{"id":80,"date":"2018-04-17T08:21:36","date_gmt":"2018-04-17T08:21:36","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=80"},"modified":"2026-10-26T14:18:39","modified_gmt":"2026-10-26T14:18:39","slug":"automatic-pipe-coiling-and-wrapping-machineryhose-coiler","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-pipe-coiling-and-wrapping-machineryhose-coiler\/","title":{"rendered":"Hose Coil Wrapping and Cartoning Line: Pacing Each Station from Your Hose Output"},"content":{"rendered":"<blockquote>\n<p><strong>Executive Summary<\/strong>\nAn automated packaging line takes extruded hose directly from coiling, wraps each coil toroidally with protective stretch film, transfers it via gantry pick-and-place into a carton, and completes inline tape sealing and strapping. Sizing this line is not a catalog-matching exercise\u2014it is governed strictly by your extrusion output: <strong>hose meters per shift<\/strong> divided by <strong>target length per coil<\/strong>, distributed across net productive shift hours. In this technical bulletin, we calculate the engineering baseline for a <strong>75 coil\/hour line<\/strong>, establishing the critical <strong>48-second theoretical station budget<\/strong> (and the net <strong>38.4-second design cycle<\/strong> required under real-world 80% OEE constraints).<\/p>\n<\/blockquote>\n<hr \/>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/irq3haBQrXU\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<h2>Table of Contents<\/h2>\n<ul>\n<li><a href=\"#line-architecture\">Line Architecture: From Coiling to Sealed Case<\/a><\/li>\n<li><a href=\"#sequence\">Automated Packaging Sequence and Kinematics<\/a><\/li>\n<li><a href=\"#pace\">Pacing Engineering: Sizing Station Cycle Budgets from Line Output<\/a><\/li>\n<li><a href=\"#reference\">Equipment Envelope and OEM Reference Specifications<\/a><\/li>\n<li><a href=\"#why-wrap\">Packaging Metallurgy: The Structural Purpose of Toroidal Wrapping<\/a><\/li>\n<li><a href=\"#safety\">Machine Safety, Controls, and Compliance Standards<\/a><\/li>\n<li><a href=\"#checklist\">Engineering Checklist for Line RFQ<\/a><\/li>\n<li><a href=\"#faq\">Frequently Asked Questions (FAQ)<\/a><\/li>\n<li><a href=\"#next-step\">Next Step: 48-Hour Engineering Review<\/a><\/li>\n<li><a href=\"#related-reading\">Related Packaging Solutions<\/a><\/li>\n<li><a href=\"#sources\">Technical References<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"line-architecture\">Line Architecture: From Coiling to Sealed Case<\/h2>\n<p>Modern flexible hose extrusion requires continuous downstream handling to prevent backpressure and line stalling. The automated turnkey system shown in the operational deployment combines five discrete sub-assemblies into an uninterrupted packaging flow:<\/p>\n<ol>\n<li><strong>Automatic Coiling Station<\/strong>: Receives continuous extruded hose, traversing it across an adjustable collapsible mandrel under an overhead containment flange to ensure uniform coil geometry.<\/li>\n<li><strong>Servo Transfer Arm<\/strong>: Unloads the tied or held coil from the coiler mandrel and indexes it onto the wrapping cradle.<\/li>\n<li><strong>Toroidal Eye-Through Wrapping Machine<\/strong>: Dual driven cradle rollers spin the coil along its horizontal axis while an orbital shuttle ring passes stretch film through the coil&#8217;s core (&#8220;eye&#8221;), wrapping it radially.<\/li>\n<li><strong>Gantry Pick-and-Place Cartoning Cell<\/strong>: A Cartesian overhead transfer unit equipped with pneumatic expanding chucks or multi-point perimeter clamps lifts the wrapped coil and lowers it into a waiting corrugated case.<\/li>\n<li><strong>Inline Case Finishing Line<\/strong>: Continuous side-belt driven top-and-bottom tape sealer followed by an integrated dual-head polypropylene (PP) strapping station.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"sequence\">Automated Packaging Sequence and Kinematics<\/h2>\n<p>The operational cycle progresses sequentially across dedicated mechanical cells. The motion profile below illustrates the functional staging of each product transfer:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Station ID<\/th>\n<th style=\"text-align: left\">Kinematic Operation<\/th>\n<th style=\"text-align: left\">Machine Mechanism<\/th>\n<th style=\"text-align: left\">Operational Reference<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>01: Winding &amp; Cut<\/strong><\/td>\n<td style=\"text-align: left\">Automatic coiling, pitch traversal, and tail clamping<\/td>\n<td style=\"text-align: left\">Expanding mandrel with pneumatic top press flange<\/td>\n<td style=\"text-align: left\">Initial forming cycle<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>02: Indexing<\/strong><\/td>\n<td style=\"text-align: left\">Coil extraction and inter-station staging<\/td>\n<td style=\"text-align: left\">Mechanical pick-up clamp transfer arm<\/td>\n<td style=\"text-align: left\">Mandrel-to-wrapper handoff<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>03: HMI Setup<\/strong><\/td>\n<td style=\"text-align: left\">Stored recipe loading (OD, ID, width, pitch)<\/td>\n<td style=\"text-align: left\">Industrial PLC with touchscreen parameter recall<\/td>\n<td style=\"text-align: left\">Pre-programmed batch run<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>04: Toroidal Wrap<\/strong><\/td>\n<td style=\"text-align: left\">Through-the-eye orbital stretch wrapping<\/td>\n<td style=\"text-align: left\">Dual driven support rollers and high-speed rotary ring<\/td>\n<td style=\"text-align: left\">100% surface encapsulation<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>05: Pick &amp; Place<\/strong><\/td>\n<td style=\"text-align: left\">Gantry coil lifting and targeted case drop-in<\/td>\n<td style=\"text-align: left\">Multi-point pneumatic clamp on overhead 2-axis gantry<\/td>\n<td style=\"text-align: left\">Direct loading into open carton<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>06: Case Seal &amp; Strap<\/strong><\/td>\n<td style=\"text-align: left\">Top flap folding, tape application, and dual band strap<\/td>\n<td style=\"text-align: left\">Synchronized belt taper and automatic arch strapper<\/td>\n<td style=\"text-align: left\">Outfeed to palletizing<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: Cycle transitions occur concurrently across stations. While Station 04 wraps coil N, Station 05 packs coil N-1, ensuring non-accumulating continuous throughput.<\/em><\/p>\n<hr \/>\n<h2 id=\"pace\">Pacing Engineering: Sizing Station Cycle Budgets from Line Output<\/h2>\n<p>Line speed cannot be chosen arbitrarily; it must absorb upstream extrusion capacity without buffer overflow. Consider the following plant output model:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Engineering Parameter<\/th>\n<th style=\"text-align: left\">Sizing Calculation<\/th>\n<th style=\"text-align: left\">Metric Value<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Extruder Shift Output<\/td>\n<td style=\"text-align: left\">Plant production schedule<\/td>\n<td style=\"text-align: left\">30,000 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Finished Hose Length per Coil<\/td>\n<td style=\"text-align: left\">Product packaging specification<\/td>\n<td style=\"text-align: left\">50 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Gross Units Required per Shift<\/td>\n<td style=\"text-align: left\">30,000 m \u00f7 50 m<\/td>\n<td style=\"text-align: left\">600 coils<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Operating Shift Duration<\/td>\n<td style=\"text-align: left\">Nominal shift hours<\/td>\n<td style=\"text-align: left\">8.0 h<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Theoretical Packaging Rate<\/td>\n<td style=\"text-align: left\">600 coils \u00f7 8 h<\/td>\n<td style=\"text-align: left\"><strong>75 coils\/hour<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Gross Station Budget (T_theoretical)<\/td>\n<td style=\"text-align: left\">3,600 s \u00f7 75 coils<\/td>\n<td style=\"text-align: left\"><strong>48.0 s\/coil<\/strong><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h3>The Critical OEE Kinematic Derivation<\/h3>\n<p>Packaging machinery in continuous operation never sustains 100% theoretical uptime. Unplanned minor stops, stretch film roll replacement, strap coil splices, and corrugated box staging degrade efficiency. <\/p>\n<p>To design a robust system, we apply an industry-standard <strong>80% Net Operating Efficiency (OEE)<\/strong> factor:<\/p>\n<p><code>T_design = T_theoretical &times; OEE = 48.0 s &times; 0.80 = 38.4 s<\/code><\/p>\n<p><strong>Engineering Takeaway<\/strong>: Every individual automated station (Wrapping, Pick-and-Place, Case Sealing) must complete its full physical cycle\u2014including mechanical clamp, dwell, transfer, and reset\u2014in <strong>\u2264 38.4 seconds<\/strong>. If the toroidal wrapper requires 42 seconds, an upstream buffer accumulation turntable is mandatory to prevent throttling the extruder.<\/p>\n<hr \/>\n<h2 id=\"reference\">Equipment Envelope and OEM Reference Specifications<\/h2>\n<p>The integrated packaging line belongs to the heavy-duty FHOPE automated coil packaging family, engineered within the following standardized mechanical envelope:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Parameter<\/th>\n<th style=\"text-align: left\">Standard Industrial Envelope<\/th>\n<th style=\"text-align: left\">Heavy-Duty Modular Range<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Coil Weight Capacity<\/strong><\/td>\n<td style=\"text-align: left\">8 to 50 kg<\/td>\n<td style=\"text-align: left\">Up to 300 kg+<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Outer Diameter (OD)<\/strong><\/td>\n<td style=\"text-align: left\">500 to 650 mm<\/td>\n<td style=\"text-align: left\">400 to 1,200 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Inner Diameter (ID)<\/strong><\/td>\n<td style=\"text-align: left\">350 to 400 mm<\/td>\n<td style=\"text-align: left\">200 to 800 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Coil Width \/ Height<\/strong><\/td>\n<td style=\"text-align: left\">150 to 250 mm<\/td>\n<td style=\"text-align: left\">Up to 500 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Orbital Ring Rotation<\/strong><\/td>\n<td style=\"text-align: left\">60 to 120 RPM (VFD controlled)<\/td>\n<td style=\"text-align: left\">High-speed dual ring options<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Packaging Consumables<\/strong><\/td>\n<td style=\"text-align: left\">LLDPE stretch film, PE, PVC, woven tape<\/td>\n<td style=\"text-align: left\">Reinforced anti-rust VCI film<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Overlap Range<\/strong><\/td>\n<td style=\"text-align: left\">10% to 90% (programmable via HMI)<\/td>\n<td style=\"text-align: left\">Proportional to ring\/roller drive ratio<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Required Operating Crew<\/strong><\/td>\n<td style=\"text-align: left\">1 Line Monitor \/ Material Stager<\/td>\n<td style=\"text-align: left\">0 (Fully lights-out integrated line)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>System configuration dictates throughput: standalone wrapping cells achieve 20\u201340 s per coil, while complete packaging and cartoning configurations are dynamically balanced based on gantry stroke distances.<\/em><\/p>\n<hr \/>\n<h2 id=\"why-wrap\">Packaging Metallurgy: The Structural Purpose of Toroidal Wrapping<\/h2>\n<p>Placing an unwrapped flexible hose directly into a corrugated box introduces severe quality liabilities during distribution:<\/p>\n<ol>\n<li><strong>Abrasion Prevention<\/strong>: Micro-vibrations during intermodal freight cause corrugated board to scuff matte or high-gloss rubber\/PVC hose exteriors. Tight LLDPE stretch film creates an immutable friction barrier.<\/li>\n<li><strong>Radial Tension Retention<\/strong>: Coiled elastomeric hoses retain internal spring energy. Toroidal wrapping locks the outer wraps to the core, preventing coil expansion that could split carton corner seams.<\/li>\n<li><strong>Moisture and Dust Ingress<\/strong>: Retail cartons frequently absorb atmospheric humidity, weakening structural crush resistance. The internal film wrap ensures the product arrives pristine even if the external carton degrades.<\/li>\n<li><strong>Standalone Merchandising<\/strong>: If a distribution hub decants the master carton, the individual coil retains tamper-evident protection and branding integrity on open retail shelves.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"safety\">Machine Safety, Controls, and Compliance Standards<\/h2>\n<p>Automated handling lines present severe crush, nip, and shear hazards across the coiler mandrel, rotating orbital ring, high-speed gantry arm, and carton drive belts.<\/p>\n<ul>\n<li><strong>Harmonized Safety Compliance<\/strong>: All integrated cells adhere to <strong>ISO 12100:2010<\/strong> (Risk Assessment and Reduction) and <strong>EN 415-6<\/strong> (Safety Requirements for Wrapping Machines).<\/li>\n<li><strong>Perimeter Guarding<\/strong>: Interlocked physical safety perimeter fencing with safety light curtains safeguarding the gantry transfer and carton infeed zones.<\/li>\n<li><strong>Control Architecture<\/strong>: Dual-channel Category 3 \/ PLd safety relays, localized Emergency Stop pushbuttons, and lockable pneumatic dump valves (LOTO compliant) to exhaust stored actuator pressure during servicing.<\/li>\n<li><strong>HMI Interlocking<\/strong>: Guard open signals instantly isolate the orbital drive inverter via Safe Torque Off (STO), bringing the high-inertia wrapping ring to a mechanical stop within standard braking thresholds.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"checklist\">Engineering Checklist for Line RFQ<\/h2>\n<p>Prior to obtaining an equipment proposal, your manufacturing team must establish the following physical boundary conditions:<\/p>\n<ul>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Hose Envelope<\/strong>: Minimum and maximum coil dimensions (OD, ID, Width, Weight range).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Extrusion Dynamics<\/strong>: Peak extruder output (meters\/minute and coils\/hour target).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Carton Automation Level<\/strong>: Manual box erection vs. integration with an upstream Automatic Case Erector.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Packaging Recipe<\/strong>: Desired film thickness (typically 20\u201335 \u00b5m LLDPE) and target overlap percentage.<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Strapping Specifications<\/strong>: None, single-strap, or cross-strapping (2 parallel bands).<\/li>\n<li style=\"margin-left:-1.25em;list-style-type:none\"><input type=\"checkbox\" disabled=\"disabled\" \/> <strong>Footprint &amp; Flow Constraints<\/strong>: Plant layout drawing showing product entry vector, carton magazine staging, and palletizer handoff height.<\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"faq\">Frequently Asked Questions (FAQ)<\/h2>\n<h3>Q: How do we calculate the line speed requirement for our extrusion cell?<\/h3>\n<p>A: Divide your gross shift output (in meters) by the hose length per coil to obtain total coils per shift. Divide this figure by your net shift hours to establish the required coils per hour, then calculate available station cycle time (<code>3,600 s &divide; Coils\/Hour<\/code>).<\/p>\n<h3>Q: Why must station cycle times be engineered lower than the line budget?<\/h3>\n<p>A: Real-world packaging efficiency hovers around 80% to 85% due to film roll splicing, strap reel reloading, and corrugated jam clearance. Sizing each sub-station to a 38-second target ensures the line comfortably fulfills a 48-second gross shift pacing requirement.<\/p>\n<h3>Q: What is the mechanical difference between orbital wrapping and eye-through wrapping?<\/h3>\n<p>A: Orbital wrapping wraps linear products along a horizontal feed axis. Eye-through (toroidal) wrapping passes a continuous film dispenser directly through the open center core (ID) of a radial coil, wrapping the circular cross-section 360 degrees.<\/p>\n<h3>Q: Can the gantry pick-and-place station handle varying carton depths?<\/h3>\n<p>A: Yes. The Cartesian gantry utilizes servo-driven vertical axes (Z-axis) managed via PLC recipe controls, allowing auto-adjusting drop depths for different carton heights without manual re-tooling.<\/p>\n<hr \/>\n<h2 id=\"next-step\">Next Step: 48-Hour Engineering Review<\/h2>\n<p>To validate your line cycle time against live extrusion production:<\/p>\n<ol>\n<li><strong>Submit Product Data<\/strong>: Send your coil OD\/ID\/Height range, hose rigidity rating, and carton drawings to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Kinematic Cycle Simulation<\/strong>: Our engineering department provides a complete 3D station simulation and layout proposal within <strong>48 hours<\/strong>.<\/li>\n<li><strong>Factory Acceptance Protocol<\/strong>: Review factory floor layouts, safety boundary clearances, and utility tie-in schematics with our technical team.<\/li>\n<\/ol>\n<hr \/>\n<h2 id=\"related-reading\">Related Packaging Solutions<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Hose-packaging-machine\/\">Automatic Hose Packaging Machinery Platforms<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/online-auto-cable-coiling-and-wrapping-machine\/\">Online Automated Cable Coiling, Tying, and Boxing Systems<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-pipe-coiling-and-wrapping-machine-for-hose-and-plastic-tubes\/\">High-Speed Industrial Tube and Conduit Coil Wrapping Equipment<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2 id=\"sources\">Technical References<\/h2>\n<ul>\n<li><strong>OEM Machine Class Portfolio<\/strong>: <a href=\"https:\/\/www.fhopepack.com\/Automatic-Coil-Packing-Line\/Hose-Coil-Packaging-line.html\">FHOPE Hose Coil Packaging Line Family Standards<\/a><\/li>\n<li><strong>Packaging Machine Functional Safety Standards<\/strong>: ISO 12100:2010 (Safety of Machinery \u2014 General Principles for Design)<\/li>\n<li><strong>Specialized Wrapping Safety Directives<\/strong>: EN 415-6 (Safety of Packaging Machines: Wrapping Machines)<\/li>\n<li><strong>Cycle &amp; Kinematic Data<\/strong>: Industrial Packaging Line Kinematics Application Guidelines (OEM Technical Library)<\/li>\n<\/ul>\n<p><em>Document Revision: Rev 3.2 | Field Validated<\/em><\/p>","protected":false},"excerpt":{"rendered":"<p>Automatic pipe coiling and wrapping machinery for PE\/PVC pipes and hoses. Coil ID 120-300mm, OD 300-500mm. 18-35 seconds per coil. PLC control. Get quote from FHOPE.<\/p>","protected":false},"author":1,"featured_media":2342,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Hose Coil Wrapping and Cartoning Line","_seopress_titles_desc":"How our hose coil line wraps each coil in clear film, lifts it into an open carton and seals the carton, with a coils-per-hour example from your 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