Questions You Should Know about Turntable Fully Automatic Pallet Wrapping Machine

The stretch wrapping system is one of the most widespread and widely used final packaging solutions to protect loads. There is a wide range of wrapping machine types with different applications and complements, depending on the product and the customer’s objective. Therefore, when choosing a pallet stretch wrapper for a packaging project, many questions arise that, as manufacturers of this system, we receive and handle on a daily basis.

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In today’s article, we will answer some of these questions and doubts about the automatic wrapping system, continuing our series of Top 10 Frequently Asked Questions.

Top 10 FAQs about Automatic Wrapping Machines

1. What types of stretch-wrapping machines are available in the market?
2. What is the difference between a semi-automatic and an automatic wrapping machine?
3. What type of wrapping machine is recommended based on production?
4. What types of cycles can a stretch wrapper perform?
5. What type of film and consumables does a stretch wrapper use?
6. How much stretch film does a stretch wrapper consume? How can I save on film?
7. How does the stretch wrapper offer total protection to the load?
8. What wrapping speed can a stretch wrapper achieve?
9. Can pallet-less loads be stretch-wrapped?
10. Which accessories can be included to improve the stretch wrapping?

1. What types of stretch-wrapping machines are available in the market?

Due to its long extension in the market, there is a multitude of stretch wrapping models according to the needs and functionalities sought in the packaging process. Even so, leaving aside manual wrapping processes, we find large categories such as:

• Wrapping robot: Semi-automatic solution with a vehicle that performs the wrapping by circling the load. Its great advantage consists in the fact that the load does not have to be moved or to be placed on any platform or automatic line. The big disadvantage is the human operation and the time required for wrapping, so it is usually recommended for low production rates.
  
  
• Turntable Stretch Wrapper: The next in the range of performance is the turntable wrapping machine, which can be semi-automatic or fully automated and integrated into the conveyor line. The load must be placed on the platform and the wrapper applies the film at different heights by rotating the load. The turntable stretch wrapper is versatile in space and performance for low to medium production and packaging needs. For this reason, it is one of the most common models on the market. This type of wrapping machine can also include accessories to improve the wrapping process, such as the load reinforcement roping system.

• Rotary arm stretch wrapper: The next level up in stretch wrapping is the rotary arm wrapper, which rotates around the palletized load. Its main advantage over the turntable pallet wrapper is that the goods remain stationary, which makes it ideal for unstable or fragile loads. This type of wrapping machine is commonly offered in automatic mode and integrated into automated lines with conveying and medium to high production.
  
  
• Ring Stretch Wrapping machine: The ultimate high-performance wrapper is the Ring Stretch Wrapper, which can even double the speed of the Rotary Arm wrapper. The concept is the same as with the arm wrapping machine, except that the wrapping is done by a ring with one or two film carriages. This top-of-the-range stretch wrapper is usually used for high production rates.
  
  

• Horizontal Orbital Wrappers: Finally, also name the orbital wrappers for the horizontal wrapping of extra-long loads, such as panels, construction materials, furniture, etc.). The objective is usually different than the rest of the vertical wrappers, since the load does not have to be palletized.

2. What is the difference between a semi-automatic and an automatic wrapping machine?

The main differentiation is the automation component. While a semi-automatic (turntable or robot) pallet stretch wrapper needs human intervention to start the cycle, the automatic pallet stretch wrapper is part of a fully automated line. On the other hand, while the semi-automatic platform stretch wrapper can be installed anywhere in the factory, its automatic variant needs a conveyor line that allows pallets to flow in and out.

Finally, automatic stretch wrappers usually offer more features such as safety extras, higher speed, accessories, etc.

3. What type of wrapping machine is recommended based on production?

Usually, for low production (less than 20 pallets/hour), we recommend semi-automatic pallet stretch wrappers, as they offer versatility yet higher wrapping quality than a robot stretch wrapper.

For a range of 30 – 40 pallets/hour, we can already recommend an automatic stretch wrapper which can be either a rotary arm or a low-production ring wrapper.

For higher outputs of 40 pallets/hour or specific wrapping requirements, the reliable choice will be a high-performance ring wrapper. High outputs of 80 – 100 pallets/hour typically use double film carriage stretch wrappers for higher speed.

4. What types of cycles can a stretch wrapper perform?

Depending on the product and packaging objectives, different types of cycles can be designed. The versatility of stretch wrapping is precisely the fact that it is possible to program a wrapper with different tension and reinforcements in the various areas of the load. Some examples of these can be:

• Base reinforcement, for light loads: The cycle will focus on reinforcing the bundle at the base for transport, either with film or with the help of the reinforcing roping device.
• Reinforcement in the upper overlap, for very high loads: The cycle will cover the entire high load, with additional support in different areas and in particular in the overlap of the upper film.
• Rope application for extra support: On heavy but fragile loads, the rope is used to generate extra support similar to strapping. The roping also serves to compact the load and can be programmed to reinforce specific areas depending on the shape of the load.

5. What type of film and consumables does a stretch wrapper use?

Usually, the pallet wrapping machines use stretch film, but they can also employ pre-stretched film or other new consumables on the market, such as kraft paper with stretching capabilities.

The standard stretch film is composed of low-density line polyethylene (LLDPE) which is what gives it its high stretch capacity. Depending on the characteristics of the plastic and the stretch wrapper (and its pre-stretching system) this type of film can stretch between 25 and 300%. If both the film and the stretch wrapper allow a higher stretching (more than 150%), allowing also a higher saving.

The pre-stretched film is a film that has already been stretched to its shrinkage limit (which is usually 100%) and is normally used in manual or semi-automatic applications without pre-stretching and low tension. It is a non-stretch film recommended for loads that need slight protection or restraint.

Lastly, stretch kraft paper fulfills a similar function to pre-stretched film, with the great difference that it has a lower stretching capacity and does not allow the application of a rope system. Even so, it has recently appeared on the market as a more sustainable alternative to film, since it is 100% recyclable.

6.  How much stretch film does a stretch wrapper consume? How can I save on film?

Film usage in a pallet stretch wrapper depends on many factors: type of stretch film, if it is stretchable, pre-stretched, or not, and its stretching capacity, but also the features of the stretch wrapper, the wrapping cycle, rope application, cover, load size… the list is almost endless. Even so, several factors make it possible to economize and optimize the film to the maximum:

• Use stretch film with a high stretch capacity of up to 400%.
• Use a pallet wrapping machine that allows this type of pre-stretching.
• Design a wrapping cycle that uses only the strictly necessary film, with tensioning points for better fastening.
• Use high-performance stretch wrappers, since, in addition to using torque control technology, they usually have a double stretch film cart to wrap the load in less time, with fewer wraps and more precise tensioning.

7. How does the stretch wrapper offer total protection to the load?

The automatic stretch wrapper system can run a cycle that covers from the base to the top of the pallet, where a cover is placed to fully protect the load. The cycle can be programmed with higher tension to ensure that no layer is detached and that the wrapping is compact and sealed.

However, an alternative for total protection in automated productions with medium-high production is usually Stretch Hood wrapping, which covers the entire load with a single layer of film.

8. What wrapping speed can a stretch wrapper achieve?

In the case of automatic stretch wrappers, a standard wrapping can perform between 60-80 pallets/hour. For speeds of 80-100 pallets/hour, ring wrapping with two reel carriages is recommended. And more than 100 pallets/hour and up to 200 p/h are achieved with high-performance stretch wrappers but also depending on the type of load and wrapping requirements.

As this is such a broadly defined aspect, we recommend consulting with an expert team in packaging, such as Innova’s, to determine which type of stretch wrapper or packaging system is best suited to your production.

9. Can pallet-less loads be stretch-wrapped?

Although most stretch wrapping equipment works with palletized loads, pallets loads can also be packaged employing a special accessory. In automatic stretch wrappers, a conveyor-lift system is usually included to raise the load so that the wrapping carriage can reach its base and protect it.

10. Which accessories can be included to improve the stretch wrapping?

The pallet wrapping system is one of the most extensive and technologically evolved solutions in recent years. For this reason, it is a very versatile system that allows to include a multitude of accessories to improve the wrapping according to the wrapping objectives.

Some of the most common accessories of automatic wrapping machines:

• Roping device: The wrapping carriage converts the film into a rope that is applied around the load to reinforce its hold and compaction. It acts as a horizontal strapping.
• Top press: For light or unstable loads the wrapper can include a top press to hold the load while wrapping.
• Cover application: Automatic systems usually include an also automatic accessory to apply the top cover for those loads that require total protection. The cover uses a different consumable than the stretch film, being a film with protective properties that overlaps with the film.
• Edge protector applicator: For special loads that require edge protection, vertical cardboard edge protectors can be included. This is the case for goods with boxes, blocks, or products such as home appliances that need to protect their edges from film application.

At Innova we have developed an accessory to include the edge protectors automatically during stretch wrapping:

Want more information on Turntable Fully Automatic Pallet Wrapping Machine? Feel free to contact us.

Do your employees still manually wrap pallets for shipping? Are you looking to improve the efficiency and safety of your packaging process? Investing in a pallet wrapping machine could be the solution for your business.

Pallet wrapping machines, also known as stretch wrappers, are automated devices designed to wrap large items or loads onto a pallet using stretch film. These machines come in various models and sizes to accommodate different load capacities and production needs.

When considering purchasing a pallet wrapping machine, it’s important to ask the right questions to ensure you’re making an informed decision. Let’s take a look at some essential questions to ask before buying a pallet wrapping machine.

How Do Pallet Wrapping Machines Work?

Before we jump into the questions you should ask, let’s briefly review how pallet wrapping machines work. These machines wrap stretch film tightly around pallets of goods. The process usually involves placing a pallet on a turntable or conveyor system, where the machine then wraps the film around the load. This ensures the items on the pallet stay put during transport.

Types of Pallet Wrapping Machines

There are different types of pallet wrapping machines, including semi-automatic, fully automatic, and mobile robotic versions.

Semi-automatic machines require manual intervention to load the pallets onto the machine and start the wrapping process. Fully automatic machines can handle everything from loading to wrapping with minimal human involvement. Mobile robotic versions are a newer development that allow for flexibility, moving around your warehouse while still efficiently wrapping pallets. When selecting a pallet wrapping machine, consider the type that best suits your warehouse’s needs and workflow.

Questions To Ask Before Purchasing a Pallet Wrapping Machine

When shopping for a pallet wrapping machine, there are a few questions you should ask to ensure you select the right one for your needs.

What Are Your Volume Requirements?

How many pallets do you need to wrap in a given period? Understanding your volume requirements is crucial to selecting the right machine, as different machines have varying output capacities. If you have a high volume of pallets to wrap, investing in a higher output machine will save time and increase efficiency in your warehouse. But if your volume is lower, a machine with a lower output may be more cost-effective.

What Are the Dimensions and Weights of Your Pallets?

Different pallet wrapping machines can handle different dimensions and weights. Therefore, it’s essential to know the exact measurements and weights of your pallets to ensure they will fit and be adequately supported by the machine. If your pallets have irregular shapes or exceed standard dimensions, you may need to invest in a custom-made machine.

What Is Your Budget?

You should have a firm budget in mind when looking for a pallet wrapping machine. Make sure to consider the initial cost, as well as potential maintenance and operational expenses, when determining which machine is within your budget. While it may be tempting to pick a cheaper option, investing in a high-quality machine can lead to long-term savings through enhanced efficiency and fewer repairs.

How Much Space Do You Have for the Machine?

Space is often a constraint in warehouses, so consider the footprint of the machine. Will it fit comfortably in your warehouse, or will you need to make adjustments? Also, consider whether the machine has any special requirements for installation, such as a designated power source or additional ventilation. These factors can determine the type of machine you choose as well as where you place it.

What Are the Film Requirements?

Different pallet wrapping machines use different types of stretch film. Make sure you understand the film requirements of the machine you’re considering; this includes the film size, thickness, and compatibility with your existing warehouse systems or methods of transport.

What Is the Maintenance Schedule?

Like any equipment, pallet wrapping machines require regular maintenance to function efficiently and prolong their lifespan. Ask the manufacturer about the recommended maintenance schedule and if there are any special procedures or training required. Knowing this information beforehand can help you plan and budget accordingly.

Is Training Provided for Operating the Machine?

Speaking of training, you’ll need to know if the manufacturer offers training on how to operate the machine. While some machines may be more user-friendly, it’s always best to have proper training to ensure safe and efficient operation.

What Is the Warranty and Technical Support Offered?

As with any major purchase, it’s important to know what kind of warranty comes with the pallet wrapping machine. This will provide peace of mind in case of any malfunctions or defects that occur within a specific time frame.

You’ll also want ask about the availability of technical support and if there are any fees associated with it. It’s always helpful to have a knowledgeable support team to turn to in case of any issues or questions.

Is There an Option for Custom Settings?

Different product loads may require different wrapping techniques and film tension levels. This makes it crucial to check if the machine has adjustable settings for these factors. This feature allows for versatility in your wrapping process and ensures your goods are securely wrapped according to their specific requirements.

Are There Any Additional Features That May Benefit My Warehouse?

Aside from the basic functions of pallet wrapping, some machines offer additional features that may benefit your warehouse operations. These include automatic film cutting, weigh scales, and even integration with other warehouse systems. Consider which features would be most beneficial to your specific needs when making a decision.

What Is the Return on Investment?

Finally, consider the return on investment (ROI) of the pallet wrapping machine. Calculate how much time and labor you’ll save by automating the pallet wrapping process, and consider the potential reductions in damaged goods and increased efficiency in warehouse operations. Taking all of these factors into account will help you determine the ROI of a pallet wrapping machine.

Choosing the ideal pallet wrapping machine for your warehouse involves asking the right questions. Consider those mentioned above, as well as any other specific requirements or concerns you may have. With these questions in mind, you’ll be able to make an informed decision and select a machine that increases efficiency and improves operations in your warehouse.

At DRM Associates, we offer a range of pallet wrapping machines, including semi-automatic, fully automatic, and mobile robotic versions. Our machines come with excellent after-purchase support to ensure you get the most out of your investment. Contact us today for a quote or for more information on our products.

For more information, please visit Rotary Arm Fully Automatic Pallet Wrapping Machine.