{"id":16943,"date":"2026-06-10T17:43:24","date_gmt":"2026-06-10T09:43:24","guid":{"rendered":"https:\/\/www.fhopepack.com\/zh\/?p=16943"},"modified":"2026-06-10T17:43:24","modified_gmt":"2026-06-10T09:43:24","slug":"high-efficiency-tire-wrapping-packing-machines-for-industrial-automation","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/zh\/high-efficiency-tire-wrapping-packing-machines-for-industrial-automation\/","title":{"rendered":"High-Efficiency Tire Wrapping Packing Machines for Industrial Automation"},"content":{"rendered":"<p><strong>A mid\u2011size tire manufacturer in Southeast Asia replaced four manual packers per shift with the FPT\u2011300, achieving 136 tires per hour, 75% labor reduction, and near\u2011zero film waste. This case study demonstrates how a $28,000 investment\u2014including optional auto\u2011cut and logo\u2011taping systems\u2014paid back in 3.5 months while raising packing OEE from 68% to 94%.<\/strong><\/p>\n<h2>\ud83d\udee0\ufe0f Client Background<\/h2>\n<iframe width=\"1057\" height=\"793\" src=\"https:\/\/www.youtube.com\/embed\/oRqQxXU3R-M\" title=\"Automatic coil packing machine for tyre\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<p><strong>The client, <a href=\"https:\/\/www.fhopepack.com\/Tyre-packing-machine\/\">a mid\u2011sized tire manufacturer <\/a>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\u2011damage rate\u2014dragging packing OEE below 70% against a plant target of 85%.<\/strong><\/p>\n<p>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\u2011parts distributor demanded reliable, high\u2011volume packing with clear barcode labeling. The factory layout had limited floor space\u2014only 8 m \u00d7 5 m available near the outfeed conveyor\u2014and the team needed a system that could handle standard passenger tires (55\u2011series, 16\u2011inch) as well as occasional SUV tires up to 20\u2011inch. 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.<\/p>\n<h2>\ud83c\udfd7\ufe0f Challenge<\/h2>\n<p><strong>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\u2011minute changeover times, and a separate label application step that added 10 seconds per tire.<\/strong><\/p>\n<table>\n<thead>\n<tr>\n<th>Issue<\/th>\n<th>Measured Baseline<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Throughput<\/td>\n<td>65 packs per hour, 4 workers<\/td>\n<\/tr>\n<tr>\n<td>Film waste<\/td>\n<td>8% from over\u2011wrap and misalignment<\/td>\n<\/tr>\n<tr>\n<td>Surface damage<\/td>\n<td>2% of tires scuffed during hand wrapping<\/td>\n<\/tr>\n<tr>\n<td>Changeover time<\/td>\n<td>15 min between tire sizes (manual adjustment)<\/td>\n<\/tr>\n<tr>\n<td>Label application<\/td>\n<td>Separate step, 10 sec extra per tire<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Every new hire required two weeks to reach full speed, and inconsistent tension caused film breakage on high\u2011speed runs. The operations manager needed a solution that would:<\/p>\n<ul>\n<li>\n<p>Increase packing speed to at least 120 tires per hour per line.<\/p>\n<\/li>\n<li>\n<p>Reduce direct labor to one operator per shift (overseeing the machine).<\/p>\n<\/li>\n<li>\n<p>Eliminate film waste and surface marks.<\/p>\n<\/li>\n<li>\n<p>Integrate optional logo\u2011taping for distributor branding.<\/p>\n<\/li>\n<\/ul>\n<h2>\ud83d\udcc8 Solution Design<\/h2>\n<p><strong>After evaluating three suppliers, the team selected FHOPEPACK\u2019s standard FPT\u2011300, a horizontal tire wrapping machine with a rotating ring that applies PE stretch film around the tire circumference. The machine\u2019s technical parameters\u2014tire OD 500\u20131300 mm, width 50\u2013350 mm, weight 5\u201380 kg\u2014exactly matched the client\u2019s tire range.<\/strong><\/p>\n<table>\n<thead>\n<tr>\n<th>Parameter<\/th>\n<th>FPT\u2011300 Spec<\/th>\n<th>Client Requirement<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Tire weight<\/td>\n<td><strong>5\u201380 kg<\/strong><\/td>\n<td>Up to 25 kg<\/td>\n<\/tr>\n<tr>\n<td>Tire width<\/td>\n<td><strong>50\u2013350 mm<\/strong><\/td>\n<td>200\u2013280 mm<\/td>\n<\/tr>\n<tr>\n<td>Tire OD<\/td>\n<td><strong>500\u20131300 mm<\/strong><\/td>\n<td>600\u2013800 mm<\/td>\n<\/tr>\n<tr>\n<td>Tire ID<\/td>\n<td><strong>300\u2013700 mm<\/strong><\/td>\n<td>380\u2013450 mm<\/td>\n<\/tr>\n<tr>\n<td>Packing speed<\/td>\n<td><strong>15\u201325 sec\/piece<\/strong><\/td>\n<td>\u226420 sec desired<\/td>\n<\/tr>\n<tr>\n<td>Rotating speed<\/td>\n<td><strong>40\u2013110 r\/min<\/strong><\/td>\n<td>Adjustable<\/td>\n<\/tr>\n<tr>\n<td>Overlap<\/td>\n<td><strong>20%\u201390%<\/strong><\/td>\n<td>50% default<\/td>\n<\/tr>\n<tr>\n<td>Film roll<\/td>\n<td>PE, ID 50 mm, OD 80\u2013120 mm, width 90 mm<\/td>\n<td>Standard 500 mm film<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>The machine operates in a horizontal pass\u2011through 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.<\/p>\n<p>Two options addressed specific client needs:<\/p>\n<ul>\n<li>\n<p><strong>Option 1 \u2013 Auto film cutting system<\/strong>: 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.<\/p>\n<\/li>\n<li>\n<p><strong>Option 2 \u2013 Auto logo taping system<\/strong>: A tape applicator places a branded tape over the final wrap (tape: core ID 76 mm, OD 120\u2013200 mm, width 70\u2013100 mm). This allowed the distributor\u2019s logo to appear on every tire without slowing the line.<\/p>\n<\/li>\n<\/ul>\n<p>The final system included a 2\u2011meter infeed conveyor and a 1.5\u2011meter outfeed conveyor. Power: 380 V \/ 50 Hz \/ 3\u2011phase, 1.5 kW. Air supply: 5\u20137 bar.<\/p>\n<h2>\ud83d\udee1\ufe0f Implementation<\/h2>\n<p><strong>Installation took six days\u2014including mechanical setup and PLC programming\u2014followed by a two\u2011day operator training session. The plant manager reported a learning curve of about four hours before operators could run at full speed.<\/strong><\/p>\n<table>\n<thead>\n<tr>\n<th>Phase<\/th>\n<th>Duration<\/th>\n<th>Activities<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Site prep<\/td>\n<td>1 day<\/td>\n<td>Floor anchors, air &amp; power drops (existing line)<\/td>\n<\/tr>\n<tr>\n<td>Mechanical installation<\/td>\n<td>3 days<\/td>\n<td>Position FPT\u2011300, align conveyors, mount ring guard<\/td>\n<\/tr>\n<tr>\n<td>Electrical &amp; PLC wiring<\/td>\n<td>1 day<\/td>\n<td>Connect to 380V\/50Hz, set up touchscreen recipes<\/td>\n<\/tr>\n<tr>\n<td>Commissioning<\/td>\n<td>1 day<\/td>\n<td>Dry run with scrap tires, calibrate tension &amp; overlap<\/td>\n<\/tr>\n<tr>\n<td>Training<\/td>\n<td>2 days<\/td>\n<td>8 operators trained on basic operation, recipe change, error recovery<\/td>\n<\/tr>\n<tr>\n<td>Production ramp<\/td>\n<td>3 days<\/td>\n<td>Gradual speed increase from 50% to 100% capacity<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Key decisions based on the client\u2019s space and workflow:<\/p>\n<ul>\n<li>\n<p><strong>Infeed conveyor placed at 1.2 m height<\/strong> to match existing outfeed from tire building machine.<\/p>\n<\/li>\n<li>\n<p><strong>Outfeed conveyor extended 3 m<\/strong> to accumulate wrapped tires before palletizing.<\/p>\n<\/li>\n<li>\n<p><strong>Recipe set<\/strong>: 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.<\/p>\n<\/li>\n<li>\n<p><strong>Auto\u2011cut system enabled<\/strong> after 20 validation cycles.<\/p>\n<\/li>\n<li>\n<p><strong>Logo\u2011taping system calibrated<\/strong> using test rolls supplied by the client\u2019s label vendor.<\/p>\n<\/li>\n<\/ul>\n<p>One supervisor was assigned to monitor OEE and film loading.<\/p>\n<h2>\u2699\ufe0f Results Data<\/h2>\n<p><strong>After eight weeks of production, the FPT\u2011300 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%.<\/strong><\/p>\n<table>\n<thead>\n<tr>\n<th>Metric<\/th>\n<th>Before (Manual)<\/th>\n<th>After (FPT\u2011300)<\/th>\n<th>Improvement<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Throughput (tires\/hour)<\/td>\n<td>65<\/td>\n<td><strong>136<\/strong><\/td>\n<td>+109%<\/td>\n<\/tr>\n<tr>\n<td>Operators per shift<\/td>\n<td>4<\/td>\n<td><strong>1<\/strong><\/td>\n<td>\u221275%<\/td>\n<\/tr>\n<tr>\n<td>Cycle time (sec\/tire)<\/td>\n<td>55<\/td>\n<td><strong>20<\/strong> (with auto\u2011cut)<\/td>\n<td>\u221264%<\/td>\n<\/tr>\n<tr>\n<td>Film waste (%)<\/td>\n<td>8%<\/td>\n<td><strong>&lt;0.5%<\/strong> (auto\u2011cut + recipe)<\/td>\n<td>\u221294%<\/td>\n<\/tr>\n<tr>\n<td>Surface damage (%)<\/td>\n<td>2%<\/td>\n<td><strong>0.1%<\/strong> (consistent tension)<\/td>\n<td>\u221295%<\/td>\n<\/tr>\n<tr>\n<td>Changeover time (min)<\/td>\n<td>15<\/td>\n<td><strong>&lt;2 min<\/strong> (recipe recall)<\/td>\n<td>\u221287%<\/td>\n<\/tr>\n<tr>\n<td>Logo tape application<\/td>\n<td>separate 10 sec<\/td>\n<td><strong>integrated, 0 sec<\/strong> (during wrap)<\/td>\n<td>eliminated<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>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: \u201cI can run two machines now with the same effort I used to run one.\u201d No unscheduled downtime occurred after the first week. The auto\u2011cut system required one blade replacement after 8,000 cycles; the supplier recommends replacement every 10,000 cycles or six months.<\/p>\n<h2>\ud83d\udee0\ufe0f ROI Analysis<\/h2>\n<p><strong>Total project cost was $28,000, comprising the base FPT\u2011300 ($21,500), auto\u2011cut system ($3,000), logo\u2011tap system ($2,500), and installation\/training ($1,000). Based on the client\u2019s 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.<\/strong><\/p>\n<table>\n<thead>\n<tr>\n<th>Cost Factor<\/th>\n<th>Before (annual)<\/th>\n<th>After (annual)<\/th>\n<th>Savings<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Labor (4 operators \u00d7 3 shifts \u00d7 $4.50\/hr \u00d7 2,080 hr)<\/td>\n<td>$112,320<\/td>\n<td>$28,080 (1 operator)<\/td>\n<td><strong>$84,240<\/strong><\/td>\n<\/tr>\n<tr>\n<td>Film waste (8% \u00d7 40 kg\/day \u00d7 300 days \u00d7 $3.00\/kg)<\/td>\n<td>$2,880<\/td>\n<td>$0 (auto\u2011cut eliminates waste)<\/td>\n<td><strong>$2,880<\/strong><\/td>\n<\/tr>\n<tr>\n<td>Surface damage (2% \u00d7 3,000 tires\/day \u00d7 300 days \u00d7 $0.50\/scratch)<\/td>\n<td>$9,000<\/td>\n<td>$450 (0.1%)<\/td>\n<td><strong>$8,550<\/strong><\/td>\n<\/tr>\n<tr>\n<td>Logo tape labor (separate step: 1 hr\/day \u00d7 $4.50 \u00d7 300 days)<\/td>\n<td>$1,350<\/td>\n<td>$0 (integrated)<\/td>\n<td><strong>$1,350<\/strong><\/td>\n<\/tr>\n<tr>\n<td>Total annual savings<\/td>\n<td><\/td>\n<td><\/td>\n<td><strong>$97,020<\/strong><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>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.<\/em><\/p>\n<p><strong>Simple payback = $28,000 \/ $97,020 = 3.5 months.<\/strong> 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\u2019s overall 85% target.<\/p>\n<blockquote>\n<p><strong>ROI Insight:<\/strong> When evaluating an automatic tire wrapping machine, include labor replacement, film waste reduction, and damage\u2011related rework costs. The FPT\u2011300\u2019s optional auto\u2011cut system alone saved $2,880 per year in film and eliminated a manual step.<\/p>\n<\/blockquote>\n<h2>\ud83c\udfd7\ufe0f Purchase\u2011Decision Checklist<\/h2>\n<p><strong>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\u2011300 specifications and the case study experience.<\/strong><\/p>\n<ul>\n<li>\n<p>[ ] <strong>Tire size envelope<\/strong> \u2013 Confirm max\/min OD, width, and weight against the machine\u2019s table. The FPT\u2011300 covers OD 500\u20131300 mm, width 50\u2013350 mm, weight 5\u201380 kg. If your tires fall outside, request a custom version.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Cycle time target<\/strong> \u2013 The FPT\u2011300 runs 15\u201325 sec\/piece. Calculate whether this matches your required output per hour (including conveyor buffer). For higher speed, consider a dual\u2011ring configuration (not covered in this case).<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Film and tape compatibility<\/strong> \u2013 Standard PE stretch film rolls: ID 50 mm, OD 80\u2013120 mm, width 90 mm. Logo tape: core ID 76 mm, OD \u2264200 mm, width 70\u2013100 mm. Ensure your supply chain can source these sizes.<\/p>\n<\/li>\n<li>\n<p>[ ] <strong>Integration requirements<\/strong> \u2013 Does your existing conveyor height match the machine\u2019s infeed\/outfeed? The FPT\u2011300 requires 5\u20137 bar compressed air and 380V\/50Hz\/3\u2011phase. Include installation costs in your budget.<\/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: How often does the auto\u2011cut system blade need replacement?<\/strong><br \/>\nBased 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.<\/p>\n<p><strong>Q: Can the FPT\u2011300 handle run\u2011flat tires or tires with sidewall protrusions?<\/strong><br \/>\nThe standard machine is designed for conventional tire profiles. For run\u2011flat tires with stiff sidewalls or protrusions, consult FHOPEPACK about a wider ring clearance or a custom soft\u2011roller option. The case study tires were standard passenger and SUV models without protrusions.<\/p>\n<p><strong>Q: What is the typical power consumption per shift?<\/strong><br \/>\nThe motor is rated at 1.5 kW. At a 75% duty cycle (running 18 seconds out of every 20\u2011second cycle), average consumption is about 1.1 kW. Over an 8\u2011hour shift with 500 cycles, that\u2019s roughly 8.8 kWh\u2014negligible compared to overall plant electricity.<\/p>","protected":false},"excerpt":{"rendered":"<p>A mid\u2011size tire manufacturer in Southeast Asia replaced four manual packers per shift with the FPT\u2011300, achieving 136 tires per hour, 75% labor reduction, and near\u2011zero film waste. This case study demonstrates how a $28,000 investment\u2014including optional auto\u2011cut and logo\u2011taping systems\u2014paid back in 3.5 months while raising packing OEE from 68% to 94%. \ud83d\udee0\ufe0f Client [&hellip;]<\/p>","protected":false},"author":1,"featured_media":16945,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_robots_primary_cat":"none","_seopress_titles_title":"","_seopress_titles_desc":"A mid\u2011size tire manufacturer in Southeast Asia replaced four manual packers per shift with the FPT\u2011300, achieving 136 tires per hour, 75% labor reduction, and near\u2011zero film waste. This case study demonstrates how a $28,000 investment\u2014including optional auto\u2011cut and logo\u2011taping systems\u2014paid back in 3.5 months while raising packing OEE from 68% to 94%.","_seopress_robots_index":"","fifu_image_url":"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2018\/04\/tyre-packing-machine-1.jpg","fifu_image_alt":"","footnotes":""},"categories":[1],"tags":[],"class_list":["post-16943","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16943","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=16943"}],"version-history":[{"count":2,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16943\/revisions"}],"predecessor-version":[{"id":16946,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16943\/revisions\/16946"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media\/16945"}],"wp:attachment":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media?parent=16943"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/categories?post=16943"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/tags?post=16943"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}