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Orbital Stretch Wrapper for Long Products: Technical Specification and Implementation Guide
What is an Orbital Stretch Wrapper and How Does It Work?
An orbital stretch wrapper is a horizontal packaging machine that wraps elongated products by rotating a film carriage around a stationary product on a conveyor. Unlike turntable wrappers (limited to 1200mm diameter), the horizontal wrapping machine manufacturer designs orbital systems to package products from 500mm to 12,000mm in length, including profiles, pipes, aluminum extrusions, lumber, and steel bars. The rotating ring mechanism orbits at 10-30 rpm while the product moves horizontally through the wrapping zone at 2-15 m/min.
Application Industries for Orbital Stretch Wrapper Systems
Orbital stretch wrapper technology serves facilities in:
- Metal fabrication: Steel profiles, aluminum extrusions (6-12m lengths)
- Building materials: Lumber bundles, PVC pipes, window frames
- Manufacturing: Carpet rolls, textile beams, industrial rollers
- Distribution centers: Bundled long products requiring protection during transit
What Packaging Challenges Do Long-Profile Products Face?
Manufacturing facilities processing profiles, pipes, aluminum extrusions, and lumber face specific wrapping constraints: conventional turntable wrappers cannot accommodate products exceeding 1200mm length, manual wrapping consumes 12-18 minutes per bundle, and film coverage inconsistency leads to 8-15% damage rates during transit. Standard horizontal wrapping machine manufacturer solutions address these through orbital rotation mechanisms.
Dimensional Limitations in Conventional Systems
Facilities report the following constraints with traditional packaging equipment:
- Maximum product length: 1200mm (turntable diameter limit)
- Film pre-stretch ratio: 150-200% (insufficient for heavy profiles)
- Wrapping cycle time: 3-5 minutes per unit (manual film carriage repositioning)
- Operator requirements: 2-3 personnel per shift
How is an Orbital Stretch Wrapper System Designed?
A horizontal wrapping machine manufacturer designs orbital stretch wrapper systems with four integrated modules that enable automated packaging of long products:
- Conveyor infeed system: Variable speed 2-15 m/min, load capacity 50-3000 kg
- Rotating ring mechanism: Orbital rotation 15-30 rpm, ring diameter 1400-3000mm
- Film delivery carriage: Pre-stretch system 200-350%, motorized tension control
- PLC control unit: Recipe storage for 50+ product configurations
Technical Specifications
| Parameter | Standard Model | Heavy-Duty Model |
|---|---|---|
| Product length range | 500-6000 mm | 1000-12000 mm |
| Product cross-section | 100×100 to 800×800 mm | 200×200 to 1200×1200 mm |
| Maximum load weight | 1000 kg | 3000 kg |
| Ring rotation speed | 15-30 rpm | 10-25 rpm |
| Film width compatibility | 250-500 mm | 500-750 mm |
| Power consumption | 7.5 kW | 15 kW |
| Compressed air requirement | 0.6 MPa, 80 L/min | 0.8 MPa, 120 L/min |
| Control system | Siemens S7-1200 PLC | Siemens S7-1500 PLC |
How Does Orbital Stretch Wrapper Performance Compare to Manual Wrapping?
| Metric | Manual Wrapping | Orbital Stretch Wrapper | Improvement |
|---|---|---|---|
| Cycle time per bundle | 12-18 min | 2.5-4 min | -72-83% |
| Film consumption (kg/m³) | 0.8-1.2 | 0.4-0.6 | -50-67% |
| Labor requirement | 2-3 operators | 1 operator | -67-75% |
| Film overlap consistency | ±25% variation | ±3% variation | Standard deviation reduction |
| Packaging defect rate | 8-15% | 0.5-2% | Quality improvement |
| Throughput (bundles/8h) | 32-48 | 120-192 | +250-300% |
What is the ROI of Implementing an Orbital Stretch Wrapper?
Capital Investment Structure
Base equipment cost: $45,000-85,000 FOB (configuration-dependent)
International freight: $2,800-4,500 (route-dependent)
Installation and commissioning: $3,500
Operator training (24 hours): $1,200
Total project cost: $52,500-94,200
Annual Operating Cost Reduction
Based on 240 working days, single-shift operation (1,920 operating hours/year):
- Labor savings: 1.5 operators × $24,000/year = $36,000
- Material efficiency: 80 bundles/day × 0.6 kg saved × $2.8/kg × 240 days = $32,256
- Damage reduction: 10% defect rate × 19,200 bundles/year × $45 average loss = $86,400
- Productivity gains: 90 additional bundles/day × $12 margin × 240 days = $259,200
Total annual benefit: $413,856
Simple payback period: 1.5-2.7 months
3-year NPV (8% discount rate): $1,018,000-1,124,000
How Long Does Orbital Stretch Wrapper Installation Take?
| Phase | Duration | Technical Requirements |
|---|---|---|
| Pre-installation engineering review | 3-5 days | Floor loading capacity (min 500 kg/m²), clearance height |
| Equipment fabrication | 20-35 days | Custom ring diameter if required |
| International shipping | 25-50 days | Route-dependent (Asia-Europe 28-38d, Asia-Americas 35-50d) |
| Customs clearance | 2-5 days | HS code 8422.40 |
| On-site assembly | 3-4 days | Forklift required (2-ton capacity minimum) |
| Electrical integration | 1-2 days | 380-480V 3-phase, 50/60Hz |
| System commissioning | 1-2 days | 30-bundle trial run |
| Operator training | 1-2 days | Operation, recipe setup, basic troubleshooting |
Total implementation: 56-105 days from PO to production
What Maintenance Does an Orbital Stretch Wrapper Require?
Horizontal wrapping machine manufacturer systems require scheduled maintenance to maintain 98%+ uptime:
- Preventive maintenance interval: Every 1,500 operating hours (approximately 3-4 months at single-shift operation)
- Critical wear components: Film carriage bearings (replace every 12,000 cycles), rotating ring motor brushes (inspect quarterly), drive chain lubrication (monthly)
- Spare parts recommended stock value: $4,500-6,800 (12-month coverage for 1,920 operating hours/year)
- Service response time: 48-96 hours via regional distributor network across 45+ countries
Frequently Asked Questions About Orbital Stretch Wrapper Systems
Q: Can an orbital stretch wrapper handle products with irregular cross-sections like I-beams and angle iron?
A: Yes. Orbital stretch wrapper systems feature film tension adjustment range 20-180N that accommodates irregular geometries including I-beams, angle iron, channels, and T-sections. Optional corner-following sensor package ($3,200-4,500) provides adaptive wrapping for complex profiles, maintaining consistent 50% overlap coverage.
Q: How does an orbital stretch wrapper integrate with upstream bundling systems?
A: Horizontal wrapping machine manufacturer designs include standard industrial protocol support: Profinet, EtherNet/IP, Modbus TCP. Digital I/O handshaking with bundling/strapping equipment included. PLC handshake signals: product ready, wrapping in progress, cycle complete, fault alarm. Integration typically requires 4-6 hours configuration time.
Q: What film materials are compatible with orbital stretch wrapper machines?
A: Orbital stretch wrapper systems support LLDPE stretch film (15-35μm thickness), PE shrink film, VCI film (for metal corrosion protection during 6-12 month storage), and paper-based wrapping materials. Standard film core diameter: 76mm. Optional 152mm core adapter available. Film width range: 250-750mm depending on model.
Q: What are the power supply requirements for international installations?
A: Horizontal wrapping machine manufacturer equipment accepts voltage range 380-480V ±10%, frequency 50/60Hz (auto-sensing). Power consumption: 7.5kW (standard model) to 15kW (heavy-duty model). Meets IEC 61000 EMC requirements. UL/CE certification standard. Requires 3-phase connection with 25-40A circuit breaker.
Q: What floor space is required for orbital stretch wrapper installation?
A: Standard orbital stretch wrapper model: 8m (L) × 2.5m (W) × 2.8m (H), total footprint 20m². Heavy-duty model: 12m × 3m × 3.2m, footprint 36m². Dimensions include required safety zone per ISO 13857 (minimum 500mm clearance). Floor loading requirement: 500-800 kg/m² depending on configuration.
What Technical Support is Available for Orbital Stretch Wrapper Systems?
Global horizontal wrapping machine manufacturer networks provide comprehensive support infrastructure:
- Remote diagnostics: 24/7 VPN access with HMI remote viewing capability, troubleshooting response within 2-4 hours
- Preventive maintenance programs: Quarterly on-site inspection available through authorized service network in 45+ countries
- Spare parts distribution: Regional warehouses (North America, Europe, Asia-Pacific, Middle East) with 48-96 hour delivery to major industrial zones
- Technical documentation: Multilingual operation manuals, electrical schematics, PLC program source code backup (English, German, Spanish, Chinese, Japanese, Portuguese)
- Training programs: On-site operator training (2 days), remote webinar sessions, video library access
How to Select the Right Orbital Stretch Wrapper Configuration
To receive detailed engineering package and quotation:
- Provide product dimensions (length, cross-section, weight range)
- Daily throughput requirement (bundles/shift, annual volume)
- Facility constraints (floor loading, ceiling height, power availability)
- Film type preference (stretch/shrink, thickness, protection requirements)
- Integration needs (existing conveyors, bundling equipment, ERP/MES systems)
Contact: Engineering team provides preliminary system configuration and budgetary pricing within 48 hours. CAD layout drawings and 3D simulations available upon request for facility integration planning.
Summary: Key Advantages of Orbital Stretch Wrapper Technology
An orbital stretch wrapper delivers measurable improvements over manual wrapping and turntable systems for long products:
Performance gains: 250-300% throughput increase (from 32-48 to 120-192 bundles per 8-hour shift), 72-83% cycle time reduction (from 12-18 minutes to 2.5-4 minutes per bundle)
Cost efficiency: ROI payback period of 1.5-2.7 months, $413,856 annual benefit through labor savings ($36,000), material efficiency ($32,256), damage reduction ($86,400), and productivity gains ($259,200)
Technical capability: Handles products from 500mm to 12,000mm length, cross-sections up to 1200×1200mm, weights to 3000 kg, with film pre-stretch ratios of 200-350%
Operational reliability: 98%+ uptime with preventive maintenance every 1,500 hours, 48-96 hour spare parts delivery globally
Implementation timeline: 56-105 days from purchase order to production, including international shipping (25-50 days), installation (3-4 days), and training (1-2 days)
A horizontal wrapping machine manufacturer with global service network ensures long-term performance through remote diagnostics, multilingual documentation, and regional spare parts distribution across North America, Europe, Asia-Pacific, and Middle East.
Technical Data Package Download: Complete specification set includes electrical load calculations, foundation requirements, compressed air sizing, safety compliance documentation (CE/UL/ISO), and ROI calculation templates for orbital stretch wrapper and horizontal wrapping machine manufacturer systems configured for global industrial applications.
