The fully sealed, weather-tight package clears the wrapping cell through powered exit roller tracks, ready for automatic strapping, forklift takeaway, or crane lifting.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"how-it-works\">How Six-Side Wrapping Works: Kinematic Sequence<\/h2>\n<p>Achieving a hermetic, puncture-resistant barrier on heavy panel stacks requires a synchronized multi-station mechanical architecture.<\/p>\n<pre><code>[Infeed Conveyor] \u2500\u2500&gt; [Longitudinal Orbital Wrap] \u2500\u2500&gt; [Transverse End-Wrap Tower] \u2500\u2500&gt; [Outfeed Discharge]\n  (Auto-Centering)      (Top \/ Bottom \/ Two Sides)       (Leading \/ Trailing Ends)       (Forklift Takeaway)<\/code><\/pre>\n<table>\n<thead>\n<tr>\n<th>Station<\/th>\n<th>Mechanism &amp; Kinematics<\/th>\n<th>Functional Surface Enclosure<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Infeed Section<\/strong><\/td>\n<td>Motorized conveyor with mechanical centering guides<\/td>\n<td>Aligns and stabilizes the bare product bundle<\/td>\n<\/tr>\n<tr>\n<td><strong>Long-Side Wrapper<\/strong><\/td>\n<td>High-speed orbital rotary ring \/ horizontal drive<\/td>\n<td>Continuous spiraling wrap across top, bottom, and long sides<\/td>\n<\/tr>\n<tr>\n<td><strong>End-Wrap Tower<\/strong><\/td>\n<td>Vertical gantry tower with rotating \/ indexing film dispenser<\/td>\n<td>Overlaps and seals the front and rear stack ends<\/td>\n<\/tr>\n<tr>\n<td><strong>Outfeed Section<\/strong><\/td>\n<td>Powered accumulation roller conveyor<\/td>\n<td>Delivers the stabilized six-side encapsulated package<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>By combining orbital rotary motion with perpendicular end-face containment, the line eliminates unprotected gaps, ensuring zero raw substrate exposure during marine shipping and outdoor yard storage.<\/p>\n<hr \/>\n<h2 id=\"film\">Planning Film Consumption per Stack: Mathematical Model<\/h2>\n<p>Stretch film consumption is determined by stack geometry, film roll parameters, target overlap ratio, and power pre-stretch carriage performance.<\/p>\n<h3>1. Calculation Parameters<\/h3>\n<ul>\n<li>Stack Length (<code>L<\/code>): 2,400 mm (2.40 m)<\/li>\n<li>Stack Width (<code>W<\/code>): 1,200 mm (1.20 m)<\/li>\n<li>Stack Height (<code>H<\/code>): 600 mm (0.60 m)<\/li>\n<li>Nominal Film Width (<code>W_film<\/code>): 500 mm (0.50 m)<\/li>\n<li>Target Film Overlap Ratio (<code>Overlap<\/code>): 50% (0.50)<\/li>\n<li>Power Pre-stretch Ratio: 250% (1 meter of raw film extends to 3.50 meters on product)<\/li>\n<\/ul>\n<h3>2. Formulas<\/h3>\n<ul>\n<li>Cross-sectional Perimeter:\n<code>Perimeter = 2 &times; (W + H) = 2 &times; (1,200 + 600) = 3,600 mm (3.60 m)<\/code><\/li>\n<li>Effective Linear Advance per Ring Revolution:\n<code>Advance = W_film &times; (1 - Overlap) = 500 &times; (1 - 0.50) = 250 mm (0.25 m)<\/code><\/li>\n<li>Longitudinal Wrapping Revolutions (<code>N_long<\/code>):\n<code>N_long = (L &divide; Advance) + Reinforcement_Wraps = (2,400 &divide; 250) + 2 = 11.6 &asymp; 12 turns<\/code><\/li>\n<li>Applied Film Length on Long Sides:\n<code>Film_long = N_long &times; Perimeter = 12 &times; 3.60 m = 43.2 m<\/code><\/li>\n<li>End-Face Area (Both Ends):\n<code>Area_ends = 2 &times; (W &times; H) = 2 &times; (1.20 m &times; 0.60 m) = 1.44 m&sup2;<\/code><\/li>\n<li>Applied Film Length on Ends (Multi-layer cross-wrap equivalent):\n<code>Film_ends &asymp; 14.4 m<\/code><\/li>\n<li>Total Film Length on Stack:\n<code>Film_total = Film_long + Film_ends = 43.2 m + 14.4 m = 57.6 m<\/code><\/li>\n<li><strong>Raw Master Roll Consumption (at 250% pre-stretch)<\/strong>:\n<code>Master_Roll_Length = Film_total &divide; 3.50 = 57.6 &divide; 3.50 &asymp; 16.45 m<\/code><\/li>\n<\/ul>\n<pre><code>+---------------------------------------------------------------------------------+\n| Stack: 2400 &times; 1200 &times; 600 mm | Perimeter: 3.6 m | Overlap: 50%                   |\n| Total Applied Film: 57.6 m  | With 250% Pre-stretch -&gt; Raw Film Used: ~16.5 m   |\n+---------------------------------------------------------------------------------+<\/code><\/pre>\n<hr \/>\n<h2 id=\"why\">Why Close All Six Sides: Industrial Vulnerability Matrix<\/h2>\n<p>Standard 4-side horizontal orbital wrapping leaves the cut ends vulnerable. In heavy manufacturing, these exposed ends frequently cause product rejection.<\/p>\n<table>\n<thead>\n<tr>\n<th>Transit &amp; Storage Risk Factor<\/th>\n<th>Four-Side Longitudinal Wrap<\/th>\n<th>Six-Side Complete Wrap<\/th>\n<th>Operational Impact<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Rain &amp; Standing Moisture<\/strong><\/td>\n<td>Open ends admit water through core capillaries<\/td>\n<td>Hermetically sealed by cross-directional film wraps<\/td>\n<td>Prevents gypsum softening, mold growth, and panel swelling<\/td>\n<\/tr>\n<tr>\n<td><strong>Container Rain &amp; Condensation<\/strong><\/td>\n<td>Top condensation drips into open package ends<\/td>\n<td>Sloped, sealed film envelope deflects falling droplets<\/td>\n<td>Eliminates overseas export corrosion and carton delamination<\/td>\n<\/tr>\n<tr>\n<td><strong>Dust &amp; Particulate Soil<\/strong><\/td>\n<td>Industrial dust settles between open board layers<\/td>\n<td>Total enclosure maintains clean, ready-to-install surfaces<\/td>\n<td>Eliminates customer cleaning claims at construction sites<\/td>\n<\/tr>\n<tr>\n<td><strong>Forklift &amp; Transit Abrasion<\/strong><\/td>\n<td>Direct impacts damage brittle panel edges and corners<\/td>\n<td>Multi-layer film tension cushions ends and perimeter corners<\/td>\n<td>Lowers transit edge-crush claims by up to 90%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<hr \/>\n<h2 id=\"safety\">Controls and Safety Engineering<\/h2>\n<p>High-inertia rotary rings and vertical lifting carriages present pinch and impact hazards. Full compliance with international machinery directives is mandatory.<\/p>\n<ul>\n<li><strong>Safety Standards Scope<\/strong>: Machinery design conforms to <strong>ISO 12100:2010<\/strong> (Safety of machinery \u2014 General principles for design \u2014 Risk assessment and risk reduction) and <strong>EN 415-10:2014<\/strong> (Safety of packaging machines \u2014 General requirements).<\/li>\n<li><strong>Perimeter Guarding<\/strong>: Heavy-duty steel wire mesh fencing with yellow warning structural posts surrounds the entire motion envelope.<\/li>\n<li><strong>Access Interlocks<\/strong>: Access doors are fitted with Category 4 \/ PL d safety interlock switches (EN ISO 13849-1) that trigger immediate safe-torque-off (STO) before personnel can reach hazardous areas.<\/li>\n<li><strong>Optoelectronic Detection<\/strong>: Infeed and outfeed zones feature Class 4 safety light curtains with muting logic to distinguish incoming board stacks from unauthorized human entry.<\/li>\n<li><strong>Control Architecture<\/strong>: Central Siemens S7-1500 or Allen-Bradley GuardLogix safety PLC handles multi-axis VFD synchronization, dynamic tension regulation, and pneumatic failsafe braking.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"selection-checklist\">Selection Checklist for a Six-Side Wrapping Line<\/h2>\n<p>Use this engineering checklist during initial project scoping:<\/p>\n<ul>\n<li><strong>Product Dimensions<\/strong>: Minimum and maximum bundle dimensions (Length \u00d7 Width \u00d7 Height, mm).<\/li>\n<li><strong>Total Bundle Weight<\/strong>: Minimum and maximum weight per stack (kg) for conveyor roller loading calculations.<\/li>\n<li><strong>Required Throughput<\/strong>: Target packaging cycle time (bundles per hour).<\/li>\n<li><strong>Substrate Sensitivity<\/strong>: Surface finish requirements (e.g., polished metal surfaces requiring pe-coated foam edge protection).<\/li>\n<li><strong>Environmental Exposure<\/strong>: Expected outdoor storage duration (UV-stabilized stretch film selection).<\/li>\n<li><strong>Upstream \/ Downstream Integration<\/strong>: Conveyor top-of-roller (TOR) elevation, automatic labeling, palletizer, or strapping integration.<\/li>\n<li><strong>Footprint Constraints<\/strong>: Available factory floor space (Length \u00d7 Width \u00d7 Clearance Height).<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: What is the fundamental difference between an orbital stretch wrapper and a six-side wrapper?<\/strong>\nA: An orbital wrapper rotates film rolls around a horizontal pass-through axis, covering only the top, bottom, and two sides (four faces). A six-side wrapper combines orbital wrapping with an integrated or downstream end-wrapping mechanism that seals the leading and trailing ends, fully enclosing the package.<\/p>\n<p><strong>Q: Can the end-wrapping station keep pace with high-speed board production?<\/strong>\nA: Yes. The line utilizes buffered conveyor staging. While the orbital wrapper completes longitudinal coverage, the end-wrapping unit simultaneously wraps the previous stack&#8217;s ends, maintaining an output of 30 to 60 stacks per hour depending on panel dimensions.<\/p>\n<p><strong>Q: Does six-side wrapping require a separate top sheet applicator?<\/strong>\nA: In most applications, the cross-overlap of pre-stretched film across the top and ends provides sufficient water shedding. For extreme outdoor storage, an optional top-sheet PE film dispenser can be integrated ahead of the orbital station to provide a continuous waterproof cap.<\/p>\n<p><strong>Q: How does the system prevent thin, flexible boards from bowing under film tension?<\/strong>\nA: The film carriage features closed-loop electronic tension control with load-cell feedback. Vertical pneumatic stabilization rollers hold the stack flat during wrapping, preventing bow deformation and shifting between panel layers.<\/p>\n<hr \/>\n<h2 id=\"next-step\">Next Step: 48-Hour Engineering Proposal<\/h2>\n<p>To automate your board stack packaging line:<\/p>\n<ol>\n<li><strong>Submit Product Data<\/strong>: Send bundle dimensions (L \u00d7 W \u00d7 H), weight ranges, and required hourly throughput to our applications team at <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Receive 3D Layout &amp; Film Plan<\/strong>: Our engineering department will deliver a customized conveyor layout drawing (DWG\/PDF) and a calculated film consumption analysis within 48 hours.<\/li>\n<li><strong>Engineering Site Alignment<\/strong>: Schedule a technical teleconference or factory survey with our chief project engineer to confirm line integration and safety interlocking.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"related-reading\">Related Reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/video-of-the-gypsum-packaging-line\/\">Gypsum Board Automatic Packaging Solutions &amp; Orbital Wrappers<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/orbital-stretch-wrapper.html\">Horizontal Orbital Stretch Wrapping Equipment Overview<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/E300-horizontal-stretch-wrapper.html\">E-Series High-Speed Horizontal Stretch Wrapper Specifications<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>Machine Technical Specifications: FHOPE Packaging Machinery Engineering Documentation, 2026-10-04.<\/li>\n<li>Kinematic &amp; Film Formula Reference: FHOPE Standard Packaging Calculation Models (LLDPE 250% Pre-stretch).<\/li>\n<li>Safety Directives &amp; International Standards:\n<ul>\n<li><a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Machinery Safety Guidelines<\/a><\/li>\n<li><a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 Packaging Machine Safety Standards<\/a><\/li>\n<\/ul><\/li>\n<\/ul>\n<p><strong>Last Reviewed:<\/strong> 2026-10-04 | <strong>Engineering Discipline:<\/strong> Industrial Packaging Automation &amp; Machine Safety System Design<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive Summary Conventional horizontal orbital wrappers enclose only the four longitudinal faces of a board stack, leaving both ends exposed to moisture penetration, edge crushing, and airborne contaminants during storage and overseas transit. A true [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2067,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Combined Six-Side Wrapping Machine for Board Stacks","_seopress_titles_desc":"How our combined machine wraps board stacks on all six sides, with a ring wrap round the length and end wrapping in a guarded tower, and how to plan 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