{"id":417,"date":"2018-04-19T06:12:33","date_gmt":"2018-04-19T06:12:33","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=417"},"modified":"2026-10-26T14:30:10","modified_gmt":"2026-10-26T14:30:10","slug":"flexible-corrugated-pipe-rolls-wrapping-machine-and-hose-packing-mahcine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/flexible-corrugated-pipe-rolls-wrapping-machine-and-hose-packing-mahcine\/","title":{"rendered":"Flexible Corrugated Pipe Rolls Wrapping Machine: Sizing, Overlap, and Model Selection Guide"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong>\nFlexible corrugated pipe and conduit rolls present unique packaging challenges: they are physically bulky, lightweight, and prone to springy radial deformation during rotation. In orbital eye-through stretch wrapping, the coil&#8217;s inner diameter (ID) and outer diameter (OD)\u2014not its weight\u2014primarily determine machine frame sizing and ring clearance. Three standardized machine platforms accommodate typical production profiles: the compact <strong>FPCA-100<\/strong> (OD 300\u2013500 mm) for electrical conduit coils, the mid-range <strong>FPH-300N<\/strong> (OD 500\u20131,000 mm) for commercial flexible hose, and the heavy-duty <strong>FPH-400W<\/strong> (OD 700\u20131,500 mm) for corrugated agricultural and civil drainage pipe rolls.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/gyrc_hwZnfU\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#how-it-works\">How the corrugated pipe wrapper works<\/a><\/li>\n<li><a href=\"#three-models\">Three models by roll size<\/a><\/li>\n<li><a href=\"#roller-support\">Why corrugated rolls need roller support<\/a><\/li>\n<li><a href=\"#overlap\">Overlap on a ribbed surface<\/a><\/li>\n<li><a href=\"#cycle-time\">Cycle time<\/a><\/li>\n<li><a href=\"#utilities-and-safety\">Utilities and safety<\/a><\/li>\n<li><a href=\"#selection-checklist\">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<h2 id=\"how-it-works\">How the corrugated pipe wrapper works<\/h2>\n<p>The horizontal-axis orbital coil wrapper secures the corrugated pipe roll between polyurethane-coated base support rollers and adjustable vertical side-guide rollers. An aluminum rotating ring carries the film carriage through the roll\u2019s central eye, while the motorized support rollers rotate the roll 360 degrees around its own axis.<\/p>\n<p>This synchronized dual-axis rotation deposits stretch film circumferentially around the entire cross-section of the roll. Variable Frequency Drives (VFDs) control the speed ratio between the rotating ring and the support rollers, allowing operators to dial in the exact film overlap percentage required.<\/p>\n<pre><code>   [ Rotating Ring (Eye-Through Orbit) ]\n                 \u2502\n           \u250c\u2500\u2500\u2500\u2500\u2500\u25bc\u2500\u2500\u2500\u2500\u2500\u2510\n           \u2502 Stretch   \u2502 \u2500\u2500&gt; Dispenses film through coil core\n           \u2502 Carriage  \u2502\n           \u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2518\n                 \u2502\n       \u2554\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u256a\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2557\n       \u2551   \u250c\u2500\u2500\u2500\u2500\u2500\u2534\u2500\u2500\u2500\u2500\u2500\u2510   \u2551\n       \u2551   \u2502 Corrugated\u2502   \u2551 &lt;\u2500\u2500 Held by side-guide rollers\n       \u2551   \u2502 Pipe Coil \u2502   \u2551\n       \u2551   \u2514\u2500\u2500\u2500\u2500\u2500\u252c\u2500\u2500\u2500\u2500\u2500\u2518   \u2551\n       \u255a\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u256a\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u2550\u255d\n                 \u2502\n      [ PU Support Rollers ] \u2500\u2500&gt; Index coil 360&deg; circumferentially<\/code><\/pre>\n<p>Engineered for ergonomic manual loading, crane loading, or inline conveyor integration, the ring incorporates an automatic soft-start and soft-stop acceleration ramp. At the end of the wrap cycle, an integrated sensor and timing relay trigger the automatic home-position ring park mechanism for rapid unloading.<\/p>\n<figure>\n<img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2023\/01\/hose-wrapping-FPH-300N-zt.webp\" alt=\"Hose wrapping machine FPH-300N with wrapping ring and support rollers for small and light corrugated hose coils\" width=\"753\" height=\"760\" class=\"skip-lazy\">\n<figcaption><strong>Hose wrapping machine FPH-300N.<\/strong> Designed to wrap small and light corrugated hose coils with precision tension control.<\/figcaption>\n<\/figure>\n<h2 id=\"three-models\">Three models by roll size<\/h2>\n<p>Coil geometry (ID, OD, and axial width) defines the required ring opening and roller spacing. Payload weight is rarely the primary sizing constraint for corrugated products.<\/p>\n<table>\n<thead>\n<tr>\n<th>Engineering Parameter<\/th>\n<th>FPCA-100<\/th>\n<th>FPH-300N<\/th>\n<th>FPH-400W<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Coil Inner Diameter (ID)<\/td>\n<td>150\u2013350 mm<\/td>\n<td>300\u2013700 mm<\/td>\n<td>300\u20131,250 mm<\/td>\n<\/tr>\n<tr>\n<td>Coil Outer Diameter (OD)<\/td>\n<td>300\u2013500 mm<\/td>\n<td>500\u20131,000 mm<\/td>\n<td>700\u20131,500 mm<\/td>\n<\/tr>\n<tr>\n<td>Coil Width \/ Axial Height<\/td>\n<td>50\u2013200 mm<\/td>\n<td>100\u2013300 mm<\/td>\n<td>150\u2013400 mm<\/td>\n<\/tr>\n<tr>\n<td>Maximum Coil Weight<\/td>\n<td>5\u201350 kg<\/td>\n<td>10\u2013100 kg<\/td>\n<td>10\u2013100 kg<\/td>\n<\/tr>\n<tr>\n<td>Wrapping Cycle Time<\/td>\n<td>25\u201335 s<\/td>\n<td>23\u201335 s<\/td>\n<td>30\u201355 s<\/td>\n<\/tr>\n<tr>\n<td>Maximum Ring Speed<\/td>\n<td>100 r\/min<\/td>\n<td>120 r\/min<\/td>\n<td>100 r\/min<\/td>\n<\/tr>\n<tr>\n<td>Packaging Film Width<\/td>\n<td>50\u201370 mm<\/td>\n<td>90\u2013100 mm<\/td>\n<td>90\u2013120 mm<\/td>\n<\/tr>\n<tr>\n<td>Connected Drive Power<\/td>\n<td>1.5 kW<\/td>\n<td>1.9 kW<\/td>\n<td>1.5 kW<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<ul>\n<li><strong>Selection scenario A<\/strong>: A corrugated electrical conduit roll with 250 mm ID, 450 mm OD, 120 mm width, and 12 kg weight fits directly on the <strong>FPCA-100<\/strong>.<\/li>\n<li><strong>Selection scenario B<\/strong>: A corrugated agricultural sub-drainage coil measuring 600 mm ID, 1,200 mm OD, 350 mm width, and 65 kg requires the expanded ring clearance of the <strong>FPH-400W<\/strong>.<\/li>\n<\/ul>\n<h2 id=\"roller-support\">Why corrugated rolls need roller support<\/h2>\n<p>Unlike rigid steel or copper coils, a corrugated pipe coil behaves like an open-wound spring. When rotating on its belly, the roll experiences dynamic radial deflection and axial buckling. Uncontrolled, this flexibility causes lateral walking, rotational vibration, and uneven film application.<\/p>\n<p>Our wrapping systems stabilize corrugated rolls using three coordinated mechanical mechanisms:<\/p>\n<ul>\n<li><strong>Twin PU-Coated Driving Rollers<\/strong>: Support the coil belly, dampening rotational vibrations while delivering consistent non-slip friction drive to ribbed plastic surfaces.<\/li>\n<li><strong>Adjustable Lateral Guide Rollers<\/strong>: Straddle the roll flanks to prevent the package from shifting axially as tensioned film exerts lateral pull forces.<\/li>\n<li><strong>Mechanical Friction Tension Brake<\/strong>: Maintains constant web tension from full film reel to core depletion, ensuring light corrugated walls do not crush under excessive film neck-down.<\/li>\n<\/ul>\n<p>On heavy-duty units like the FPH-400W, roller drive friction and side-roller distance are independently adjustable to handle varying profile stiffness across HDPE, PP, and PVC materials.<\/p>\n<h2 id=\"overlap\">Overlap on a ribbed surface<\/h2>\n<p>Stretch film bridges across the outer ridges of corrugated pipe rather than conforming down into the annular valleys. Because air and moisture ingress occur primarily along these bridged gaps, maintaining an airtight package requires precise overlap control.<\/p>\n<p>The FPH-300N offers programmable overlap from 10% to 90%, while the FPH-400W operates between 20% and 90%.<\/p>\n<p>Because orbital wrapping creates a fan-like film distribution\u2014tightly bunched at the inner core and spread widest at the outer perimeter\u2014we calculate the required wrap count strictly at the outer diameter (OD), where gaps are most likely to open.<\/p>\n<pre><code>       Film Overlap Distribution on Annular Profile:\n\n            [ Outer Diameter (OD) ] \u2500\u2500 Wider spacing (Target: 30%&ndash;50% overlap)\n                   \\        \/\n                    \\      \/\n                     \\    \/\n                      \\  \/\n             [ Inner Diameter (ID) ] \u2500\u2500 Heavy film accumulation (Denser seal)<\/code><\/pre>\n<h3>Calculation Example: 250 mm ID \u00d7 450 mm OD Coil with 60 mm Film<\/h3>\n<ol>\n<li><strong>Outer Circumference Calculation<\/strong>:\n<code>C_OD = &pi; &times; OD = 3.1416 &times; 450 mm = 1,414 mm<\/code><\/li>\n<li><strong>Effective Pitch at 30% Overlap<\/strong>:\nWith a 60 mm film roll, 30% overlap means 70% effective advance per ring revolution:\n<code>Advance = 60 mm &times; (1 - 0.30) = 42 mm\/rev<\/code><\/li>\n<li><strong>Total Ring Wraps Required<\/strong>:\n<code>Wraps = 1,414 mm &divide; 42 mm\/rev &asymp; 34 wraps<\/code><\/li>\n<li><strong>Resulting Overlap at Inner Circumference (ID)<\/strong>:\n<code>C_ID = &pi; &times; ID = 3.1416 &times; 250 mm = 785 mm<\/code>\nThe same 34 wraps over 785 mm advance only:\n<code>Advance_ID = 785 mm &divide; 34 wraps &asymp; 23.1 mm\/rev<\/code>\nThis yields an overlap of:\n<code>[ (60 mm - 23.1 mm) &divide; 60 mm ] &times; 100% &asymp; 61.5%<\/code><\/li>\n<\/ol>\n<p>The film naturally forms a multi-layer protective barrier at the coil eye. The carriage&#8217;s mechanical brake prevents film twisting or neck-down creasing throughout the cycle.<\/p>\n<h2 id=\"cycle-time\">Cycle time<\/h2>\n<p>Net packaging throughput depends on ring rotation speed, programmed overlap percentage, and operator handling speed:<\/p>\n<table>\n<thead>\n<tr>\n<th>Machine Model<\/th>\n<th>Pure Wrapping Cycle<\/th>\n<th>Theoretical Output (Excluding Handling)*<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>FPCA-100<\/strong><\/td>\n<td>25\u201335 s \/ roll<\/td>\n<td>102\u2013144 rolls \/ hour<\/td>\n<\/tr>\n<tr>\n<td><strong>FPH-300N<\/strong><\/td>\n<td>23\u201335 s \/ roll<\/td>\n<td>102\u2013156 rolls \/ hour<\/td>\n<\/tr>\n<tr>\n<td><strong>FPH-400W<\/strong><\/td>\n<td>30\u201355 s \/ roll<\/td>\n<td>65\u2013120 rolls \/ hour<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>*Note: Actual floor capacity depends on whether loading is performed manually, with an overhead balancer, or via powered indexing conveyors. Loading and unloading typically add 15 to 30 seconds per cycle for standalone operations.<\/em><\/p>\n<h2 id=\"utilities-and-safety\">Utilities and safety<\/h2>\n<table>\n<thead>\n<tr>\n<th>Technical Utility<\/th>\n<th>Specification \/ Parameter<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Connected Power<\/td>\n<td>1.5 kW (FPCA-100, FPH-400W) \/ 1.9 kW (FPH-300N)<\/td>\n<\/tr>\n<tr>\n<td>Standard Supply Voltage<\/td>\n<td>380 V AC, 50\/60 Hz, 3-Phase (Optional 220 V \/ 480 V configurations)<\/td>\n<\/tr>\n<tr>\n<td>Film Core Internal Diameter<\/td>\n<td>50 mm ID core (standard orbital film roll)<\/td>\n<\/tr>\n<tr>\n<td>Control Circuit<\/td>\n<td>24 V DC safe control voltage<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>Safety Systems and Regulatory Compliance<\/h3>\n<ul>\n<li><strong>Physical Guarding<\/strong>: Integrated perimeter mesh guard enclosures isolate the orbital ring rotation path from the operator loading station.<\/li>\n<li><strong>Drive Protection<\/strong>: Motor overcurrent detection, thermal overload protection, and dynamic braking prevent ring overrun.<\/li>\n<li><strong>Jog &amp; Setup Modes<\/strong>: Auxiliary foot-switch control allows controlled, low-speed jogging during film loading and roll positioning.<\/li>\n<li><strong>International Standards<\/strong>: Built to comply with <strong>ISO 12100:2010<\/strong> (Safety of machinery \u2014 Basic concepts, general principles for design) and <strong>EN 415-10:2014<\/strong> (Safety of packaging machines \u2014 General requirements).<\/li>\n<\/ul>\n<h2 id=\"selection-checklist\">Selection checklist<\/h2>\n<p>Confirm the following engineering parameters prior to requesting a formal proposal:<\/p>\n<ul>\n<li><strong>Coil Dimensions<\/strong>: Minimum and maximum ID, OD, and width (axial face thickness).<\/li>\n<li><strong>Weight Range<\/strong>: Minimum and maximum gross roll weight (kg).<\/li>\n<li><strong>Material Specification<\/strong>: Corrugated material type (PE, PP, PVC, PA) and single-wall vs. double-wall rib profile.<\/li>\n<li><strong>Target Throughput<\/strong>: Required continuous production output (rolls per hour).<\/li>\n<li><strong>Wrapping Material<\/strong>: Stretch film (PE), crepe paper, woven polypropylene tape, or knit-mesh stretch film.<\/li>\n<li><strong>Material Handling<\/strong>: Manual operator loading, pneumatic ejector ramp, or automated infeed\/outfeed integration.<\/li>\n<li><strong>Site Utilities<\/strong>: Exact plant voltage, frequency, and local safety disconnect requirements.<\/li>\n<\/ul>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<h3>Q: Which wrapping model is recommended for small electrical corrugated conduit?<\/h3>\n<p><strong>A:<\/strong> The <strong>FPCA-100<\/strong> is specifically proportioned for small conduit coils with inner diameters between 150\u2013350 mm, outer diameters between 300\u2013500 mm, and coil weights up to 50 kg.<\/p>\n<h3>Q: Which model handles large agricultural and stormwater drainage coils?<\/h3>\n<p><strong>A:<\/strong> The <strong>FPH-400W<\/strong> accommodates large pipe bundles up to 1,500 mm OD and 1,250 mm ID, featuring heavy-duty guide assemblies designed for wide-face coils.<\/p>\n<h3>Q: How does the system prevent flexible pipe rolls from uncoiling during wrapping?<\/h3>\n<p><strong>A:<\/strong> The machine combines adjustable polyurethane base rollers with vertical side-guide rollers to constrain the coil radially and laterally. In addition, the tension-controlled film carriage applies balanced hoop stress, pulling the ribs tightly into an integral bundle.<\/p>\n<h3>Q: What is the realistic continuous output for a single machine?<\/h3>\n<p><strong>A:<\/strong> For a standard model such as the FPCA-100 or FPH-300N, the automated wrapping cycle runs in 25\u201335 seconds. With manual staging and removal, average production yields between 60 and 90 wrapped rolls per hour.<\/p>\n<h3>Q: How is film overlap adjusted for different transport environments?<\/h3>\n<p><strong>A:<\/strong> Overlap is controlled directly from the control console via independent inverter frequency presets. Increasing ring speed relative to roller rotation increases overlap (up to 90%) for complete weather protection and moisture sealing.<\/p>\n<h2 id=\"next-step\">Next step<\/h2>\n<p>To size your pipe coil wrapping equipment:<\/p>\n<ol>\n<li><strong>Submit your dimensional matrix<\/strong> (minimum\/maximum ID, OD, width, weight, and hourly target) to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Receive an engineering proposal within 48 hours<\/strong>, including recommended ring sizing, roller configuration, film consumption estimates, and overlap calculations.<\/li>\n<li><strong>Schedule an application review<\/strong> with our engineering team to finalize layout drawings and conveyor interfaces.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/corrugated-hose-packing-machine.html\">Corrugated hose packing machine FPCA-100 technical details<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/Hose-wrapping-machine-FPH-300.html\">Hose wrapping machine FPH-300N specifications<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/Hose-Coil-wrapping-machinery-FPH-400.html\">Hose coil wrapping machinery FPH-400W configuration<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/\">Full range of horizontal &amp; orbital hose packaging systems<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/hose-stretch-wrapping-machine-pipe-coil-packing-machines-4\/\">Video library: automatic hose and coil wrapping equipment<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li>FPCA-100 Technical Specifications &amp; Operating Guidelines: <a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/corrugated-hose-packing-machine.html\">FHOPE Corrugated Hose Packing Series<\/a><\/li>\n<li>FPH-300N Engineering Data &amp; Speed Ratings: <a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/Hose-wrapping-machine-FPH-300.html\">FHOPE FPH-300N Product Page<\/a><\/li>\n<li>FPH-400W Heavy-Duty Dimensional Ranges: <a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/Hose-Coil-wrapping-machinery-FPH-400.html\">FHOPE FPH-400W Overview<\/a><\/li>\n<li>Machine Operation Video Demonstration: <a href=\"https:\/\/www.fhopepack.com\/videos\/hose-stretch-wrapping-machine-pipe-coil-packing-machines-4\/\">FHOPE Corrugated Pipe Rolls Wrapping Demonstration<\/a><\/li>\n<li>Machinery Safety Directives: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 Safety of Machinery<\/a>, <a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 Safety of Packaging Machines<\/a><\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-04<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary Flexible corrugated pipe and conduit rolls present unique packaging challenges: they are physically bulky, lightweight, and prone to springy radial deformation during rotation. In orbital eye-through stretch wrapping, the coil&#8217;s inner diameter (ID) [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2455,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Flexible Corrugated Pipe Rolls Wrapping Machine Guide","_seopress_titles_desc":"How we size a wrapping machine for flexible corrugated pipe rolls: coil windows for FPCA-100, FPH-300N and FPH-400W, roller support, overlap and cycle 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