{"id":266,"date":"2018-04-19T01:51:08","date_gmt":"2018-04-19T01:51:08","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=266"},"modified":"2026-11-06T13:22:09","modified_gmt":"2026-11-06T13:22:09","slug":"automatic-bar-wrapping-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-bar-wrapping-machine\/","title":{"rendered":"Automatic Bar Wrapping Machine: Sizing, Weight Limits, and Orbital Spiral Packaging"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nAutomatic horizontal orbital bar wrapping machines spiral wrap continuous bundles of round, square, and hexagonal profiles as they pass through a high-speed rotating ring. An integrated pneumatic clamp-and-cut mechanism automatically secures, indexes, and severs stretch film at bundle transitions, enabling fully unattended inline finishing. Because structural metal alloys possess high volumetric mass density (~7,850 kg\/m\u00b3 for steel, ~2,700 kg\/m\u00b3 for aluminum), dynamic conveyor bearing ratings limit equipment payload long before bundle dimensions fill the ring aperture.8 kg<strong>; a standard 100 kg payload wrapper reaches its structural threshold with just <\/strong>6 bars**, regardless of residual ring clearance.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/0fa8nvL-YfU\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2>How the machine wraps a bar bundle<\/h2>\n<p>In automated bar mills, cold-drawing lines, and profile distribution centers, the horizontal orbital stretch wrapper integrates directly into powered roller handling lines. Metal bundles feed horizontally through the rotating ring axis, eliminating overhead crane staging or manual secondary strapping. The wrapping sequence follows four synchronized operations:<\/p>\n<ol>\n<li><strong>Infeed and Indexing:<\/strong> Powered V-groove or flat conveyor rollers transfer the rigid bundle into the wrapping station. Heavy-duty retro-reflective photocells detect the bundle front end to trigger wrapping cycles.<\/li>\n<li><strong>Orbital Spiral Wrapping:<\/strong> A balanced rotating ring guides the film carriage circumferentially around the workpiece while motorized conveyors control linear transit. This synchronized motion applies a continuous, tight helical protective layer.<\/li>\n<li><strong>Pneumatic Cut and Clamp:<\/strong> At the bundle tail end, a pneumatic scissor-blade mechanism severs the film web while an automated mechanical gripper secures the film tail for seamless introduction onto the next incoming package.<\/li>\n<li><strong>Outfeed Discharge:<\/strong> Motorized outfeed conveyors transfer the wrapped bundle to downstream staging racks, accumulation tables, or strapping equipment.<\/li>\n<\/ol>\n<p>Dual variable-frequency drives (VFD) regulate ring angular rotation and conveyor linear travel independently. Packaging film overlap is fully adjustable between 10% and 90% via the HMI operator interface, governed by the kinematic formula:<\/p>\n<p><code>Overlap % = [1 - (V_conveyor \/ (N_ring &times; W_film))] &times; 100%<\/code><\/p>\n<p>Where:<\/p>\n<ul>\n<li><code>V_conveyor<\/code> = Linear line speed (m\/min)<\/li>\n<li><code>N_ring<\/code> = Orbital ring rotation speed (r\/min)<\/li>\n<li><code>W_film<\/code> = Effective film web width (m)<\/li>\n<\/ul>\n<hr \/>\n<h2>Why weight decides the model<\/h2>\n<p>Selecting an orbital wrapper requires evaluating both geometric envelope (usable ring diameter) and dynamic structural payload (roller bearings, chassis deflection limits, and drive motors). For dense metal bundles, structural limits are reached well before exhausting the physical aperture.<\/p>\n<p>The nominal linear mass of solid round metal bars is calculated from material density and cross-sectional area:<\/p>\n<p><code>Linear mass (kg\/m) = &rho; &times; (&pi; \/ 4) &times; d&sup2;<\/code><\/p>\n<p>Where:<\/p>\n<ul>\n<li><code>&rho;<\/code> = Material density (Carbon\/Alloy Steel \u2248 7,850 kg\/m\u00b3; Aluminum Alloys \u2248 2,700 kg\/m\u00b3)<\/li>\n<li><code>d<\/code> = Bar diameter (m)<\/li>\n<\/ul>\n<p>Reference mass values for standard stock sizes:<\/p>\n<ul>\n<li><strong>\u00d820 mm solid steel bar:<\/strong> Cross-sectional area = 0.000314 m\u00b2; linear mass = <strong>2.47 kg\/m<\/strong>. A standard 6 m bar weighs <strong>14.8 kg<\/strong>.<\/li>\n<li><strong>\u00d812 mm solid steel bar:<\/strong> Cross-sectional area = 0.000113 m\u00b2; linear mass = <strong>0.89 kg\/m<\/strong>. A standard 6 m bar weighs <strong>5.3 kg<\/strong>.<\/li>\n<li><strong>\u00d820 mm solid aluminum bar:<\/strong> Cross-sectional area = 0.000314 m\u00b2; linear mass = <strong>0.85 kg\/m<\/strong>. A standard 6 m bar weighs <strong>5.1 kg<\/strong>.<\/li>\n<\/ul>\n<hr \/>\n<h2>Bars per bundle: Geometric sizing and payload verification<\/h2>\n<p>Determining how many bars fit into a stable bundle requires a two-step validation: cross-sectional geometric packing and total payload verification.<\/p>\n<p>[ Bar Diameter (d) ]\n\u2193\n[ Hexagonal Packing Approximation ] \u2192 Bundle OD \u2248 d \u00d7 [1 + \u221a3 \u00d7 (n_layers &#8211; 1)]\n\u2193\n[ Calculate Total Mass (m_total) ] \u2192 m_total = n_bars \u00d7 Unit Weight\n\u2193\n[ Payload Gate Check ] \u2192 Is m_total \u2264 100 kg (E300\/E400) or \u2264 200 kg (E600)?<\/p>\n<h3>1. Geometric Bar Count Solving<\/h3>\n<p>When round bars are stacked in a nested hexagonal configuration, bundle outer envelope diameter (<code>OD_bundle<\/code>) relates to the individual bar diameter (<code>d_bar<\/code>) and concentric stacking layers (<code>n_layers<\/code>):<\/p>\n<p><code>OD_bundle &asymp; d_bar &times; [1 + &radic;3 &times; (n_layers - 1)]<\/code><\/p>\n<p>For a tight cluster where individual bars <code>n<\/code> fit inside a target circular diameter:<\/p>\n<ul>\n<li>For <strong>\u00d820 mm bars<\/strong> inside a target 100 mm bundle envelope:\n<code>n &asymp; 4 to 5 bars<\/code> (A 4-bar diamond or 5-bar clustered geometry yields an outer boundary of ~60\u201385 mm).<\/li>\n<li>A 7-bar concentric hexagon (1 center + 6 outer) yields:\n<code>OD_bundle &asymp; 20 &times; (1 + 1.732 &times; 1) &asymp; 54.6 mm<\/code> envelope diameter.<\/li>\n<\/ul>\n<h3>2. Structural Mass Gate Check<\/h3>\n<p>Once the bar count <code>n<\/code> is established geometrically, total bundle mass (<code>m_total = n &times; unit weight<\/code>) determines machine compatibility:<\/p>\n<table>\n<thead>\n<tr>\n<th>Bar Diameter<\/th>\n<th>Unit Weight (6 m Steel)<\/th>\n<th>Max Count (100 kg Limit)<\/th>\n<th>Max Count (200 kg Limit)<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>\u00d812 mm<\/strong><\/td>\n<td>~5.3 kg<\/td>\n<td><strong>18 bars<\/strong> (~95.4 kg)<\/td>\n<td><strong>37 bars<\/strong> (~196.1 kg)<\/td>\n<\/tr>\n<tr>\n<td><strong>\u00d820 mm<\/strong><\/td>\n<td>~14.8 kg<\/td>\n<td><strong>6 bars<\/strong> (~88.8 kg)<\/td>\n<td><strong>13 bars<\/strong> (~192.4 kg)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>The &#8220;Heavy but Slim&#8221; Engineering Dilemma<\/h3>\n<p>Thirteen \u00d820 mm bars in a cluster weigh ~192.4 kg and need an <a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E600.html\">E600<\/a>, yet the cluster is only 80\u2013100 mm OD \u2014 far below the E600&#8217;s 200\u2013600 mm working envelope.<\/p>\n<p>This lower boundary is governed by tooling mechanics:<\/p>\n<ul>\n<li><strong>Cylinder Stroke Limits:<\/strong> Standard overhead vertical hold-down pneumatic cylinders bottom out before contacting bundles under 200 mm OD, leading to bundle shifting under rotational film tension.<\/li>\n<li><strong>Conveyor Bridge Gaps:<\/strong> The central gap between infeed and outfeed roller conveyors causes narrow, heavy bundles to sag under deadweight.<\/li>\n<\/ul>\n<p>To process slim, heavy profiles safely, our engineering designs incorporate extended-stroke hold-down cylinders and lagged intermediate bridge rollers across the ring throat, specified per project.<\/p>\n<hr \/>\n<h2>Model windows and cycle time estimation<\/h2>\n<p>Model selection follows unambiguous structural and dimensional boundaries:<\/p>\n<ol>\n<li><strong>E300 Threshold:<\/strong> Bundle OD \u2264 300 mm and total bundle weight \u2264 100 kg.<\/li>\n<li><strong>E400 Threshold:<\/strong> Bundle OD between 300 mm and 400 mm with total bundle weight \u2264 100 kg.<\/li>\n<li><strong>E600 Heavy-Duty Escalation:<\/strong> Mandatory whenever bundle weight exceeds 100 kg (rated to 200 kg) OR bundle OD exceeds 400 mm (rated to 600 mm).<\/li>\n<\/ol>\n<table>\n<thead>\n<tr>\n<th>Machine Model<\/th>\n<th>Bundle OD Envelope<\/th>\n<th>Dynamic Load Limit<\/th>\n<th>Workpiece Length<\/th>\n<th>Ring Speed<\/th>\n<th>Linear Wrapping Speed<\/th>\n<th>Installed Power<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong><a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E300.html\">E300<\/a><\/strong><\/td>\n<td>100\u2013300 mm<\/td>\n<td>15\u2013100 kg<\/td>\n<td>\u2265 1,000 mm<\/td>\n<td>20\u201390 r\/min<\/td>\n<td>5\u201315 m\/min<\/td>\n<td>~2.5 kW (380V 3ph 60Hz)<\/td>\n<\/tr>\n<tr>\n<td><strong><a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E400.html\">E400<\/a><\/strong><\/td>\n<td>100\u2013400 mm<\/td>\n<td>15\u2013100 kg<\/td>\n<td>\u2265 1,200 mm<\/td>\n<td>20\u201390 r\/min<\/td>\n<td>5\u201325 m\/min<\/td>\n<td>~2.5 kW<\/td>\n<\/tr>\n<tr>\n<td><strong><a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E600.html\">E600<\/a><\/strong><\/td>\n<td>200\u2013600 mm<\/td>\n<td>20\u2013200 kg<\/td>\n<td>\u2265 800 mm<\/td>\n<td>Adjustable<\/td>\n<td>Conveyor: 3\u201312 m\/min<\/td>\n<td>~4.5 kW (380V 3ph 50Hz)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Packaging Tact Time Calculation<\/h3>\n<p>Linear line speed (<code>v<\/code>) and bundle length (<code>L<\/code>) govern continuous packaging cycle time (<code>t<\/code>), estimated by:<\/p>\n<p><code>t = L \/ v<\/code><\/p>\n<p><em>(The formula assumes constant-speed wrapping; acceleration, deceleration and the clamp\/cut actions add time per cycle, so measure the actual cycle on the line before quoting a throughput figure.)<\/em><\/p>\n<ul>\n<li><strong>On the E300 (5\u201315 m\/min line speed):<\/strong> Wrapping a standard 6 m bar bundle takes <strong>24 to 72 seconds<\/strong>.<\/li>\n<li><strong>On the E400 (5\u201325 m\/min line speed):<\/strong> Wrapping a standard 6 m bar bundle takes <strong>14.4 to 72 seconds<\/strong>.<\/li>\n<li><strong>On the E600 (3\u201312 m\/min conveyor speed):<\/strong> Traversing a 6 m bundle takes <strong>30 to 120 seconds<\/strong>.<\/li>\n<\/ul>\n<hr \/>\n<h2>Unmanned film cut and feed<\/h2>\n<p>The automatic clamping, feeding, and cutting unit eliminates manual handling during active wrapping cycles:<\/p>\n<ul>\n<li><strong>Automated Clamping and Feeding:<\/strong> At cycle start, an internal pneumatic clamp positions the film tail into the ring path. Forward bundle travel traps the film web against the material, and the gripper releases automatically once helical tension stabilizes.<\/li>\n<li><strong>Precision Pneumatic Cut:<\/strong> Once the preset wrap count is completed at the trailing edge, a double-acting pneumatic cylinder drives an industrial serrated blade to sever the film web cleanly.<\/li>\n<li><strong>Home Position Indexing:<\/strong> A proximity sensor and motor dynamic brake lock the orbital ring at its precise zero-point datum after cycle completion, ensuring proper mechanical alignment for the next feed cycle.<\/li>\n<li><strong>System Monitoring:<\/strong> The integrated PLC tracks film breakage, roll exhaustion, pneumatic pressure drops, and photocell blockages, displaying system status on stack lights and the touchscreen HMI.<\/li>\n<\/ul>\n<hr \/>\n<h2>Utilities and safety<\/h2>\n<table>\n<thead>\n<tr>\n<th>Utility \/ Parameter<\/th>\n<th>E300 System<\/th>\n<th>E400 Multi-Material System<\/th>\n<th>E600 Heavy-Duty System<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Electrical Supply<\/strong><\/td>\n<td>380V, 3-Phase, 60 Hz (~2.5 kW)<\/td>\n<td>380V, 3-Phase, 50\/60 Hz (~2.5 kW)<\/td>\n<td>380V, 3-Phase, 50 Hz (~4.5 kW)<\/td>\n<\/tr>\n<tr>\n<td><strong>Compressed Air<\/strong><\/td>\n<td>0.5\u20130.8 MPa (5\u20138 kgf\/cm\u00b2), dry<\/td>\n<td>0.5\u20130.8 MPa (5\u20138 kgf\/cm\u00b2), dry<\/td>\n<td>0.5\u20130.8 MPa (5\u20138 kgf\/cm\u00b2), dry<\/td>\n<\/tr>\n<tr>\n<td><strong>Supported Packaging Media<\/strong><\/td>\n<td>PE film (OD 100\u2013200 mm, Width 100\u2013200 mm, ID 50 mm)<\/td>\n<td>PE, Paper, PP, Woven tape (OD 100\u2013200 mm, Width 100\u2013200 mm, ID 50\/76 mm)<\/td>\n<td>LLDPE, Paper, Woven tape (OD 100\u2013250 mm, Width 150\u2013300 mm, ID 50 mm)<\/td>\n<\/tr>\n<tr>\n<td><strong>Conveyor Bed Configuration<\/strong><\/td>\n<td>Infeed &amp; Outfeed: 2,000 mm each; Speed: 6\u201312 m\/min<\/td>\n<td>Infeed &amp; Outfeed: 2,000 mm each; Speed: 6\u201312 m\/min<\/td>\n<td>Infeed &amp; Outfeed: 2,000 \u00d7 800 mm; Speed: 3\u201312 m\/min<\/td>\n<\/tr>\n<tr>\n<td><strong>Machine Dimensions<\/strong><\/td>\n<td>Standard inline modular layout<\/td>\n<td>Standard inline modular layout<\/td>\n<td>Approx. L 5,200 \u00d7 W 1,800 \u00d7 H 1,800 mm<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Industrial Safety Compliance<\/h3>\n<ul>\n<li><strong>ISO 12100:2010:<\/strong> Comprehensive machinery safety risk assessment and hazard elimination.<\/li>\n<li><strong>EN 415-10:2014:<\/strong> Standardized safety requirements for automated packaging and wrapping machines.<\/li>\n<\/ul>\n<hr \/>\n<h2>Selection checklist<\/h2>\n<p>When specifying an orbital bar wrapping configuration, supply the following parameters:<\/p>\n<ul>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Material profile and grade (round bar, hex rod, square stock, hollow tube; steel or aluminum).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Individual bar dimensions: Cross-section \/ OD (mm), standard cut length (mm), and unit mass (kg).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Target bundle configuration: Total bar count per bundle and total bundle weight (kg).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Bundle envelope dimension: Measured minimum and maximum diagonal envelope (<code>OD_bundle<\/code>, mm).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Packaging medium: LLDPE film, VCI anti-corrosion film, crepe paper, or reinforced woven polypropylene.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Line speed requirement: Target bundles per hour and available upstream cycle time.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Integration mode: Standalone packaging cell with manual feeding vs fully automated inline roller integration.<\/li>\n<\/ul>\n<hr \/>\n<h2>Engineering FAQ<\/h2>\n<p><strong>Q: How do you calculate the weight of a solid 6 m, \u00d820 mm steel bar?<\/strong>\nA: Linear mass is calculated as <code>7,850 kg\/m&sup3; &times; [&pi; &times; (0.010 m)&sup2;] = 2.466 kg\/m<\/code>. Multiplying by 6 m yields <strong>14.80 kg<\/strong>.<\/p>\n<p><strong>Q: Why does a 100 kg rated wrapper only take 6 pieces of 6 m, \u00d820 mm steel bars?<\/strong>\nA: Each 6 m bar weighs 14.8 kg. Six bars total 88.8 kg, safely under the 100 kg frame rating. Adding a seventh bar brings total weight to 103.6 kg, exceeding conveyor bearings and structural drive design limits. Bundles of 7 to 13 bars require an <a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E600.html\">E600<\/a> system (up to 200 kg).<\/p>\n<p><strong>Q: Why cannot a standard E600 clamp an 80 mm OD steel bundle despite its 192 kg mass?<\/strong>\nA: Standard E600 tooling is optimized for 200\u2013600 mm OD profiles. On an 80 mm bundle, vertical hold-down pneumatic cylinders reach maximum stroke without applying adequate clamping force, allowing bundles to rotate under film tension. Sizing this application requires engineered long-stroke cylinders and center bridge rollers.<\/p>\n<hr \/>\n<h2>Next step<\/h2>\n<p>Our mechanical design group configures custom bar handling and orbital wrapping systems:<\/p>\n<ol>\n<li><strong>Submit Process Data:<\/strong> Send material profiles, bundle packing drawings, and plant layout drawings to our application engineering team.<\/li>\n<li><strong>Technical Quotation within 24\u201348 Hours:<\/strong> Receive a detailed proposal including ring sizing calculations, overlap kinematics, payload ratings, and dimensional footprints.<\/li>\n<li><strong>Engineering Integration Review:<\/strong> Confirm conveyor height matching, VFD synchronization, safety interlocking, and PLC handshakes.<\/li>\n<\/ol>\n<hr \/>\n<h2>Sources<\/h2>\n<ul>\n<li>Fhopepack product pages: <a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E300.html\">E300<\/a>, <a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E400.html\">E400<\/a>, <a href=\"https:\/\/www.fhopepack.com\/Horizontal-orbital-stretch-wrapper\/E600.html\">E600<\/a> horizontal orbital stretch wrappers.<\/li>\n<li>ISO 12100:2010 \u2014 Safety of machinery: general principles for design, risk assessment and risk reduction.<\/li>\n<li>EN 415-10:2014 \u2014 Safety of packaging machines: general requirements.<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-11-05<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary Automatic horizontal orbital bar wrapping machines spiral wrap continuous bundles of round, square, and hexagonal profiles as they pass through a high-speed rotating ring. An integrated pneumatic clamp-and-cut mechanism automatically secures, indexes, and [&hellip;]<\/p>","protected":false},"author":1,"featured_media":14715,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Automatic Bar Wrapping Machine: Sizing Steel Bar Bundles","_seopress_titles_desc":"How we size an automatic bar wrapping machine for steel bar bundles: weight per metre, bars per bundle, OD window, and unmanned film cut and 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