{"id":16971,"date":"2026-06-24T15:07:51","date_gmt":"2026-06-24T07:07:51","guid":{"rendered":"https:\/\/www.fhopepack.com\/zh\/?p=16971"},"modified":"2026-06-24T15:07:51","modified_gmt":"2026-06-24T07:07:51","slug":"ready-to-deploy-high-speed-line-retrofit-how-to-seamlessly-integrate-bottle-shrink-wrappers-with-trayless-conveyors","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/zh\/ready-to-deploy-high-speed-line-retrofit-how-to-seamlessly-integrate-bottle-shrink-wrappers-with-trayless-conveyors\/","title":{"rendered":"Ready-to-Deploy High-Speed Line Retrofit: How to Seamlessly Integrate Bottle Shrink Wrappers with Trayless Conveyors"},"content":{"rendered":"<p>A Midwest condiment producer needed to integrate a <a href=\"https:\/\/www.fhopepack.com\/Shrinking_machine.html\">high-speed shrink wrapper<\/a> with a trayless conveyor for oval ketchup bottles. This case study demonstrates how the FHOPEPACK automatic bundler (model FH\u2011S120) handled the irregular 1.25:1 ovality ratio, delivered 120 bundles per minute on a 2\u00d76 pack pattern, cut film waste by 34% relative, and achieved a 14\u2011month payback on a $148,000 investment.<\/p>\n<h2>\ud83d\udee0\ufe0f Client Background<\/h2>\n<iframe width=\"100%\" height=\"420\" src=\"https:\/\/www.youtube.com\/embed\/bw_vPpeasLQ?rel=0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture\" allowfullscreen><\/iframe>\n<p><strong>The client, a Midwestern condiment manufacturer, produces 1.5 million bottles of ketchup per week on a single high\u2011speed line. Their bottles are slightly oval (major axis 65 mm, minor axis 52 mm, height 220 mm, ovality ratio 1.25:1) and historically required cardboard trays for stability during packaging. The company aimed to eliminate tray costs and switch to a trayless conveyor system while boosting line speed from 80 to 120 bundles per minute. Their existing downstream equipment could not handle the oval geometry without tray support, creating a clear gap between cost\u2011reduction goals and technical feasibility.<\/strong><\/p>\n<p>The production team had already invested in a new trayless conveyor but found that oval bottles toppled during accumulation and film wrapping. They needed a shrink bundler that could gently orient and stabilize the bottles without trays, while maintaining the high output required for their 24\/5 operation. Three suppliers were evaluated; FHOPEPACK was the only one that provided a documented case of handling similar non\u2011round containers at the required speed and pack pattern.<\/p>\n<h2>\ud83c\udfd7\ufe0f Challenge<\/h2>\n<p><strong>The primary challenge was achieving stable, high\u2011speed bundling of 12\u2011bottle packs (2\u00d76 layout) where the oval shape caused uneven film tension and package shifting. Without trays, the bottle necks had to be aligned precisely within \u00b12 mm of the pack centerline to prevent film tears. The trayless conveyor introduced lateral forces of up to 15 N during merges, which could misalign oval bottles if not counteracted by the wrapper\u2019s infeed system.<\/strong><\/p>\n<p>Additional constraints included:<\/p>\n<ul>\n<li>\n<p><strong>Bottle ovality ratio:<\/strong> 1.25:1 (major\/minor axis), which exceeds the typical &lt;1.1:1 that standard wrappers handle without active orientation.<\/p>\n<\/li>\n<li>\n<p><strong>Film type:<\/strong> 25\u2011\u00b5m PE shrink film, minimum acceptable seal strength 12 N\/15 mm.<\/p>\n<\/li>\n<li>\n<p><strong>Changeover:<\/strong> Required in under 15 minutes between bottle sizes (planned future SKUs).<\/p>\n<\/li>\n<li>\n<p><strong>Space limit:<\/strong> Only 4.2 m of linear infeed available between the trayless conveyor and the wrapper.<\/p>\n<\/li>\n<\/ul>\n<p>Historical data from the client\u2019s earlier tray\u2011dependent lines showed a 7% rejection rate on oval bottles; any solution had to reduce that to below 1%.<\/p>\n<h2>\ud83d\udcc8 Solution Design<\/h2>\n<p><strong>The FHOPEPACK automatic bundler (model FH\u2011S120) was selected after a pilot test using the client\u2019s actual bottles. The machine features a servo\u2011driven rotary infeed with optical sensors that detect the bottle\u2019s major axis orientation and rotate each bottle into the correct pack position. The trayless conveyor merges two lanes into a 2\u00d76 pattern using a synchronized timing belt, with lateral guides adjusted to \u00b10.5 mm tolerance.<\/strong><\/p>\n<p>The FH\u2011S120 applies pre\u2011stretched film at 250% elongation, with a dual\u2011roll film carriage that reduces film waste by up to 18% compared to single\u2011roll systems (this contributes to the overall 34% reduction documented in Results). The solution integrated four subsystems:<\/p>\n<table>\n<thead>\n<tr>\n<th>Subsystem<\/th>\n<th>Component \/ Spec<\/th>\n<th>Purpose<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Infeed orientation<\/td>\n<td>Rotary ring with 4 servo\u2011motor fingers, cycle time 0.3 s<\/td>\n<td>Rotate oval bottles to align major axis<\/td>\n<\/tr>\n<tr>\n<td>Accumulation<\/td>\n<td>Timed belt with adjustable side rails, 2.5 m length<\/td>\n<td>Create stable 2\u00d76 packs without trays<\/td>\n<\/tr>\n<tr>\n<td>Shrink tunnel<\/td>\n<td>Hot air (185 \u00b0C setpoint, \u00b12 \u00b0C control), 3.2 m length<\/td>\n<td>Uniform film shrinkage at 120 packs\/min<\/td>\n<\/tr>\n<tr>\n<td>Film system<\/td>\n<td>Dual\u2011roll carriage, 500 mm roll width, PLC\u2011controlled tension<\/td>\n<td>Minimize film scrap during start\/stop<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>A quick\u2011change module for the orientation fingers was included, cutting changeover time to 11 minutes for bottle dimension changes.<\/p>\n<h2>\ud83d\udee1\ufe0f Implementation<\/h2>\n<p><strong>Installation was completed over a 7\u2011day shutdown, with FHOPEPACK field engineers on site for commissioning and training. The first three days focused on mechanical integration of the rotary infeed with the existing trayless conveyor, including real\u2011time alignment of the side rails to match bottle ovality. Days 4\u20115 covered electrical wiring and PLC communication (EtherNet\/IP to the client\u2019s Rockwell system). Days 6\u20117 were used for dry runs and tuning the film sealing temperature.<\/strong><\/p>\n<p>Initial tuning revealed that the optical sensors needed a 10\u2011ms exposure adjustment because the dark red ketchup reduced contrast. After a firmware update, orientation accuracy reached 99.7% on first pass. Operators received 8 hours of hands\u2011on training (4 hours on normal operation and start\u2011up, 2 hours on changeover, 2 hours on fault recovery). The FHOPEPACK remote support system (via Modbus TCP) was activated for the first two months of production.<\/p>\n<p>A pre\u2011production run of 50,000 packs was completed with zero major defects. The only adjustment needed was increasing tunnel air velocity from 2.5 m\/s to 3.0 m\/s to prevent film sag on the flat sides of the oval bottles.<\/p>\n<h2>\u2699\ufe0f Results Data<\/h2>\n<p><strong>After six months of production, the FH\u2011S120 delivered a consistent throughput of 120 bundles per minute with a defect rate of 0.4%. Film waste fell from 6.2% to 4.1% (a 34% relative reduction). Line availability reached 98.2%, with unplanned downtime limited to film roll changes and one sensor recalibration.<\/strong><\/p>\n<p>Key metrics measured on the line:<\/p>\n<table>\n<thead>\n<tr>\n<th>Metric<\/th>\n<th>Before Retrofit<\/th>\n<th>After Retrofit<\/th>\n<th>Improvement<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Line speed (packs\/min)<\/td>\n<td>80<\/td>\n<td>120<\/td>\n<td>+50%<\/td>\n<\/tr>\n<tr>\n<td>Bottle rejection rate<\/td>\n<td>7.0%<\/td>\n<td>0.4%<\/td>\n<td>\u201394%<\/td>\n<\/tr>\n<tr>\n<td>Film waste per shift (kg)<\/td>\n<td>12.4<\/td>\n<td>8.2<\/td>\n<td>\u201334%<\/td>\n<\/tr>\n<tr>\n<td>Changeover time (min)<\/td>\n<td>22<\/td>\n<td>11<\/td>\n<td>\u201350%<\/td>\n<\/tr>\n<tr>\n<td>Energy consumption (kWh\/1,000 packs)<\/td>\n<td>4.8<\/td>\n<td>4.2<\/td>\n<td>\u201312.5%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><strong>Note on daily throughput:<\/strong> At 120 packs\/min over two 8\u2011hour shifts (960 min\/day), the line processes 115,200 packs per day. This is the basis for all annual calculations below. The earlier reference to 216,000 packs\/day in the original summary was a typographical error; the correct value is 115,200 packs\/day.<\/p>\n<p>The FH\u2011S120 required only two scheduled preventive maintenance stops in six months: one for bearing lubrication at 1,000 hours and one for seal bar replacement at 500,000 cycles.<\/p>\n<h2>\ud83d\udee0\ufe0f ROI Analysis<\/h2>\n<p><strong>The total project investment was $148,000, including the FH\u2011S120 wrapper, installation, training, and one year of remote support. The elimination of cardboard trays saved $0.0042 per 12\u2011bottle pack (based on the client\u2019s actual tray cost). At 115,200 packs per day and 250 operating days per year, that yields $120,960 in annual tray savings. Combined with film waste savings ($8,640\/year) and lower energy costs ($1,728\/year at $0.10\/kWh), total annual savings reach $131,328. The payback period is approximately 14 months ($148,000 \u00f7 $131,328 = 1.13 years).<\/strong><\/p>\n<p>Tray elimination accounts for 92% of the savings. Energy savings are calculated as the 0.6 kWh\/1,000 packs reduction \u00d7 28.8 million packs per year (115,200 packs\/day \u00d7 250 days) \u00d7 $0.10\/kWh = $1,728.<\/p>\n<p>Additional non\u2011quantified benefits include:<\/p>\n<ul>\n<li>\n<p>Freed 40 m\u00b2 of storage space previously used for trays.<\/p>\n<\/li>\n<li>\n<p>Eliminated one operator per shift for tray handling.<\/p>\n<\/li>\n<li>\n<p>Improved sustainability score (trayless = less cardboard waste).<\/p>\n<\/li>\n<\/ul>\n<p>The internal rate of return (IRR) over 5 years, assuming 3% annual volume growth, is estimated at 32%. <strong>This is an illustrative calculation only<\/strong>; actual IRR depends on regional tray costs, electricity rates, and volume growth. Verify with your own cost data before committing.<\/p>\n<blockquote>\n<p><strong>Actionable insight:<\/strong> If your line runs at 100+ packs\/min and uses trays primarily for bottle stability, eliminating trays with a shrink wrapper designed for non\u2011round containers can yield payback in under 18 months. The key is verifying the wrapper\u2019s orientation mechanism with your actual bottle geometry \u2013 don\u2019t rely on generic \u201coval\u2011capable\u201d claims.<\/p>\n<\/blockquote>\n<h2>\ud83c\udfd7\ufe0f Purchase\u2011Decision Checklist<\/h2>\n<p>Before ordering a high\u2011speed shrink wrapper for trayless conveyance of oval bottles, verify these five items:<\/p>\n<ol>\n<li>\n<p><strong>Bottle geometry data<\/strong> \u2013 Provide major\/minor axis, height, weight, and surface texture to the supplier. Request a trial using your bottles.<\/p>\n<\/li>\n<li>\n<p><strong>Infeed orientation accuracy<\/strong> \u2013 Confirm the wrapper can detect and rotate oval bottles at full line speed (e.g., 120 packs\/min). Sensors must work with your bottle color.<\/p>\n<\/li>\n<li>\n<p><strong>Film type and tension specs<\/strong> \u2013 Specify minimum seal strength and pre\u2011stretch ratio. Dual\u2011roll carriages reduce waste; confirm compatibility.<\/p>\n<\/li>\n<li>\n<p><strong>Changeover time guarantee<\/strong> \u2013 Ask for documented &lt;15\u2011minute changeover for different bottle sizes (including oval variants).<\/p>\n<\/li>\n<li>\n<p><strong>Integration interfaces<\/strong> \u2013 Validate conveyor height, PLC protocol (e.g., EtherNet\/IP), and available infeed length. FHOPEPACK\u2019s FH\u2011S120 performs optimally with a 2.5 m minimum infeed.<\/p>\n<\/li>\n<\/ol>\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 FH\u2011S120 handle bottles with a 1.3:1 ovality ratio?<\/strong><br \/>\nA: The machine was verified for 1.25:1. For higher ratios, request a custom orientation module. Typical upper limit is 1.35:1 without major modification \u2013 confirm with FHOPEPACK.<\/p>\n<p><strong>Q: How much floor space does the shrink tunnel require?<\/strong><br \/>\nA: The FH\u2011S120 with hot\u2011air tunnel occupies approximately 6.5 m \u00d7 1.8 m including infeed and discharge. The tunnel length is 3.2 m. Allow a 1 m clearance on each side for maintenance.<\/p>\n<p><strong>Q: Is the film roll width fixed at 500 mm?<\/strong><br \/>\nA: The standard dual\u2011roll carriage accepts 500 mm rolls. Roll width is adjustable from 400 mm to 550 mm with an optional kit \u2013 specify when ordering.<\/p>\n<p><strong>Q: What is the typical payback if bottles are not oval?<\/strong><br \/>\nA: For round bottles on trayless conveyors, payback is often shorter (8\u201312 months) because orientation is simpler. Film and tray savings remain similar. Use the calculation template from the ROI section with your own numbers.<\/p>","protected":false},"excerpt":{"rendered":"<p>A Midwest condiment producer needed to integrate a high-speed shrink wrapper with a trayless conveyor for oval ketchup bottles. This case study demonstrates how the FHOPEPACK automatic bundler (model FH\u2011S120) handled the irregular 1.25:1 ovality ratio, delivered 120 bundles per minute on a 2\u00d76 pack pattern, cut film waste by 34% relative, and achieved a [&hellip;]<\/p>","protected":false},"author":1,"featured_media":16978,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_robots_primary_cat":"none","_seopress_titles_title":"","_seopress_titles_desc":"A Midwest condiment producer needed to integrate a high-speed shrink wrapper with a trayless conveyor for oval ketchup bottles. This case study demonstrates how the FHOPEPACK automatic bundler (model FH\u2011S120) handled the irregular 1.25:1 ovality ratio, delivered 120 bundles per minute on a 2\u00d76 pack pattern, cut film waste by 34% relative, and achieved a 14\u2011month payback on a $148,000 investment.","_seopress_robots_index":"","fifu_image_url":"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2025\/01\/Shrinking-machine-jpg.webp","fifu_image_alt":"","footnotes":""},"categories":[1385],"tags":[],"class_list":["post-16971","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-bottle-shrink-wrappers"],"amp_enabled":true,"_links":{"self":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16971","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=16971"}],"version-history":[{"count":2,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16971\/revisions"}],"predecessor-version":[{"id":16979,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/posts\/16971\/revisions\/16979"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media\/16978"}],"wp:attachment":[{"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/media?parent=16971"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/categories?post=16971"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.fhopepack.com\/zh\/wp-json\/wp\/v2\/tags?post=16971"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}