{"id":324,"date":"2018-04-19T02:38:50","date_gmt":"2018-04-19T02:38:50","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=324"},"modified":"2026-10-26T15:28:00","modified_gmt":"2026-10-26T15:28:00","slug":"automatic-aluminum-profile-packaging-machine-wrapping-line-2","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-aluminum-profile-packaging-machine-wrapping-line-2\/","title":{"rendered":"Aluminum Profile Packaging Line: Engineering &#038; Sizing Guide"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nAluminum extrusion profiles leave the press with delicate, easily scratched finishes, making in-line protection critical to factory yield. An automated horizontal packaging line protects extrusion surfaces, compacts and straps profiles, and orbital-wraps the finished bundles in a single continuous workflow \u2014 integrating infeed indexing, protective film\/paper application, strapping, orbital ring wrapping, and automated stacking. Line throughput must be synchronized with extrusion press output: calculate required pacing by dividing <strong>extrusion metres per shift<\/strong> by <strong>bundle length<\/strong>, and then by net operating shift hours. In standard plant operations yielding 3,600 m per 8-hour shift in 6 m bundles, the target rate is <strong>75 bundles per hour<\/strong>, giving an available gross cycle time of <strong>48 s per bundle<\/strong>.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"358\" height=\"636\" src=\"https:\/\/www.youtube.com\/embed\/LOzn1qAc6z8\" title=\"Aluminum Profile Packaging: Complete Guide\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2>Table of Contents<\/h2>\n<ul>\n<li><a href=\"#line\">The packaging line, station by station<\/a><\/li>\n<li><a href=\"#ring\">The ring wrapping station<\/a><\/li>\n<li><a href=\"#envelope\">Published reference figures for the horizontal wrapping machine class<\/a><\/li>\n<li><a href=\"#pace\">Bundles per hour from your extrusion output<\/a><\/li>\n<li><a href=\"#verify\">What to verify before you specify<\/a><\/li>\n<li><a href=\"#cover\">What the cover does \u2014 and does not \u2014 do<\/a><\/li>\n<li><a href=\"#safety\">Safety and industrial standards<\/a><\/li>\n<li><a href=\"#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=\"line\">The packaging line, station by station<\/h2>\n<p>An integrated packaging line links five discrete processing stages along a synchronized roller conveyor, processing long bundles continuously without intermediate manual crane handling:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Station<\/th>\n<th style=\"text-align: left\">Primary Function<\/th>\n<th style=\"text-align: left\">Core Mechanical Safeguards<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>1. Infeed conveyor<\/strong><\/td>\n<td style=\"text-align: left\">Receives extrusions onto driven roller beds<\/td>\n<td style=\"text-align: left\">Polyurethane-coated rollers prevent base metal scarring<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>2. Film \/ paper application<\/strong><\/td>\n<td style=\"text-align: left\">Applies continuous protective wrap to bundle surfaces<\/td>\n<td style=\"text-align: left\">Controlled web tension prevents profile bunching<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>3. Strapping \/ bundling<\/strong><\/td>\n<td style=\"text-align: left\">Compresses and binds profiles into rigid bundles<\/td>\n<td style=\"text-align: left\">Pneumatic side\/top clamps prevent cross-sectional shifting<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>4. Orbital ring wrapping<\/strong><\/td>\n<td style=\"text-align: left\">Helically wraps stretch film or paper around the bundle<\/td>\n<td style=\"text-align: left\">High-speed orbital ring with balanced dual-film carriages<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>5. Outfeed and stacking<\/strong><\/td>\n<td style=\"text-align: left\">Transfers wrapped bundles to storage or staging cradles<\/td>\n<td style=\"text-align: left\">Automated scissor lifters and pneumatic indexing pushers<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Surface protection occurs at Station 2 before bundling because internal friction between bare profiles causes micro-abrasions during transit. Intermediate strapping secures the pack into a rigid column, and the orbital wrapper applies a continuous outer barrier against moisture and industrial dust.<\/p>\n<p>Because all stations share a common conveyor indexing speed, engineers must specify the primary surface protective layer, the compression strapping method, and the outer wrapping cover simultaneously to balance cycle times.<\/p>\n<h2 id=\"ring\">The ring wrapping station<\/h2>\n<p>The core station of this line is the horizontal orbital wrapper: a heavy-duty circular ring rotates continuously in a vertical plane while the profile bundle travels horizontally through its central aperture, applying film in a controlled spiral helix. Because the workpiece translates axially without spinning, long extrusion lengths (from 2 m up to 12 m) wrap evenly without rotational deflection.<\/p>\n<p>To maintain uniform film overlap and constant pre-stretch tension, the cross-sectional centre of the bundle must track as close to the ring rotation axis as possible. Sizing the ring opening requires calculating the profile&#8217;s circumscribed diagonal and providing clear mechanical margin:<\/p>\n<p><code>D_ring &ge; &radic;(Width&sup2; + Height&sup2;) + 2 &times; Clearances<\/code><\/p>\n<p>Here, clearances must account for the physical envelope of the rotating film tension dispenser, pneumatic top-hold-down rollers, and conveyor side guides.<\/p>\n<p>Line speed ranges from 1 to 20 m\/min under variable-frequency drive (VFD) control. Active wrapping throughput depends directly on the ratio between ring rotational speed (RPM), film roll width, and the specified overlap percentage:<\/p>\n<p><code>Conveyor Speed (m\/min) = [Ring RPM &times; Film Width (m) &times; (1 - Overlap%)]<\/code><\/p>\n<h2 id=\"envelope\">Published reference figures for the horizontal wrapping machine class<\/h2>\n<p>The orbital ring wrapping station belongs to FHOPE&#8217;s industrial horizontal wrapping family. The factory reference envelope below outlines typical design boundaries:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Parameter<\/th>\n<th style=\"text-align: left\">Standard Class Value<\/th>\n<th style=\"text-align: left\">Custom Engineering Options<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Supply Voltage<\/strong><\/td>\n<td style=\"text-align: left\">AC 380 V \/ 50 Hz, 3-Phase<\/td>\n<td style=\"text-align: left\">220 V \/ 415 V \/ 480 V (60 Hz optional)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Installed Power<\/strong><\/td>\n<td style=\"text-align: left\">4.8 kW \u2013 7.5 kW<\/td>\n<td style=\"text-align: left\">High-speed servo drive upgrades<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Bundle Circumscribed Diameter<\/strong><\/td>\n<td style=\"text-align: left\">300\u20131,500 mm<\/td>\n<td style=\"text-align: left\">Custom aperture rings up to 2,200 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Profile Length Range<\/strong><\/td>\n<td style=\"text-align: left\">2,000\u20138,000 mm<\/td>\n<td style=\"text-align: left\">Continuous long-bed variants to 12,000 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Bundle Weight Capacity<\/strong><\/td>\n<td style=\"text-align: left\">100\u20132,500 kg<\/td>\n<td style=\"text-align: left\">Heavy-duty steel roller beds<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Wrapping Materials<\/strong><\/td>\n<td style=\"text-align: left\">PE film \/ stretch film \/ VCI paper \/ woven tape<\/td>\n<td style=\"text-align: left\">Dual-material composite dispensers<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Ring Rotation Speed<\/strong><\/td>\n<td style=\"text-align: left\">30\u201360 RPM<\/td>\n<td style=\"text-align: left\">Inverter-controlled stepless adjustment<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Conveyor Feed Speed<\/strong><\/td>\n<td style=\"text-align: left\">2\u201316 m\/min<\/td>\n<td style=\"text-align: left\">Synchronized linear encoder tracking<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Overlap Rate<\/strong><\/td>\n<td style=\"text-align: left\">10%\u201390%<\/td>\n<td style=\"text-align: left\">Adjustable via PLC touchscreen recipe<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Engineering Note:<\/em> Extrusion bundles form square, rectangular, or hexagonal cross-sections. The 300\u20131,500 mm rating represents the <strong>circumscribed diagonal<\/strong>, not mere bundle width. Sizing evaluations must verify that this diagonal clears the ring frame with overhead hold-down tooling installed.<\/p>\n<h2 id=\"pace\">Bundles per hour from your extrusion output<\/h2>\n<p>Line line-speed planning begins with press discharge volume. The benchmark figures below demonstrate a high-capacity single-press or twin-press finishing line:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Input \/ Calculation Step<\/th>\n<th style=\"text-align: left\">Target Metric<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Extrusion shift output<\/td>\n<td style=\"text-align: left\">3,600 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Shift duration<\/td>\n<td style=\"text-align: left\">8 hours (28,800 s)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Average hourly extrusion rate (3,600 \u00f7 8)<\/td>\n<td style=\"text-align: left\">450 m\/h<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Required line baseline speed (450 \u00f7 60)<\/td>\n<td style=\"text-align: left\">7.5 m\/min<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Profile bundle unit length<\/td>\n<td style=\"text-align: left\">6 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Bundle volume per shift (3,600 \u00f7 6)<\/td>\n<td style=\"text-align: left\">600 bundles<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Target hourly throughput (600 \u00f7 8)<\/strong><\/td>\n<td style=\"text-align: left\"><strong>75 bundles\/h<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Gross station cycle budget (3,600 s \u00f7 75)<\/strong><\/td>\n<td style=\"text-align: left\"><strong>48 s\/bundle<\/strong><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>A linear baseline speed of 7.5 m\/min fits well within the equipment envelope of 2\u201316 m\/min. However, engineers must account for net station cycle budgets. In a 48 s gross window, conveyor deceleration, bundle positioning, end-tail film cutting\/wiping, and pneumatic clamp indexing consume 12\u201316 s. The net active wrapping time available is roughly 32 s per 6 m bundle, requiring an effective transit wrapping speed of at least 11.2 m\/min through the ring.<\/p>\n<h2 id=\"verify\">What to verify before you specify<\/h2>\n<p>Equipment procurement requires concrete physical boundary data. Confirm these engineering specifications with the OEM engineering team:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Specification Checkpoint<\/th>\n<th style=\"text-align: left\">Engineering Validation Purpose<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Cross-sectional diagonal (Min \/ Max)<\/strong><\/td>\n<td style=\"text-align: left\">Verifies ring aperture clearance and carriage swing radius.<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Minimum wall thickness &amp; alloy profile<\/strong><\/td>\n<td style=\"text-align: left\">Determines maximum pneumatic top-roller clamping pressure to avoid crushing thin-walled profiles.<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Target shift pace (Metres &amp; Bundles\/h)<\/strong><\/td>\n<td style=\"text-align: left\">Sets motor power, inverter sizing, and roller conveyor gear ratios.<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Consumable film type and core sizes<\/strong><\/td>\n<td style=\"text-align: left\">Matches tensioning pre-stretch carriages (mechanical friction brake vs. powered pre-stretch).<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Strapping band specification<\/strong><\/td>\n<td style=\"text-align: left\">Dictates PET\/PP tension ranges and ultrasonic\/heat-friction weld parameters.<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Tail-end film cut and wipe mechanism<\/strong><\/td>\n<td style=\"text-align: left\">Ensures film ends adhere without manual operator intervention at line speed.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"cover\">What the cover does \u2014 and does not \u2014 do<\/h2>\n<p>A spiral-wrapped outer film layer serves definite protective purposes, but engineers must recognize its structural limits:<\/p>\n<ul>\n<li><strong>What it does:<\/strong> Orbital wrapping binds individual extrusions against internal rubbing, stops longitudinal scuffing, protects anodized\/powder-coated surfaces from UV discoloration, and blocks airborne dirt and workshop grease.<\/li>\n<li><strong>What it does not do:<\/strong> Helical spiral wrapping alone is not a hermetic, vapor-tight seal. Capillary action at overlapping film seams can admit standing water during uncovered sea freight or open-air yard storage.<\/li>\n<\/ul>\n<p>For export cargo requiring corrosion protection, specify VCI (Vapor Corrosion Inhibitor) base paper or add an automated polyethylene sleeve applicator before the ring wrapper to establish a true moisture barrier.<\/p>\n<h2 id=\"safety\">Safety and industrial standards<\/h2>\n<p>Horizontal orbital packaging machinery contains high-inertia rotating rings and automated linear pinch points. Compliance requires adherence to harmonized international industrial standards:<\/p>\n<ul>\n<li><strong>EN 415-6:<\/strong> Machine safety standard covering horizontal and orbital stretch-wrapping equipment, mandating guarded operational zones and feed-aperture distance safety.<\/li>\n<li><strong>ISO 12100:2010:<\/strong> Fundamental risk assessment and risk-reduction design principles applied to automated packaging integration.<\/li>\n<li><strong>ISO 13849-1 (PLd \/ Cat. 3):<\/strong> Performance levels required for safety circuits controlling safety light curtains, interlocking tunnel guards, and dynamic ring-brake assemblies.<\/li>\n<li><strong>Perimeter guarding:<\/strong> Fixed perimeter wire fencing (minimum 2,000 mm height) equipped with interlocked access doors and localized E-stop pushbuttons along each conveyor segment.<\/li>\n<\/ul>\n<h2 id=\"faq\">Engineering FAQ<\/h2>\n<p><strong>Q: Does the aluminum bundle spin during wrapping?<\/strong>\nA: No. The extrusion bundle travels axially along the roller bed without rotating. The orbital ring carriage turns around the linear path of the bundle to lay down the protective film.<\/p>\n<p><strong>Q: How is the 48-second station cycle time calculated?<\/strong>\nA: A shift producing 3,600 m across 8 hours in 6 m packs yields 75 bundles per hour. Dividing 3,600 seconds per hour by 75 gives an available cycle budget of 48 seconds per bundle.<\/p>\n<p><strong>Q: Can orbital wrapping machines handle single extrusions as well as bundles?<\/strong>\nA: Yes. With customized pneumatic vertical and horizontal centering rollers, single profiles down to 50 mm \u00d7 20 mm cross-sections run securely through the same ring wrapper.<\/p>\n<p><strong>Q: What prevents bundle marring under strapping pressure?<\/strong>\nA: Automatic plastic or fiberboard edge-corner applicators can be integrated upstream of the strapping station, distributing strapping tension evenly across profile corners.<\/p>\n<p><strong>Q: How do we protect delicate powder coatings from film adhesive residue?<\/strong>\nA: Cast LLDPE stretch films without tackifiers (cling agents) on the product side, or protective paper rolls, are applied to preserve sensitive surface finishes without transfer residue.<\/p>\n<h2 id=\"next-step\">Next step<\/h2>\n<p>To size an automated packaging line for your extrusion layout:<\/p>\n<ol>\n<li>Provide your minimum and maximum profile cross-sections (Width \u00d7 Height), bundle weights, and typical cut lengths.<\/li>\n<li>Share current press output rates (kg\/h and extrusion m\/min) to verify cycle balance.<\/li>\n<li>Submit specifications directly to our engineering division at <strong>info@fhopepack.com<\/strong> for a preliminary layout drawing, cycle simulation, and formal technical proposal.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/aluminum-profile-packing-machine-and-wrapping-machine-line-2\/\">Aluminum Profile Packing Machine and Wrapping Line: Stations and Pace<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/aluminum-profile-stretch-wrapping-machine-mvi-0364\/\">Aluminum Profile Stretch Wrapping Machine for Single Profiles and Small Bundles<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-aluminum-profile-packaging-line-for-paper-packing-and-stacking\/\">Automatic Aluminum Profile Packaging Line for Paper Packing and Stacking<\/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 Standard: <a href=\"https:\/\/standards.iteh.ai\/catalog\/standards\/cen\/49195b4f-8f83-4ce4-8ef8-278eb084ef75\/en-415-6-2013\">EN 415-6: Packaging Machines Safety \u2014 Part 6: Pallet and Product Wrapping Machines<\/a><\/li>\n<li>Machine Classification: <a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/Aluminum_wrapping_machine.html\">FHOPE Horizontal Orbital Aluminum Wrapping Machinery Specifications<\/a><\/li>\n<\/ul>\n<p><em>Last engineering review: 2026-10-25<\/em>\n<em>Document ID: FHP-ENG-ALM-048<\/em><\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary Aluminum extrusion profiles leave the press with delicate, easily scratched finishes, making in-line protection critical to factory yield. An automated horizontal packaging line protects extrusion surfaces, compacts and straps profiles, and orbital-wraps the [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2241,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Automatic Aluminum Profile Packaging Line Wrapping","_seopress_titles_desc":"What an automatic aluminum profile packaging machine wrapping line does, how a yellow ring wraps a single profile, and what to verify with a 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