A mid‑size tire manufacturer in Southeast Asia replaced four manual packers per shift with the FPT‑300, achieving 136 tires per hour, 75% labor reduction, and near‑zero film waste. This case study demonstrates how a $28,000 investment—including optional auto‑cut and logo‑taping systems—paid back in 3.5 months while raising packing OEE from 68% to 94%.
🛠️ Client Background
The client, a mid‑sized tire manufacturer producing 3,000 passenger tires daily on two lines, faced a chronic bottleneck in their packing area. Manual stretch wrapping consumed four operators per shift, 40 kg of film per day, and incurred a 2% surface‑damage rate—dragging packing OEE below 70% against a plant target of 85%.
The plant manager (referred to here as the plant manager) reported that a new contract for 50,000 tires per month with a major auto‑parts distributor demanded reliable, high‑volume packing with clear barcode labeling. The factory layout had limited floor space—only 8 m × 5 m available near the outfeed conveyor—and the team needed a system that could handle standard passenger tires (55‑series, 16‑inch) as well as occasional SUV tires up to 20‑inch. The plant manager began searching for a compact, automatic tire wrapping machine that would integrate with the existing roller conveyor and minimize downtime during installation.
🏗️ Challenge
The manual packing process could not keep pace with the new production target of 125 tires per hour per line, and 30% annual labor turnover compounded the problem. Baseline metrics showed 65 packs per hour with 8% film waste, 2% surface damage, 15‑minute changeover times, and a separate label application step that added 10 seconds per tire.
| Issue | Measured Baseline |
|---|---|
| Throughput | 65 packs per hour, 4 workers |
| Film waste | 8% from over‑wrap and misalignment |
| Surface damage | 2% of tires scuffed during hand wrapping |
| Changeover time | 15 min between tire sizes (manual adjustment) |
| Label application | Separate step, 10 sec extra per tire |
Every new hire required two weeks to reach full speed, and inconsistent tension caused film breakage on high‑speed runs. The operations manager needed a solution that would:
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Increase packing speed to at least 120 tires per hour per line.
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Reduce direct labor to one operator per shift (overseeing the machine).
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Eliminate film waste and surface marks.
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Integrate optional logo‑taping for distributor branding.
📈 Solution Design
After evaluating three suppliers, the team selected FHOPEPACK’s standard FPT‑300, a horizontal tire wrapping machine with a rotating ring that applies PE stretch film around the tire circumference. The machine’s technical parameters—tire OD 500–1300 mm, width 50–350 mm, weight 5–80 kg—exactly matched the client’s tire range.
| Parameter | FPT‑300 Spec | Client Requirement |
|---|---|---|
| Tire weight | 5–80 kg | Up to 25 kg |
| Tire width | 50–350 mm | 200–280 mm |
| Tire OD | 500–1300 mm | 600–800 mm |
| Tire ID | 300–700 mm | 380–450 mm |
| Packing speed | 15–25 sec/piece | ≤20 sec desired |
| Rotating speed | 40–110 r/min | Adjustable |
| Overlap | 20%–90% | 50% default |
| Film roll | PE, ID 50 mm, OD 80–120 mm, width 90 mm | Standard 500 mm film |
The machine operates in a horizontal pass‑through configuration: tires move on a short roller conveyor, the ring rotates around the tire, and film is applied with programmable overlap. The standard model includes a PLC touchscreen with 10 recipe presets.
Two options addressed specific client needs:
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Option 1 – Auto film cutting system: A heated knife cuts the film automatically at each cycle end, eliminating manual tearing or cutting. This reduced cycle time by 3 seconds and prevented film tail waste.
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Option 2 – Auto logo taping system: A tape applicator places a branded tape over the final wrap (tape: core ID 76 mm, OD 120–200 mm, width 70–100 mm). This allowed the distributor’s logo to appear on every tire without slowing the line.
The final system included a 2‑meter infeed conveyor and a 1.5‑meter outfeed conveyor. Power: 380 V / 50 Hz / 3‑phase, 1.5 kW. Air supply: 5–7 bar.
🛡️ Implementation
Installation took six days—including mechanical setup and PLC programming—followed by a two‑day operator training session. The plant manager reported a learning curve of about four hours before operators could run at full speed.
| Phase | Duration | Activities |
|---|---|---|
| Site prep | 1 day | Floor anchors, air & power drops (existing line) |
| Mechanical installation | 3 days | Position FPT‑300, align conveyors, mount ring guard |
| Electrical & PLC wiring | 1 day | Connect to 380V/50Hz, set up touchscreen recipes |
| Commissioning | 1 day | Dry run with scrap tires, calibrate tension & overlap |
| Training | 2 days | 8 operators trained on basic operation, recipe change, error recovery |
| Production ramp | 3 days | Gradual speed increase from 50% to 100% capacity |
Key decisions based on the client’s space and workflow:
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Infeed conveyor placed at 1.2 m height to match existing outfeed from tire building machine.
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Outfeed conveyor extended 3 m to accumulate wrapped tires before palletizing.
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Recipe set: Three presets for passenger tire (OD 650 mm, width 220 mm, 50% overlap, 80 r/min), SUV tire (OD 800 mm, width 280 mm, 60% overlap, 70 r/min), and a spare for future models.
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Auto‑cut system enabled after 20 validation cycles.
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Logo‑taping system calibrated using test rolls supplied by the client’s label vendor.
One supervisor was assigned to monitor OEE and film loading.
⚙️ Results Data
After eight weeks of production, the FPT‑300 delivered a 210% increase in throughput while reducing labor by 75% and cutting film waste to near zero. Cycle time dropped from 55 seconds to 20 seconds, changeover time from 15 minutes to under 2 minutes, and surface damage from 2% to 0.1%.
| Metric | Before (Manual) | After (FPT‑300) | Improvement |
|---|---|---|---|
| Throughput (tires/hour) | 65 | 136 | +109% |
| Operators per shift | 4 | 1 | −75% |
| Cycle time (sec/tire) | 55 | 20 (with auto‑cut) | −64% |
| Film waste (%) | 8% | <0.5% (auto‑cut + recipe) | −94% |
| Surface damage (%) | 2% | 0.1% (consistent tension) | −95% |
| Changeover time (min) | 15 | <2 min (recipe recall) | −87% |
| Logo tape application | separate 10 sec | integrated, 0 sec (during wrap) | eliminated |
The machine ran at an average rotating speed of 95 r/min with 50% overlap, later reduced to 35% for SUV tires. Air consumption remained stable at 6 bar. Operator feedback: “I can run two machines now with the same effort I used to run one.” No unscheduled downtime occurred after the first week. The auto‑cut system required one blade replacement after 8,000 cycles; the supplier recommends replacement every 10,000 cycles or six months.
🛠️ ROI Analysis
Total project cost was $28,000, comprising the base FPT‑300 ($21,500), auto‑cut system ($3,000), logo‑tap system ($2,500), and installation/training ($1,000). Based on the client’s Southeast Asian labor and material costs (regional averages; verify for your location), annual savings totaled $97,020, yielding a simple payback of 3.5 months.
| Cost Factor | Before (annual) | After (annual) | Savings |
|---|---|---|---|
| Labor (4 operators × 3 shifts × $4.50/hr × 2,080 hr) | $112,320 | $28,080 (1 operator) | $84,240 |
| Film waste (8% × 40 kg/day × 300 days × $3.00/kg) | $2,880 | $0 (auto‑cut eliminates waste) | $2,880 |
| Surface damage (2% × 3,000 tires/day × 300 days × $0.50/scratch) | $9,000 | $450 (0.1%) | $8,550 |
| Logo tape labor (separate step: 1 hr/day × $4.50 × 300 days) | $1,350 | $0 (integrated) | $1,350 |
| Total annual savings | $97,020 |
Note: Labor and material cost figures are based on regional averages for Southeast Asia at the time of the case study. Readers should verify local rates and supply prices for their own ROI calculation.
Simple payback = $28,000 / $97,020 = 3.5 months. The client recovered the entire investment in less than one production quarter. After one year, net savings exceeded $69,000, and the machine added capacity headroom for future volume increases without adding labor. Additionally, safety incidents from manual film handling dropped to zero (vs. two minor hand cuts in the prior year). OEE for the packing station rose from 68% to 94%, directly contributing to the plant’s overall 85% target.
ROI Insight: When evaluating an automatic tire wrapping machine, include labor replacement, film waste reduction, and damage‑related rework costs. The FPT‑300’s optional auto‑cut system alone saved $2,880 per year in film and eliminated a manual step.
🏗️ Purchase‑Decision Checklist
Before ordering an automatic tire wrapping machine, verify these four items using your actual tire mix and production data. This checklist is based on the FPT‑300 specifications and the case study experience.
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[ ] Tire size envelope – Confirm max/min OD, width, and weight against the machine’s table. The FPT‑300 covers OD 500–1300 mm, width 50–350 mm, weight 5–80 kg. If your tires fall outside, request a custom version.
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[ ] Cycle time target – The FPT‑300 runs 15–25 sec/piece. Calculate whether this matches your required output per hour (including conveyor buffer). For higher speed, consider a dual‑ring configuration (not covered in this case).
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[ ] Film and tape compatibility – Standard PE stretch film rolls: ID 50 mm, OD 80–120 mm, width 90 mm. Logo tape: core ID 76 mm, OD ≤200 mm, width 70–100 mm. Ensure your supply chain can source these sizes.
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[ ] Integration requirements – Does your existing conveyor height match the machine’s infeed/outfeed? The FPT‑300 requires 5–7 bar compressed air and 380V/50Hz/3‑phase. Include installation costs in your budget.
🛡️ Compliance Note: This equipment is designed to meet ISO and ASTM requirements. Verify with the manufacturer.
📈 FAQ
Q: How often does the auto‑cut system blade need replacement?
Based on supplier recommendations, the heated knife should be checked every 10,000 cycles or six months, whichever comes first. In the case study, the first blade lasted 8,000 cycles. Replacement cost is approximately $80 per blade.
Q: Can the FPT‑300 handle run‑flat tires or tires with sidewall protrusions?
The standard machine is designed for conventional tire profiles. For run‑flat tires with stiff sidewalls or protrusions, consult FHOPEPACK about a wider ring clearance or a custom soft‑roller option. The case study tires were standard passenger and SUV models without protrusions.
Q: What is the typical power consumption per shift?
The motor is rated at 1.5 kW. At a 75% duty cycle (running 18 seconds out of every 20‑second cycle), average consumption is about 1.1 kW. Over an 8‑hour shift with 500 cycles, that’s roughly 8.8 kWh—negligible compared to overall plant electricity.
