{"id":3215,"date":"2020-07-01T06:54:37","date_gmt":"2020-07-01T06:54:37","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=3215"},"modified":"2026-10-27T14:44:42","modified_gmt":"2026-10-27T14:44:42","slug":"master-horizontal-wrapping-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/master-horizontal-wrapping-machine\/","title":{"rendered":"Master Horizontal Orbital Wrapping Machine: Engineering Specifications and Kinematics"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong><\/p>\n<p>A master horizontal wrapping machine is an automated orbital stretch wrapper engineered for continuous packaging of long-format bundles, including composite panels, aluminum extrusions, timber packs, and insulated sandwich sheets. The system utilizes a precision-guided circular rotary ring that orbits stretch film rolls around products advancing through the ring aperture via motorized infeed and outfeed roller conveyors. By pairing an overhead continuous top-film dispenser with circumferential helical wrapping, the machine creates a five-sided weatherproof barrier that binds loose profiles into a unified, rigid pack. Designed for load lengths from 1,000 mm to 6,000 mm and payloads up to 2,000 kg, the equipment operates at feed rates of 2\u20139 m\/min. The following technical report outlines machine kinematics, overlap calculations, structural parameters, and safety requirements under EN 415-10.<\/p>\n<\/blockquote>\n<hr \/>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#machine\">How the horizontal wrapper works<\/a><\/li>\n<li><a href=\"#overlap\">Ring speed, conveyor speed and overlap<\/a><\/li>\n<li><a href=\"#specs\">Wrapper data<\/a><\/li>\n<li><a href=\"#example\">Worked example: a 6 m bundle<\/a><\/li>\n<li><a href=\"#options\">Film, belt or paper, and full coverage<\/a><\/li>\n<li><a href=\"#selection-checklist\">Selection checklist<\/a><\/li>\n<li><a href=\"#safety\">Safety: EN 415-10 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<hr \/>\n<h2 id=\"machine\">How the horizontal wrapper works<\/h2>\n<p>The master horizontal wrapper integrates an automated infeed conveyor, an overhead uncoiling station for top protective film, a heavy-duty orbital rotation ring, and a synchronized outfeed discharge section.<\/p>\n<ol>\n<li><strong>Infeed and Top Sheet Application:<\/strong> Long-format bundles enter via the heavy-duty motorized infeed roller bed. Before entering the orbital chamber, an overhead uncoiling carriage pulls a continuous sheet of virgin polyethylene (PE) film or protective bubble lining, draping it over the upper surface of the bundle across its entire width.<\/li>\n<li><strong>Pneumatic Stabilization:<\/strong> Vertically acting pneumatic hold-down press rollers lower onto the product bundle. These rollers apply calibrated downward clamping force (adjustable between 200 N and 1,500 N) to stabilize loose layers, preventing profile shuffling, edge skidding, or rotational dislocation caused by film tension forces.<\/li>\n<li><strong>Orbital Helical Wrapping:<\/strong> The structural cast-aluminum or welded steel orbital ring rotates inside a fully enclosed, interlocked yellow perimeter housing. Driven by an inverter-duty gear motor via high-friction drive belts, the ring carries one or two film carriage assemblies. As the conveyor feeds the product horizontally through the center of the ring, the film orbits around the cross-section, laying down a continuous helical wrap.<\/li>\n<li><strong>Discharge and Containment:<\/strong> The orbital spiral overlaps the edges of the top sheet, locking it tightly against the bundle flanks and bottom face. The finished bundle exits onto the outfeed conveyor as a structurally unified, moisture-resistant, and dust-sealed package ready for forklift lifting and transport.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"overlap\">Ring speed, conveyor speed and overlap<\/h2>\n<p>Film overlap percentage determines the weatherproofing integrity, puncture resistance, and structural holding force of the finished bundle. Overlap is governed by the kinematic relationship between conveyor linear velocity, ring rotational speed, and effective film web width.<\/p>\n<p>The horizontal linear pitch or bundle advance per complete ring rotation (<code>a<\/code>, in mm) is calculated as:<\/p>\n<p><code>a = (v &times; 1000) &divide; n<\/code><\/p>\n<p>Where:<\/p>\n<ul>\n<li><code>a<\/code> = Linear forward travel per ring revolution (mm\/rev)<\/li>\n<li><code>v<\/code> = Conveyor linear feed rate (m\/min)<\/li>\n<li><code>n<\/code> = Ring rotational speed (r\/min)<\/li>\n<li><code>1000<\/code> = Conversion factor from meters to millimeters<\/li>\n<\/ul>\n<p>Given an effective film roll width <code>W<\/code> (mm), the theoretical film overlap ratio (<code>Overlap<\/code>, expressed as a percentage) is:<\/p>\n<p><code>Overlap = [1 &minus; (a &divide; W)] &times; 100%<\/code><\/p>\n<p><em>Kinematic Relationship:<\/em><\/p>\n<ul>\n<li>Increasing conveyor speed <code>v<\/code> or reducing ring speed <code>n<\/code> increases the pitch <code>a<\/code>, decreasing overlap percentage and minimizing consumable consumption.<\/li>\n<li>Decreasing conveyor speed <code>v<\/code> or elevating ring speed <code>n<\/code> reduces pitch <code>a<\/code>, raising the overlap percentage to produce multi-layer containment for heavy or sharp-edged profiles.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"specs\">Wrapper data<\/h2>\n<p>The standard structural specifications for the master horizontal orbital wrapping machine are listed in the engineering matrix below:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Machine Parameter<\/th>\n<th style=\"text-align: left\">Standard Specification<\/th>\n<th style=\"text-align: left\">Engineering Notes \/ Tolerances<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Cross-Sectional Envelope (W \u00d7 H)<\/strong><\/td>\n<td style=\"text-align: left\">800\u20131,500 mm \u00d7 800\u20131,500 mm<\/td>\n<td style=\"text-align: left\">Diagonal must clear ring inner diameter by \u2265 150 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Bundle Process Length<\/strong><\/td>\n<td style=\"text-align: left\">1,000\u20136,000 mm<\/td>\n<td style=\"text-align: left\">Custom outfeed extensions available for lengths &gt; 6 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Bundle Load Capacity<\/strong><\/td>\n<td style=\"text-align: left\">100\u20132,000 kg<\/td>\n<td style=\"text-align: left\">Distributed load rating on conveyor roller bed<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Orbital Ring Rotational Speed<\/strong><\/td>\n<td style=\"text-align: left\">30\u201360 r\/min<\/td>\n<td style=\"text-align: left\">VFD frequency control with soft start\/stop profiling<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Line Wrapping Throughput<\/strong><\/td>\n<td style=\"text-align: left\">2\u20139 m\/min<\/td>\n<td style=\"text-align: left\">Synchronized to downstream production speeds<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Overlap Range<\/strong><\/td>\n<td style=\"text-align: left\">20% to 80%<\/td>\n<td style=\"text-align: left\">Operator adjustable via HMI recipe management<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Applicable Consumable Materials<\/strong><\/td>\n<td style=\"text-align: left\">LLDPE Stretch Film, Knit Mesh Belt, VCI Paper<\/td>\n<td style=\"text-align: left\">Core ID 76 mm (3 in); Roll OD \u2264 250 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Web Width<\/strong><\/td>\n<td style=\"text-align: left\">200\u2013500 mm<\/td>\n<td style=\"text-align: left\">Typically 250 mm or 300 mm standard<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Total Connected Electrical Load<\/strong><\/td>\n<td style=\"text-align: left\">6.5 kW<\/td>\n<td style=\"text-align: left\">AC 380 V \u00b1 10%, 3-Phase, 50\/60 Hz<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Pneumatic Supply Pressure<\/strong><\/td>\n<td style=\"text-align: left\">0.5\u20130.7 MPa<\/td>\n<td style=\"text-align: left\">Clean, filtered, non-lubricated compressed air<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note for Cylindrical Products:<\/em> For dedicated long round tubes, pipes, and bar stock bundles (OD 800\u20132,000 mm), a customized circular cradle variant operates at ring speeds of 20\u201360 r\/min and wrapping speeds of 2\u201310 m\/min.<\/p>\n<hr \/>\n<h2 id=\"example\">Worked example: a 6 m bundle<\/h2>\n<p>The following engineering calculation illustrates throughput, pitch, and stretch film consumption for a typical industrial sandwich panel bundle.<\/p>\n<p><strong>Bundle Parameters:<\/strong><\/p>\n<ul>\n<li>Width (<code>W_b<\/code>) = 1,000 mm<\/li>\n<li>Height (<code>H_b<\/code>) = 800 mm<\/li>\n<li>Total Length (<code>L<\/code>) = 6,000 mm<\/li>\n<li>Total Weight = 1,500 kg<\/li>\n<li>Stretch Film Width (<code>W<\/code>) = 300 mm<\/li>\n<li>Process Conveyor Speed (<code>v<\/code>) = 6 m\/min<\/li>\n<li>Ring Operational Speed (<code>n<\/code>) = 40 r\/min<\/li>\n<\/ul>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Verification Step<\/th>\n<th style=\"text-align: left\">Engineering Calculation Formula<\/th>\n<th style=\"text-align: left\">Calculated Output<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Diagonal vs. Clearance<\/strong><\/td>\n<td style=\"text-align: left\"><code>&radic;(1000&sup2; + 800&sup2;) = &radic;(1,000,000 + 640,000)<\/code><\/td>\n<td style=\"text-align: left\">1,280.6 mm (Passes \u2264 1,500 mm envelope)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Linear Advance per Turn (a)<\/strong><\/td>\n<td style=\"text-align: left\"><code>a = (6 &times; 1000) &divide; 40<\/code><\/td>\n<td style=\"text-align: left\">150 mm\/rev<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Overlap Ratio<\/strong><\/td>\n<td style=\"text-align: left\"><code>[1 &minus; (150 &divide; 300)] &times; 100%<\/code><\/td>\n<td style=\"text-align: left\"><strong>50% Overlap<\/strong> (Guarantees double-layer skin)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Total Revolutions Required<\/strong><\/td>\n<td style=\"text-align: left\"><code>6,000 mm &divide; 150 mm\/rev<\/code><\/td>\n<td style=\"text-align: left\">40 Revolutions<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Cross-Sectional Perimeter<\/strong><\/td>\n<td style=\"text-align: left\"><code>2 &times; (1,000 mm + 800 mm)<\/code><\/td>\n<td style=\"text-align: left\">3.6 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Gross Film Length on Product<\/strong><\/td>\n<td style=\"text-align: left\"><code>40 rev &times; 3.6 m\/rev<\/code><\/td>\n<td style=\"text-align: left\">144 m (relaxed state on load)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Active Machine Cycle Time<\/strong><\/td>\n<td style=\"text-align: left\"><code>6 m &divide; 6 m\/min<\/code><\/td>\n<td style=\"text-align: left\">1.0 min (60 seconds)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><strong>Engineering Analysis:<\/strong>\nAt 6 m\/min conveyor feed and 40 r\/min ring velocity, the 300 mm film delivers exactly 50% overlap, providing continuous dual-layer coverage across every linear millimeter of the panel bundle.<\/p>\n<p>Because the mechanical pre-stretch carriage elongates the LLDPE film by 150% to 200% prior to contact, actual film consumption pulled from the raw core is significantly lower than the 144 m wrapped perimeter measurement:<\/p>\n<p><code>Actual Roll Consumption = 144 m &divide; (1 + Pre-stretch Ratio)<\/code><\/p>\n<p>At a standard 150% pre-stretch setting (<code>1 + 1.5 = 2.5<\/code>), actual raw material drawn from the master roll is approximately 57.6 meters, offering substantial consumable cost reduction.<\/p>\n<p>To achieve a 3-layer protective rating (67% overlap) for severe overseas freight conditions, the conveyor speed is simply indexed down to 4 m\/min at 40 r\/min (<code>a = 100 mm<\/code>). Programmable terminal reinforces (e.g., 3 extra dead-cycles at the leading and trailing ends) can be stored within PLC parameter presets.<\/p>\n<hr \/>\n<h2 id=\"options\">Film, belt or paper, and full coverage<\/h2>\n<p>Selecting the appropriate wrapping media depends on mechanical surface sensitivity, atmospheric exposure, and product geometry:<\/p>\n<ul>\n<li><strong>LLDPE Cast\/Blown Stretch Film:<\/strong> The standard packaging medium. Delivers high elasticity, puncture resistance, optical transparency for barcode scanning, and low cost.<\/li>\n<li><strong>Knit Reinforced Mesh Belt:<\/strong> Utilized for non-planar bundles, timber with sharp unplaned edges, or building materials requiring internal ventilation to prevent mold growth.<\/li>\n<li><strong>VCI (Vapor Corrosion Inhibitor) Paper:<\/strong> Interleaved underneath the outer film layer to protect mirror-finish copper tubes, bright steel bars, or painted sheet edges from condensation staining and oxidation.<\/li>\n<\/ul>\n<p>Standard orbital spiral wrapping seals the four primary longitudinal perimeter faces while leaving the front and rear cross-cut ends exposed. For operations requiring comprehensive hermetic or moisture-tight packaging, four process configurations are available:<\/p>\n<ol>\n<li><strong>Six-Sided Fully Enclosed Wrapping:<\/strong> A multi-axis combination packaging cell that executes longitudinal wrapping followed by transverse orbital wrapping to close both cut ends.<\/li>\n<li><strong>Pre-Draped Full Enclosure:<\/strong> Applying full perimeter polyethylene (PE) or barrier bubble wrap sheets over the top, sides, and leading ends prior to entering the orbital ring.<\/li>\n<li><strong>Overhead Top Film Covering (Standard in this unit):<\/strong> Continuously dispenses a single-layer polyethylene dust\/rain barrier over the top surface. The orbital spiral locks the overhang edges, providing robust five-sided weather resistance at high cycle speeds with low material waste.<\/li>\n<li><strong>Automated End-Sheet Insertion:<\/strong> A dedicated pneumatic mechanism cuts and clamps protective foam or plastic sheet caps over the leading and trailing ends before orbital entry.<\/li>\n<\/ol>\n<p>For heat-tolerant bundles, downstream automated PE shrink packaging tunnels provide an alternative high-clarity contoured skin pack.<\/p>\n<hr \/>\n<h2 id=\"selection-checklist\">Selection checklist<\/h2>\n<p>To configure an orbital wrapper tailored to specific plant integration requirements, verify the following mechanical parameters:<\/p>\n<ol>\n<li><strong>Bundle Dimensional Extremes:<\/strong> Minimum and maximum cross-sectional width, height, diagonal measurement, and total length (mm).<\/li>\n<li><strong>Structural Rigidity and Mass:<\/strong> Minimum and maximum bundle weight (kg), including deflection limits of flexible timber or plastic extrusions under transport.<\/li>\n<li><strong>Packaging Consumable Matrix:<\/strong> Specification of stretch film (thickness in \u00b5m, roll width, pre-stretch ratio) or requirements for dual-material wrapping (VCI + film).<\/li>\n<li><strong>Line Cycle Throughput:<\/strong> Required package output rate measured in bundles per hour or conveyor transit speed (m\/min).<\/li>\n<li><strong>Conveyor Bed Configuration:<\/strong> Infeed and outfeed roller pitch, motorized roller vs. belt conveyor surface, and integration with upstream extrusion or panel saw runout tables.<\/li>\n<li><strong>Enclosure Level:<\/strong> Four-side spiral vs. five-side (top sheet) vs. six-side sealed wrapping, automated end-sheet placement, corner protector applicators, and automatic weighing\/labeling modules.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"safety\">Safety: EN 415-10 and ISO 12100<\/h2>\n<p>Master horizontal orbital wrapping machines are built in strict compliance with <strong>EN 415-10<\/strong> (Safety of Packaging Machines: Part 10 &#8211; Wrapping Machines) and risk-assessed according to <strong>ISO 12100:2010<\/strong>.<\/p>\n<ul>\n<li><strong>Rotary Ring Enclosure:<\/strong> The orbital ring and film carriage assemblies are contained within heavy-gauge sheet steel and structural polycarbonate perimeter housing guards. Access doors are monitored by Category 4, PL e safety interlock switches, cutting power instantly if opened during operation.<\/li>\n<li><strong>Pneumatic Pinch Point Protection:<\/strong> Vertical hold-down cylinders are equipped with anti-drop check valves and dual-channel safety pneumatic dumping. Press rollers incorporate physical safety clearances and slow-speed homing modes.<\/li>\n<li><strong>Infeed\/Outfeed Safety:<\/strong> Light curtains (Type 4 optical guards) or physical perimeter fences prevent personnel intrusion into the pinch zones where conveyors interface with the ring aperture.<\/li>\n<li><strong>LOTO Provisions:<\/strong> High-visibility lockable main electrical disconnects and pneumatic residual-pressure dump valves comply with international Lockout\/Tagout (LOTO) protocols for safe ring balancing and film reel changeovers.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: How is the film overlap percentage adjusted on the machine?<\/strong>\nA: Overlap is controlled electronically via the main touchscreen HMI by altering the speed ratio between the conveyor variable-frequency drive (VFD) and the orbital ring VFD, matching the calibrated web width of the film roll.<\/p>\n<p><strong>Q: What prevents lightweight or stacked bundles from separating during wrapping?<\/strong>\nA: Synchronized overhead pneumatic hold-down rollers exert controlled vertical clamping force onto the bundle, suppressing torsional movement and bundle deflection caused by centrifugal film roll tension.<\/p>\n<p><strong>Q: Can the horizontal orbital wrapper seal the leading and trailing ends of the product?<\/strong>\nA: Spiral orbital wrapping seals the top, bottom, and lateral flanks. To seal the cut ends, the machine must be integrated with an automated end-capping unit or configured as a dual-direction six-sided packaging cell.<\/p>\n<p><strong>Q: What is the primary function of the overhead top film applicator?<\/strong>\nA: It applies a single, unbroken sheet of continuous protective film over the top face before orbital wrapping begins. The orbiting film then binds down the longitudinal edges, creating an impermeable shed-roof effect that repels dust and rain during yard storage.<\/p>\n<p><strong>Q: What CE machinery standards govern the electrical and mechanical safety of this wrapper?<\/strong>\nA: Mechanical safety conforms to EN 415-10 and ISO 12100:2010. Electrical engineering, emergency stop circuitry, and control enclosures comply with IEC \/ EN 60204-1 and ISO 13849-1.<\/p>\n<hr \/>\n<h2 id=\"next-step\">Next step<\/h2>\n<ol>\n<li><strong>Submit Product Envelope Data:<\/strong> Send your minimum\/maximum package dimensions, load profiles, line speed targets, and packaging material preferences to <code>info@fhopepack.com<\/code>.<\/li>\n<li><strong>Engineering Layout Review:<\/strong> Our packaging engineering group will determine the optimum ring internal diameter (ID), conveyor configuration, hold-down geometry, and kinematic recipe.<\/li>\n<li><strong>Commercial &amp; Technical Proposal:<\/strong> Receive a fully dimensioned 2D\/3D plant layout drawing, cycle time simulation, and formal capital equipment quotation within 24\u201348 hours.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/Horizontal-orbital-stretch-wrapping_mach.html\">Horizontal orbital stretch wrapping machine (product)<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/Horizontal_orbital-stretch-wrapper.html\">Horizontal orbital stretch wrapper for long products (product)<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-orbital-stretch-wrapper-with-bubble-film-covering-for-door-panel-furniture\/\">Automatic orbital stretch wrapper with bubble film for door panels<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/giant-horizontal-orbital-stretch-wrapping-machine-with-film-covering-unit\/\">Giant horizontal orbital stretch wrapping machine with film covering unit<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/horizontal-orbital-ring-stretch-wrapper-for-sheet-metal-building-materials-industry\/\">Horizontal orbital ring stretch wrapper for sheet metal building materials<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>FHOPE Packaging Machinery System Documentation: Horizontal Orbital Series Engineering Technical Manuals.<\/li>\n<li>Project Applications: Continuous Top-Film Dispensing and Automated Orbital Helical Containment for Panel and Extrusion Bundles.<\/li>\n<li>Kinematic calculations derived from standard industrial packaging machine drive train formulas.<\/li>\n<li>European Standards: EN 415-10:2014 (Safety of packaging machines &#8211; Part 10: General requirements); EN ISO 12100:2010 (Safety of machinery &#8211; General principles for design &#8211; Risk assessment and risk reduction); IEC 60204-1 (Safety of machinery &#8211; Electrical equipment of machines).<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-19<\/p>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/oI515gdMjh0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>","protected":false},"excerpt":{"rendered":"<p>Executive summary A master horizontal wrapping machine is an automated orbital stretch wrapper engineered for continuous packaging of long-format bundles, including composite panels, aluminum extrusions, timber packs, and insulated sandwich sheets. 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