{"id":330,"date":"2018-04-19T02:41:14","date_gmt":"2018-04-19T02:41:14","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=330"},"modified":"2026-10-26T06:20:52","modified_gmt":"2026-10-26T06:20:52","slug":"automatic-horizontal-wrapping-machine-and-oribtal-wrapper","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-horizontal-wrapping-machine-and-oribtal-wrapper\/","title":{"rendered":"Automatic Horizontal Wrapping Machine and Orbital Wrapper for Tube Bundles"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong> \u2014 Our automatic horizontal orbital wrappers secure loose and tied tube bundles by passing them through a continuously rotating ring that applies high-tension stretch film, paper, or woven material. The E300 handles bundles up to <strong>300 mm<\/strong> in outer diameter (OD), while the heavy-duty E400 expands the envelope to <strong>400 mm<\/strong> OD and incorporates secondary film tension controls for paper, polypropylene (PP), and composite woven tape. Bundle cross-section geometry, axial feed speed, and calculated film overlap dictate machine sizing, ring bore clearance, and production cycle times.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/twhXiK2pO_E\" 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=\"#how-the-wrapper-runs-a-bundle\">How the wrapper runs a bundle<\/a><\/li>\n<li><a href=\"#bundle-od-from-tube-count\">Bundle OD from tube count<\/a><\/li>\n<li><a href=\"#e300-or-e400\">E300 or E400<\/a><\/li>\n<li><a href=\"#cycle-time\">Cycle time<\/a><\/li>\n<li><a href=\"#long-flexible-or-heavy-bundles\">Long, flexible or heavy bundles<\/a><\/li>\n<li><a href=\"#film-loading-and-daily-setup\">Film loading and daily setup<\/a><\/li>\n<li><a href=\"#utilities-and-safety\">Utilities and safety<\/a><\/li>\n<li><a href=\"#selection-checklist-for-a-tube-bundle-wrapper\">Selection checklist<\/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>How the wrapper runs a bundle<\/h2>\n<p>The automatic horizontal wrapper carries the bundle through the wrapping zone using synchronized, motor-driven infeed and outfeed conveyors positioned on both sides of the orbital ring frame.<\/p>\n<ol>\n<li><strong>Infeed and Optical Positioning<\/strong>: As the bundle moves forward, an optical reflex sensor detects the leading edge and commands the variable frequency drive (VFD) to position the tube bundle within the wrapping plane.<\/li>\n<li><strong>Orbital Spiral Wrapping<\/strong>: Adjustable vertical side guides center the bundle along the conveyor path. The aluminum cast ring rotates around the bundle on heavy-duty polyurethane drive friction wheels, spiraling film under pre-regulated tension.<\/li>\n<li><strong>Pneumatic Cut and Clamp<\/strong>: Once the trailing edge passes the optical detection gate, the ring applies reinforcement wraps, and an integrated pneumatic clamp-and-cut unit slices the film, holding the tail firmly in place for the subsequent cycle without manual re-threading.<\/li>\n<\/ol>\n<p>Both ring rotation and conveyor linear travel are driven by independent VFDs, allowing operators to dial in the exact film pitch across fragile, polished, or rigid extruded surfaces.<\/p>\n<p>For specialized end-support requirements on extra-long bundles, see <a href=\"#long-flexible-or-heavy-bundles\">Long, flexible or heavy bundles<\/a>.<\/p>\n<hr \/>\n<h2>Bundle OD from tube count<\/h2>\n<p>Bundle outer diameter (OD) defines the circumscribed circle enclosing the tube array. For standard hexagonal packing\u2014one center core tube enveloped by six outer tubes\u2014the theoretical envelope diameter equals three tube diameters:<\/p>\n<p><code>Bundle OD = 3 &times; Tube OD<\/code><\/p>\n<table>\n<thead>\n<tr>\n<th>Tube OD<\/th>\n<th>Seven-tube bundle OD<\/th>\n<th>Recommended Model<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>40 mm<\/td>\n<td>120 mm<\/td>\n<td>E300 or E400<\/td>\n<\/tr>\n<tr>\n<td>75 mm<\/td>\n<td>225 mm<\/td>\n<td>E300 or E400<\/td>\n<\/tr>\n<tr>\n<td>110 mm<\/td>\n<td>330 mm<\/td>\n<td>E400<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>For square, rectangular, or irregular profiles, measure the maximum cross-sectional diagonal (<code>W_max<\/code> and <code>H_max<\/code>):<\/p>\n<p><code>Diagonal = &radic;(W_max&sup2; + H_max&sup2;)<\/code><\/p>\n<p>The orbital ring bore must clear this diagonal plus a radial clearance zone of at least 80\u2013120 mm to prevent product-to-dispenser collisions during ring rotation.<\/p>\n<hr \/>\n<h2>E300 or E400<\/h2>\n<p>The selection between E300 and E400 hinges on bundle cross-section dimensions and packaging material compatibility.<\/p>\n<table>\n<thead>\n<tr>\n<th>Parameter<\/th>\n<th>E300<\/th>\n<th>E400<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Maximum Bundle OD<\/td>\n<td>100\u2013300 mm<\/td>\n<td>100\u2013400 mm<\/td>\n<\/tr>\n<tr>\n<td>Minimum Bundle Length<\/td>\n<td>1,000 mm<\/td>\n<td>1,200 mm<\/td>\n<\/tr>\n<tr>\n<td>Standard Weight Capacity<\/td>\n<td>15\u2013100 kg (Standard PVC rollers)<\/td>\n<td>15\u2013100 kg (Standard; upgradeable to 500+ kg)<\/td>\n<\/tr>\n<tr>\n<td>Ring Rotational Speed<\/td>\n<td>20\u201390 r\/min<\/td>\n<td>20\u201390 r\/min<\/td>\n<\/tr>\n<tr>\n<td>Catalog Wrapping Capacity<\/td>\n<td>5\u201315 m\/min line speed<\/td>\n<td>5\u201325 m\/min line speed<\/td>\n<\/tr>\n<tr>\n<td>Conveyor Feed Speed<\/td>\n<td>6\u201312 m\/min (Inverter controlled)<\/td>\n<td>6\u201312 m\/min (Inverter controlled)<\/td>\n<\/tr>\n<tr>\n<td>Infeed\/Outfeed Conveyor<\/td>\n<td>2,000 mm motorized per side<\/td>\n<td>2,000 mm motorized per side<\/td>\n<\/tr>\n<tr>\n<td>Packaging Material Types<\/td>\n<td>Stretch film (PE)<\/td>\n<td>PE film, VCI anti-rust paper, PP, or woven mesh<\/td>\n<\/tr>\n<tr>\n<td>Film Roll Core Specifications<\/td>\n<td>Width: 100\u2013200 mm; OD: 100\u2013200 mm; Core: 50 mm<\/td>\n<td>Width: 100\u2013200 mm; OD: 100\u2013200 mm; Core: 50 or 76 mm<\/td>\n<\/tr>\n<tr>\n<td>Film Overlap Setting<\/td>\n<td>10%\u201390% (HMI adjustable)<\/td>\n<td>10%\u201390% (HMI adjustable)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Choose the <strong>E400<\/strong> whenever the bundle cross-section exceeds 300 mm OD, or when protective paper, VCI corrosion-inhibitor tape, or woven plastic tape is required alongside or instead of stretch film.<\/p>\n<p><em>Note: Heavy-gauge steel or solid copper bundles exceeding 100 kg utilize our heavy-duty steel or polyurethane-coated V-roller chassis options, configured on an engineering proposal basis.<\/em><\/p>\n<hr \/>\n<h2>Cycle time<\/h2>\n<p>Packaging overlap dictates the axial advance rate per revolution. For a film width (<code>W_f<\/code>) of 200 mm running at 50% overlap, the bundle advances by half the film width per ring cycle:<\/p>\n<p><code>Axial Pitch = W_f &times; (1 - Overlap) = 200 mm &times; (1 - 0.50) = 100 mm\/rev (0.1 m\/rev)<\/code><\/p>\n<p>At a maximum ring rotational speed of 90 r\/min, the linear conveyor must advance at:<\/p>\n<p><code>Conveyor Speed = 90 r\/min &times; 0.1 m\/rev = 9.0 m\/min<\/code><\/p>\n<p>For a standard 6.0 m bundle, the continuous spiral transit duration is:<\/p>\n<p><code>Transit Time = 6.0 m \/ 9.0 m\/min = 0.667 min = 40 seconds<\/code><\/p>\n<h3>Full Dry-to-Dry Cycle Breakdown<\/h3>\n<p>Catalog &#8220;wrapping speed&#8221; (5\u201325 m\/min) indicates the maximum mechanical line throughput under low-overlap indexing. Actual line production capacity must incorporate dwelling sequences:<\/p>\n<ul>\n<li><strong>Head Reinforcement Turns<\/strong>: 2 stationary wraps = ~3 s<\/li>\n<li><strong>Continuous 6 m Travel Wrap<\/strong>: 40 s<\/li>\n<li><strong>Tail Reinforcement Turns<\/strong>: 2 stationary wraps = ~3 s<\/li>\n<li><strong>Pneumatic Cut, Wipe, and Clamp Action<\/strong>: ~4 s<\/li>\n<li><strong>Total Bundle Cycle Time<\/strong>: <strong>~50 seconds<\/strong> (Yielding an effective throughput of 60\u201370 bundles per hour under continuous staging).<\/li>\n<\/ul>\n<hr \/>\n<h2>Long, flexible or heavy bundles<\/h2>\n<p>Long or flexible extrusions (such as small-diameter conduit, PEX tubing, or lightweight aluminum profiles) require controlled support across the open ring throat. Our application team evaluates three operational criteria before finalizing machine layout:<\/p>\n<ol>\n<li><strong>Throat Span and Sag Control<\/strong>: Standard conveyors leave an unsupported ring throat gap of 300\u2013400 mm. For flexible bundles with deflection greater than 15 mm, optional central bridge rollers or lower pneumatic lifting saddles bridge the gap between conveyors.<\/li>\n<li><strong>Cantilever End-Whip Mitigation<\/strong>: Bundles exceeding 4 meters in length experience inertial oscillations during rapid acceleration. Optional pneumatic overhead pinch wheels stabilize the bundle&#8217;s leading and trailing edges, keeping the product centered on the conveyor V-groove.<\/li>\n<li><strong>Heavy-Duty Roller Upgrades<\/strong>: When tube bundles exceed 100 kg, standard light-duty conveyor rollers are replaced with steel-core V-rollers or polyurethane-sheathed cradles to prevent marring and avoid roller bearing burnout under sustained load.<\/li>\n<\/ol>\n<hr \/>\n<h2>Film loading and daily setup<\/h2>\n<p>Daily operation requires minimal operator intervention once recipes are saved in the PLC interface:<\/p>\n<ol>\n<li><strong>Loading the Roll<\/strong>: Mount the material spool onto the expanding core shaft (50 mm or 76 mm) situated inside the orbital ring housing.<\/li>\n<li><strong>Calibrating Mechanical Tension<\/strong>: Adjust the friction brake disc on the carriage to achieve film pre-stretch without necking down or collapsing thin-walled tubes.<\/li>\n<li><strong>Setting the Overlap Ratio<\/strong>: Enter the bundle diameter and desired overlap (10% to 90%) on the touchscreen HMI. The PLC automatically locks the ratio between the ring inverter frequency and conveyor drive speed.<\/li>\n<li><strong>Homing Position Check<\/strong>: The machine automatically returns the ring carriage to the 6 o&#8217;clock parking position at cycle end, aligning the film web with the pneumatic cutting jaw.<\/li>\n<\/ol>\n<hr \/>\n<h2>Utilities and safety<\/h2>\n<table>\n<thead>\n<tr>\n<th>Utility \/ Specification<\/th>\n<th>Requirement \/ Rating<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Connected Electrical Load<\/td>\n<td>Approximately 2.5 kW<\/td>\n<\/tr>\n<tr>\n<td>Power Supply<\/td>\n<td>380 V AC, 3-Phase, 50\/60 Hz (Optional 220 V \/ 480 V configurations)<\/td>\n<\/tr>\n<tr>\n<td>Pneumatic Supply<\/td>\n<td>0.5\u20130.7 MPa (5\u20137 bar), clean, dry compressed air; ~80 NL\/min consumption<\/td>\n<\/tr>\n<tr>\n<td>Floor and Foundation<\/td>\n<td>Industrial grade, flat, vibration-free concrete slab rated for total static load<\/td>\n<\/tr>\n<tr>\n<td>Control Hardware<\/td>\n<td>Siemens or Mitsubishi PLC with dedicated Color Touch HMI<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Safety Standards and Interlocks<\/h3>\n<p>All orbital wrappers destined for CE and international industrial markets comply with:<\/p>\n<ul>\n<li><strong>EN 415-6:2013<\/strong>: Safety requirements for wrapping machines.<\/li>\n<li><strong>ISO 12100:2010<\/strong>: Risk assessment and risk reduction for industrial machinery.<\/li>\n<li><strong>ISO 13849-1<\/strong>: Safety-related parts of control systems (Category 3, PL d safety interlocked mesh enclosure panels and emergency stop loops).<\/li>\n<\/ul>\n<p>Optical light curtains or physical interlocked perimeter fencing prevent operator intrusion into the orbital rotation ring zone while power is applied.<\/p>\n<hr \/>\n<h2>Selection checklist for a tube bundle wrapper<\/h2>\n<ul>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Tube material, single tube outer diameter, and wall thickness.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Number of tubes per bundle and bundle cross-section geometry (hexagonal, round, square).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Minimum and maximum bundle lengths (verifying minimum conveyor bridging).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Minimum and maximum single-bundle weights (determining standard vs. heavy-duty rollers).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Target cycle time (bundles per hour).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Wrapping media: Stretch film, paper, VCI tape, or woven PP band.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Target overlap percentage (e.g., 50% for standard storage, 75% for export transport).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Integration mode: Standalone offline cell or fully automatic inline transfer with tube strapping\/bundling stations.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> Pneumatic air availability at the machine drop (0.6 MPa dry air).<\/li>\n<\/ul>\n<hr \/>\n<h2>Engineering FAQ<\/h2>\n<p><strong>Q: What is the calculated OD of a seven-tube bundle?<\/strong>\nA: Exactly three tube diameters when arranged in a compact hexagonal pattern. For example, seven 75 mm tubes produce an envelope diameter of 225 mm (<code>3 &times; 75 mm = 225 mm<\/code>).<\/p>\n<p><strong>Q: When should we specify the E400 instead of the E300?<\/strong>\nA: Choose the E400 whenever your maximum bundle diameter (or diagonal cross-section) exceeds 300 mm, up to 400 mm, or when wrapping with paper, PP, or woven tape materials that require larger material spools and heavier tension carriages.<\/p>\n<p><strong>Q: What is the true production cycle time for a 6-meter bundle?<\/strong>\nA: Under standard settings (200 mm film, 50% overlap, 90 r\/min ring speed), the in-ring continuous transit time is approximately 40 seconds. Adding lead reinforcement wraps, tail wraps, and the pneumatic clamp-cut cycle results in a total dry-to-dry cycle time of approximately 50 seconds per bundle.<\/p>\n<p><strong>Q: Does the operator need to re-attach the film to each bundle?<\/strong>\nA: No. The machine features a fully automatic pneumatic clamp and hot-wire or serrated blade cut mechanism. After cutting the film on a finished bundle, the jaw holds the film tail in position, ready to engage the leading edge of the next incoming bundle automatically.<\/p>\n<p><strong>Q: What foundation and utilities must the plant supply?<\/strong>\nA: The machine requires a level concrete industrial floor capable of supporting the combined weight of the machine and loaded bundles, a 380 V 3-phase electrical supply (2.5 kW), and a regulated compressed air line delivering 0.5\u20130.7 MPa.<\/p>\n<hr \/>\n<h2>Next step<\/h2>\n<p>We engineer and deliver turnkey horizontal orbital wrapper cells based on your plant&#8217;s exact tube bundle specifications:<\/p>\n<ol>\n<li><strong>Submit Your Application Data<\/strong>: Send bundle dimensions (min\/max length, bundle OD, bundle weight) and output requirements to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Receive Technical Proposal<\/strong>: Our packaging engineering team delivers a 3D line drawing, model recommendation, utility matrix, and calculated cycle-time projection.<\/li>\n<li><strong>Application Testing &amp; Line Integration<\/strong>: Run trials with your actual tube profiles at our testing center or schedule an engineering site review for automated inline integration.<\/li>\n<\/ol>\n<hr \/>\n<h2>Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/E400-horizontal-stretch-wrapper.html\">E400 horizontal stretch wrapper<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/E300-horizontal-stretch-wrapper.html\">E300 horizontal stretch wrapper<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/Horizontal_orbital-stretch-wrapper.html\">Horizontal orbital stretch wrapper<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-bar-wrapping-machine\/\">Video: automatic bar wrapping machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/horizontal-orbital-ring-stretch-wrapper-for-sheet-metal-building-materials-industry\/\">Video: horizontal orbital ring stretch wrapper for sheet metal<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2>Sources<\/h2>\n<ul>\n<li>Machine Specifications: <a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/E400-horizontal-stretch-wrapper.html\">E400 Horizontal Stretch Wrapper Data<\/a><\/li>\n<li>Machine Specifications: <a href=\"https:\/\/www.fhopepack.com\/Automatic-horizontal-stretch-wrapper\/E300-horizontal-stretch-wrapper.html\">E300 Horizontal Stretch Wrapper Data<\/a><\/li>\n<li>Kinematics Demonstration: <a href=\"https:\/\/www.youtube.com\/watch?v=twhXiK2pO_E\">Automatic Horizontal Wrapping Machine on YouTube<\/a><\/li>\n<li>Harmonized Safety Standards: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Machinery Safety<\/a>, <a href=\"https:\/\/www.en-standard.eu\/csn-en-415-6-a1-safety-of-packaging-machines-part-6-pallet-wrapping-machines\/\">EN 415-6:2013 Wrapping Machine Safety<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-25<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary \u2014 Our automatic horizontal orbital wrappers secure loose and tied tube bundles by passing them through a continuously rotating ring that applies high-tension stretch film, paper, or woven material. The E300 handles bundles [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2240,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Automatic Horizontal Wrapping Machine for Tube Bundles","_seopress_titles_desc":"How we run and size an automatic horizontal orbital wrapper for tube bundles: bundle OD from tube count, E300 vs E400, film loading, speeds and cycle 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