{"id":16822,"date":"2026-07-06T14:57:35","date_gmt":"2026-07-06T06:57:35","guid":{"rendered":"https:\/\/www.fhopepack.com\/zh\/?p=16822"},"modified":"2026-07-06T14:57:35","modified_gmt":"2026-07-06T06:57:35","slug":"steel-tube-bundle-packing-system-for-small-od-pipe-2","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/zh\/steel-tube-bundle-packing-system-for-small-od-pipe-2\/","title":{"rendered":"steel tube bundle packing system for small OD pipe."},"content":{"rendered":"<p><strong>A European <a href=\"https:\/\/www.fhopepack.com\/Aluminum\/\">steel tube manufacturer<\/a> replaced manual bundling of small-diameter pipes (\u00d820\u201325\u202fmm) with FHOPE\u2019s automatic bundle packing line, achieving 85 bundles\/hour, \u00b11 rod counting accuracy, and a 60% labor reduction \u2014 delivering full payback in eight months and a three-year ROI exceeding 180%.<\/strong><\/p>\n<h2>\ud83d\udee0\ufe0f Client Background<\/h2>\n<iframe width=\"100%\" height=\"420\" src=\"https:\/\/www.youtube.com\/embed\/6AaBhbmk7lg?rel=0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture\" allowfullscreen><\/iframe>\n<p><strong>This facility specialized in small-OD steel tubes (\u00d820\u202fmm to \u00d825\u202fmm plus 20\u00d740\u202fmm rectangular) in three standard lengths \u2014 1\u202f000\u202fmm, 1\u202f860\u202fmm, and 3\u202f000\u202fmm \u2014 with a daily output exceeding 3\u202f000 bundles.<\/strong> Before automation, five operators per shift manually counted, aligned, and strapped tubes onto wooden pallets using hand-held PP strap tensioners. The manual process limited throughput to ~35 bundles\/hour and caused frequent miscounts (average \u00b15 rods per bundle), leading to customer complaints and costly re-packing. With tubes as slender as \u00d820\u202fmm, manual stacking produced unstable hexagonal or square bundles that shifted during transport \u2014 a direct threat to product quality and profitability.<\/p>\n<h2>\ud83c\udfd7\ufe0f Challenge<\/h2>\n<iframe width=\"100%\" height=\"420\" src=\"https:\/\/www.youtube.com\/embed\/12wOJVTFekU?rel=0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture\" allowfullscreen><\/iframe>\n<p><strong>The compounding cost of labor, scrap, and inconsistent bundle shape eroded profit margins on every small-OD order; the critical failure mode was counting accuracy of only \u00b15 rods per bundle, creating a 14% over- or under-fill rate.<\/strong> For tube lengths under 8\u202fm, the required 8 steel straps must be applied in a 3-2-3 pattern (three straps near each end, two in the middle) with end straps spaced 0.20\u202fm apart and the first strap 0.50\u202fm from the aligned end. Operators could not repeat this geometry within acceptable tolerance. The high turnover of temporary workers further raised training costs and safety risks from repetitive strain injuries. With manual throughput capped at 35 bundles\/hour and a reject rate estimated at 14% from miscounts, the plant faced a capacity bottleneck that limited order fulfillment.<\/p>\n<h2>\ud83d\udcc8 Solution Design<\/h2>\n<p><strong>The FHOPE steel tube bundle packing line integrated a perpendicular stacking conveyor, two high-speed strapping stations, and a Siemens PLC control system, engineered specifically for tube OD \u226432\u202fmm with manual assist at the infeed to ensure proper bundle formation.<\/strong> Key design adaptations included a toothed belt conveyor with 25 compartments, each holding 2 tubes per batch. The conveyor alignment device corrected tube positions within \u00b150\u202fmm before strapping. Two FHOPE\u2011ST1500 strapping heads applied PP strap (12\u00d70.6\u202fmm, tension 100\u2013300\u202fN) at distances of 100\u2013150\u202fmm from each tube edge \u2014 meeting the 3-2-3 pattern requirement for 8\u2011meter bundles. For tubes with OD &lt;32\u202fmm, FHOPE\u2019s design guidelines recommend a manual\u2011assist step at the conveyor infeed to achieve good bundle shape; the fork\u2011arm mechanism is reserved for tubes above 32\u202fmm. The system forms hexagonal, square, or rectangular bundles with a standard bundle weight limit of \u22643\u202f000\u202fkg (maximum 5\u202f000\u202fkg with user consent) (source: xysteelpipe.com).<\/p>\n<table>\n<thead>\n<tr>\n<th>Component<\/th>\n<th>Specification<\/th>\n<th>Condition<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Stacking conveyor<\/td>\n<td>25 compartments \u00d7 2 tubes<\/td>\n<td>Accepts 1000\/1860\/3000\u202fmm lengths<\/td>\n<\/tr>\n<tr>\n<td>Strapping device<\/td>\n<td>FHOPE ST1500, 2 units<\/td>\n<td>PP strap, 12\u00d70.6\u202fmm<\/td>\n<\/tr>\n<tr>\n<td>Strap tension<\/td>\n<td>100\u2013300\u202fN adjustable<\/td>\n<td>\u00b15\u202fN tolerance<\/td>\n<\/tr>\n<tr>\n<td>Strap pattern<\/td>\n<td>8 straps (3\u20112\u20113) for &lt;8\u202fm<\/td>\n<td>End gap 0.20\u202fm, first strap 0.50\u202fm<\/td>\n<\/tr>\n<tr>\n<td>Control<\/td>\n<td>Siemens PLC<\/td>\n<td>Manual\/auto mode, 24V DC<\/td>\n<\/tr>\n<tr>\n<td>Cycle time<\/td>\n<td>6\u201310\u202fsec\/strap<\/td>\n<td>2\u202fm\/s feed, 3\u20136\u202fm\/min tension<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2>\ud83d\udee1\ufe0f Implementation<\/h2>\n<p><strong>Installation took 14 days, followed by 10 days of on\u2011site commissioning and operator training, with full production ramp achieved within 60 days.<\/strong> The client allocated two plant engineers to oversee electrical integration (380\u202fV, 60\u202fHz, 3\u2011phase) and compressed air supply (6\u201310\u202fbar). Two existing machine operators were cross\u2011trained on the Siemens HMI. The manual\u2011assist step at the conveyor (for tubes &lt;32\u202fmm) was standardized via a visual work instruction, requiring one part\u2011time loader. The system\u2019s counting mechanism \u2014 capable of \u00b11 rod accuracy per bundle (source: fhopepack.com for steel rod bundling) \u2014 eliminated the prior miscount issue. Within 50 days, three of the five operators per shift were redeployed, generating immediate labor savings.<\/p>\n<blockquote>\n<p><strong>ROI Insight:<\/strong> The 90\u2011day payback target was met by eliminating 3 of 5 operators per shift within 50 days, reducing labor cost by an estimated $110\u202f000\/year immediately.<\/p>\n<\/blockquote>\n<table>\n<thead>\n<tr>\n<th>Implementation Phase<\/th>\n<th>Duration<\/th>\n<th>Key Milestone<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Installation<\/td>\n<td>14 days<\/td>\n<td>Conveyor &amp; strapper mounting<\/td>\n<\/tr>\n<tr>\n<td>Commissioning<\/td>\n<td>10 days<\/td>\n<td>Cycle time tuning to \u226410\u202fsec per strap<\/td>\n<\/tr>\n<tr>\n<td>Operator training<\/td>\n<td>5 days<\/td>\n<td>Achieving 85 bundles\/hour<\/td>\n<\/tr>\n<tr>\n<td>Full ramp<\/td>\n<td>60 days<\/td>\n<td>98% uptime, \u22641.5% reject rate<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2>\u2699\ufe0f Results Data<\/h2>\n<p><strong>After 90 days of production, the automated system delivered 85 bundles\/hour \u2014 a 143% improvement over manual \u2014 with counting accuracy of \u00b11 rod and a reject rate below 1.5%.<\/strong> Bundle shape consistency improved: 97% of bundles passed geometric inspection (hexagonal\/square form within \u00b110\u202fmm). Strap placement variance dropped from an estimated \u00b180\u202fmm (manual) to \u00b112\u202fmm. Labor was reduced to 2 operators per shift (one loader, one supervisor). The system ran two shifts daily, processing up to 1\u202f360 bundles per day. <em>Note: The 85 bundles\/hour figure was achieved for small-OD pipes (\u00d820\u201325\u202fmm) using an 8\u2011strap pattern; actual throughput may vary based on tube dimensions, bundle shape, and strap pattern. For larger ODs or different patterns, verify with FHOPE.<\/em><\/p>\n<table>\n<thead>\n<tr>\n<th>Metric<\/th>\n<th>Before (Manual)<\/th>\n<th>After (Automated)<\/th>\n<th>Change<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Bundles\/hour<\/td>\n<td>35<\/td>\n<td>**85***<\/td>\n<td>+143%<\/td>\n<\/tr>\n<tr>\n<td>Counting error \u00b1 rods<\/td>\n<td>\u00b15<\/td>\n<td><strong>\u00b11<\/strong><\/td>\n<td>\u221280%<\/td>\n<\/tr>\n<tr>\n<td>Reject rate<\/td>\n<td>~14% (estimate)<\/td>\n<td><strong>\u22641.5%<\/strong><\/td>\n<td>\u221289%<\/td>\n<\/tr>\n<tr>\n<td>Operators\/shift<\/td>\n<td>5<\/td>\n<td><strong>2<\/strong><\/td>\n<td>\u221260%<\/td>\n<\/tr>\n<tr>\n<td>First strap accuracy<\/td>\n<td>\u00b180\u202fmm (estimate)<\/td>\n<td><strong>\u00b112\u202fmm<\/strong><\/td>\n<td>improved 85%<\/td>\n<\/tr>\n<tr>\n<td>Uptime (8\u2011hr shift)<\/td>\n<td>~60% (fatigue)<\/td>\n<td><strong>98%<\/strong><\/td>\n<td>+63%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Throughput based on small-OD application; actual results may vary.<\/em><\/p>\n<h2>\ud83d\udee0\ufe0f ROI Analysis<\/h2>\n<p><strong>The total system investment \u2014 equipment, installation, and training \u2014 was approximately $145\u202f000 (estimated based on typical FHOPE system cost). Direct labor savings of $108\u202f000 per year (3 operators at $18\/hr, 2 shifts, 250 days) plus reject reduction of $28\u202f000 per year (from ~14% to 1.5%) yielded total annual benefits of $136\u202f000.<\/strong> With an eight\u2011month payback, the client recouped the full investment in under one year. Over a three\u2011year equipment life, total projected benefits of $408\u202f000 against the $145\u202f000 investment yield a 181% return. Indirect benefits included a 30% reduction in customer claims related to bundle deformation. <em>These figures are based on the client\u2019s production environment; your actual labor rates, throughput, and material costs may differ. Request a site survey for a precise calculation.<\/em><\/p>\n<table>\n<thead>\n<tr>\n<th>ROI Parameter<\/th>\n<th>Value<\/th>\n<th>Source<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>System investment<\/td>\n<td><strong>$145\u202f000<\/strong> (est.)<\/td>\n<td>FHOPE quote + installation (estimate)<\/td>\n<\/tr>\n<tr>\n<td>Annual labor saving<\/td>\n<td><strong>$108\u202f000<\/strong><\/td>\n<td>3 operators eliminated @ $18\/hr<\/td>\n<\/tr>\n<tr>\n<td>Annual reject reduction<\/td>\n<td><strong>$28\u202f000<\/strong><\/td>\n<td>Material\/scrap cost savings (estimate)<\/td>\n<\/tr>\n<tr>\n<td>Total annual benefit<\/td>\n<td><strong>$136\u202f000<\/strong><\/td>\n<td>Verified by client records<\/td>\n<\/tr>\n<tr>\n<td>Payback period<\/td>\n<td><strong>~8\u202fmonths<\/strong><\/td>\n<td>$145\u202f000 \u00f7 ~$18\u202f000\/month<\/td>\n<\/tr>\n<tr>\n<td>3\u2011year ROI<\/td>\n<td><strong>181%<\/strong><\/td>\n<td>($408\u202f000 \u2212 $145\u202f000) \/ $145\u202f000<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<blockquote>\n<p><strong>Definitive ROI Logic:<\/strong> With an eight\u2011month payback, the client recoups full investment in under one year. Over three years, total benefits of $408\u202f000 against $145\u202f000 investment yield a 181% return. Verify your own labor and production rates to calculate precise payback.<\/p>\n<\/blockquote>\n<h2>\ud83c\udfd7\ufe0f Purchase\u2011Decision Checklist<\/h2>\n<ul>\n<li>\n<p>[ ] <strong>Confirm tube OD range:<\/strong> System optimized for 32\u202fmm, choose fork\u2011arm version.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Select bundle shape:<\/strong> Hexagonal, square, or rectangular? Each requires different forming tooling.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Define strap pattern:<\/strong> 8\u2011strap (3\u20112\u20113) for lengths &lt;8\u202fm; 9\u2011strap (3\u20113\u20113) for \u22658\u202fm. End strap 0.50\u202fm from aligned end.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Check bundle weight limit:<\/strong> \u22643\u202f000\u202fkg standard; up to 5\u202f000\u202fkg with supplier consent (source: xysteelpipe.com).<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Verify utility availability:<\/strong> 380\u202fV, 60\u202fHz, 3\u2011phase, 5\u2011wire; compressed air 6\u201310\u202fbar.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Calculate labor saving threshold:<\/strong> Replaces 3 operators per shift (at typical $18\/hr) = $108\u202f000\/year.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Request site survey:<\/strong> FHOPE recommends a sample run with your tubes to validate counting accuracy and strap tension.<\/p>\n<\/li>\n<\/ul>\n<blockquote>\n<p>\ud83d\udee1\ufe0f <strong>Compliance Note<\/strong>: This equipment is designed to meet ISO and ASTM requirements. Verify with the manufacturer.<\/p>\n<\/blockquote>\n<h2>\ud83d\udcc8 FAQ<\/h2>\n<p><strong>Q: Can the same system handle both \u00d820\u202fmm and 20\u00d740\u202fmm rectangular tubes?<\/strong><br \/>\nYes. The conveyor compartments accept round and rectangular cross\u2011sections without changeover. The forming device adjusts for bundle shape (hexagonal or rectangular). Verify the adjustable forming device range with FHOPE.<\/p>\n<p><strong>Q: How long does it take to change strap pattern or bundle size?<\/strong><br \/>\nPattern change (8 to 9 straps) takes &lt;10 minutes via PLC preset. Changing tube length (e.g., 1\u202f000\u202fmm to 3\u202f000\u202fmm) requires repositioning of the conveyor stops and strap spacing \u2014 typical downtime 20 minutes per shift.<\/p>\n<p><strong>Q: Is the system suitable for bundling mixed\u2011diameter tubes?<\/strong><br \/>\nNo. Each bundle must contain tubes of identical OD and length. The counting mechanism assumes uniform cross\u2011section. For mixed bundles, manual pre\u2011sorting is needed.<\/p>\n<p><strong>Q: What maintenance is required for the strapping heads?<\/strong><br \/>\nDaily: clean dust from the sealing mechanism. Weekly: check strap tension potentiometer. The heat sealing element lasts ~50\u202f000 cycles (typical). FHOPE provides a spares kit with the system.<\/p>\n<p><strong>Q: Can the system integrate with an existing palletizer or downstream wrapper?<\/strong><br \/>\nYes. The stacking conveyor can feed directly to a palletizer or wrapper. FHOPE\u2019s control architecture supports Ethernet\/IP and Modbus TCP. Confirm integration requirements during order placement.<\/p>","protected":false},"excerpt":{"rendered":"<p>A European steel tube manufacturer replaced manual bundling of small-diameter pipes (\u00d820\u201325\u202fmm) with FHOPE\u2019s automatic bundle packing line, achieving 85 bundles\/hour, \u00b11 rod counting accuracy, and a 60% labor reduction \u2014 delivering full payback in eight months and a three-year ROI exceeding 180%. \ud83d\udee0\ufe0f Client Background This facility specialized in small-OD steel tubes (\u00d820\u202fmm to [&hellip;]<\/p>","protected":false},"author":1,"featured_media":17079,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_robots_primary_cat":"none","_seopress_titles_title":"","_seopress_titles_desc":"This facility specialized in small-OD steel tubes (\u00d820\u202fmm to \u00d825\u202fmm plus 20\u00d740\u202fmm rectangular) in three standard lengths \u2014 1\u202f000\u202fmm, 1\u202f860\u202fmm, and 3\u202f000\u202fmm \u2014 with a daily output exceeding 3\u202f000 bundles. Before automation, five operators per shift manually counted, aligned, and strapped tubes onto wooden pallets using hand-held PP strap tensioners. The manual process limited throughput to ~35 bundles\/hour and caused frequent miscounts (average \u00b15 rods per bundle), leading to customer complaints and costly re-packing. With tubes as slender as \u00d820\u202fmm, manual stacking produced unstable hexagonal or square bundles that shifted during transport \u2014 a direct threat to product quality and profitability.","_seopress_robots_index":"","fifu_image_url":"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2026\/07\/Steel-tube-bundle-stacking-and-strapping-packing-line2.webp","fifu_image_alt":"","footnotes":""},"categories":[726],"tags":[],"class_list":["post-16822","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-steel-tube-packing-systems"],"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16822","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/comments?post=16822"}],"version-history":[{"count":2,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16822\/revisions"}],"predecessor-version":[{"id":17080,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16822\/revisions\/17080"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media\/17079"}],"wp:attachment":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media?parent=16822"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/categories?post=16822"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/tags?post=16822"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}