5 Must-Have Features in a Pallet Wrapping Machine

When selecting a packaging system for your end of line, it is important to take into account the objectives sought with this system: protection, grip, stability, safety, hygiene… In terms of pallet handling, one of the solutions preferred by many industries is always the wrapping system, either in its automatic or semi-automatic versions. Today, we are outlining the advantages and technical highlights of the automatic wrapping system, as a single packaging solution or used as a holding complement in a Stretch Hood packaging line, a combination commonly used in the ceramics sector.

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Why the wrapping system for subjection?

As its name describes, this system wraps the load with a Stretch film that provides support on all four visible sides. It is therefore a system that is highly valued for its stability, as the film stretches and adapts to the load. Usually, the wrapping system includes the option of applying cord to provide extra support similar to that offered by horizontal and vertical strapping systems.

What kind of wrapping machine do I need for my product?

Being one of the most widespread systems, it is also one with the most models and options on the market. From semi-automatic wrapping machines, with rotating or mobile plate, to fully automatic wrapping machines, usually with platform, rotating ring or rotating arm, among other options. Depending on the type of product and production needs, technical managers usually choose a semi-automatic or fully automated system for large productions.

The automatic wrapping system allows to pack an average of 100 pallets/hour, so it is a system widely used at the end of the line in many industrial sectors, offering the total automation of its packaging.

Technical highlights of the automatic pallet wrapping system

As experts in end-of-line solutions, we analyzed the key features of the automatic wrapping machine:

1. Stretch wrapping and stability:

The wrapping system provides support and stability by two factors: on one hand it wraps and compacts the load by stretching and adapting the film to the product, and on the other it holds the load thanks to the application of the elastic cord. In the case of the ring wrapper, the accuracy of the film and cord is higher since it includes a height position control for the application of the film and cord layers.

For light or unstable loads, the automatic wrapping machine can include a top press to hold the pallet while wrapping, thus ensuring efficiency.

2. Wrapping with custom finish

The automatic wrapping machines provides customized packaging finishes according to the needs of fastening and protection. In the case of the ring wrapping machine, it provides different types of upward or downward wrapping or both to ensure the best hold and finish. The wrapping cycle is also carried out at any height defined, according to the needs. Optionally it also includes the option of applying a plastic cover to protect the top of the load for storage outdoors or in adverse conditions.

3. Adapted to different types of load

Stretch wrapping is a very versatile system that can be adapted to different pallet heights and load shapes. The film reel is easily replaceable and can be adapted to different sizes according to production requirements. This makes it the system that adapts to more industries and products, and even recommended for picking or logistics pallets, as it allows a more suitable grip than other systems such as automatic strapping.

4. The extra holding option in a packaging line

The wrapping system can be used to provide extra hold on a Stretch Hood packaging line. This is a solution that meets the needs of total product protection, for which the Stretch Hood system is recommended, with the wrap-around fastening provided by the wrapping machine.

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For the ceramics sector this is a common combination, using strapping and wrapping to hold and Stretch Hood to protect the pallet. With special loads, or composed of small boxes, the wrapping system provides a hold that adapts to the load without applying excessive pressure. The wrapping machine’s cord acts as the strapping, joining the load to the pallet and offering greater stability. This type of line includes the horizontal strapping system before the wrapping machine, with or without edge protectors. The horizontal strapping helps to compact the ceramic load, turning it into a block before it reaches the wrapping machine. The final objective of this type of line is that the ceramic load reaches the customer as safely and flawlessly as possible, thanks to this specialized packaging combination.

5. Sustainability and reduced film consumption

Finally, the most advanced wrapping systems, like the case of the ring wrapper Etherna from Innova, have a very precise control of the film used, thus contributing to reduce costs and film waste, in a more sustainable line of work. Thanks to its electronic system with a Torque control, the wrapper uses the exact amount of stretch film needed according to the load and dimensions of the pallet. The stretch wrappers developed by Innova use low energy consumption and have a low maintenance cost, as well as reducing CO2 emissions compared to pallet wrapping systems such as Shrink Hood wrapping.

What wrapping system do I need? What speed does the pallet stretch wrapper deliver? Which securing accessories are recommended? When choosing an automatic pallet wrapper, there are many aspects to consider depending on the packaging objectives and characteristics of your product. In this article, we will explore the fundamental factors to evaluate when selecting the most suitable stretch wrapper to optimize the wrapping process and ensure load stability and safety.

1. Do we need an automatic or semi-automatic Stretch Wrapper?

This is the turning point when choosing an industrial wrapping machine since their performance and objectives are very different. This choice will depend on the production level, being the automatic one more appropriate for medium and high productions, while the semi-automatic stretch wrapper can be sufficient for low productions.

2. Which wrapping system is best suited to my product?

Although it may be a subjective decision to the company’s preferences, different types of vertical pallet wrappers can offer different performances depending on the product and securing objectives.

In the case of automatic pallet wrapping systems, we can find:

• Turntable Stretch Wrapper: The turntable wrapping machines are versatile, simple, and usually do not take up too much space in the factory. However, it is not recommended for unstable products, as the load rotates during wrapping. It also has lower speed and fewer performance features than other stretch wrapping systems.
• Arm Stretch Wrapper: In addition to versatility, the Arm Stretch Wrapping system t offers greater safety since the arm is the one that rotates around the load, providing greater stability to the wrapping.
• Ring Stretch Wrapper:  The Ring Stretch Wrapper is usually the highest performance and speed system. It provides maximum support and stability using a wrapping ring that envelops the entire load with customized cycles.

3. What technical and programming features should be taken into account?

Wrapper Technical features:

There are certain aspects of the technical performance of the wrapping machines available on the market that are essential for choosing a wrapping machine system or specific wrapping brand:

• Pre-stretching film system: Although it is an essential feature of automatic stretch wrapping systems, it is important to have a wrapper with a pre-stretching film system as it provides greater savings and optimization of the film used.

• Wrapping speed and machine capacity: To meet production needs, it is essential to know the speed and wrapping capacity. A second film cart can also be considered to increase the speed and autonomy of stretch wrapping with fewer film changes.
• Load dimensions: It is important to take into account all the formats and dimensions to which the wrapping machine must be adapted.
• Wrapping finish system: Another essential point is the automatic wrapping finishing system, which is usually done by welding, but in other wrapping systems, it may be done by adhesive or other finishing systems.

Programming features to be taken into account:

The programming functions of the stretch wrapper are essential to optimize the wrapping process, and therefore another aspect that should not be forgotten when choosing a pallet wrapper.

• Own programmable PLC: A programmable controller lets you adapt the wrapping cycle to different load dimensions and wrapping needs. The PLC system allows greater flexibility and better maintenance, without the need for replacement of electrical components (such as cards) in case of failure.
• Customizable wrapping cycle: In the programming section, the stretch wrapper must be able to perform various types of wrapping operations depending on the size of the load to be packaged. This way, it is possible to program a cycle with different finishes at different heights of the load.
• Customizable wrapping tension: Following the previous point, it is also important to determine the ideal containment force for our product to provide greater load securing and stability.
• Remote access to the machine: A remote access system not only facilitates troubleshooting and avoids trips to the factory, but is also useful for updating programs remotely.

4. What complements and accessories are needed to improve wrapping?

These complements may be additional, but some products or load types may require these accessories to ensure optimal stretch wrapping:

• Reinforcement cord system (roping device): The roping is an essential part of the pallet wrapping machine, as it provides a better hold on the load, especially in the case of fragile or unstable products.
• Vertical top-press system: The top-press is used to improve the wrapping of lightweight or unstable loads since it enables the load to be secured during the cycle. The top-presser device can be pneumatic or motorized, scissor or “press” type.
• Automatic top cover applicator: In automatic wrapping systems, the automatic cover accessory is essential to offer total protection to the load, since it covers and protects the 5 visible sides of the pallet.
• Edge Protector Applicator: Edge protectors are an accessory widely used in strapping systems, but they are also included in the stretch wrapper to protect the edges of the load during handling and to shield the product from the wrapping application itself. Edge protectors, which are usually vertical, are used on boxed products or products presented in a block such as household appliances.

5. Other aspects to check in an automatic wrapping system:

In addition to these main features, it is essential to review other important aspects of the wrapping machine:

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• Machine structure: The structure of the machine itself, with columns and wrapping frame, must be robust and durable. For example, at Innova, our automatic stretch wrapping systems are equipped with a 4-column chassis for greater stability and safety during wrapping.
• Wrapping machine dimensions: The dimensions and footprint of the wrapping machine must be taken into account to adapt it to the space in the factory.
• Adaptability to the factory environment: Characteristics such as the temperature, whether the environment is corrosive or humid, whether it is an ATEX zone, etc., are requirements that must also be considered when choosing a stretch wrapper and passed on to the manufacturer of the stretch wrapping system.
• Wrapping machine electrical panel: Whether the electrical control panel is integrated into the machine or in the packaging line itself, depending on the needs of the project.
• Machine safety elements: The automatic wrapping machine must have a secure perimeter area, security access, and safe maintenance protocols, among others.
• Communication technology: The wrapping machine can be equipped with wireless or wired communication systems, depending on the technical requirements of the system itself. For example, the Innova ring wrapper uses a wireless communication system for better efficiency and maintenance of the wrapping carriage.
• Adaptability to the conveyor line: The wrapping machine must be compatible with the existing conveyors in the production line, in terms of type (rollers, chains, etc.) and height.
• Accessibility to Cargo Vehicles: The wrapping machine must allow easy access to loading vehicles such as pallet trucks, forklifts, AGVs, or others.
• Weighing and Detection Systems: Other aspects to evaluate are whether the stretch wrapper includes additional safety systems such as a load weighing system, or a height detection system to improve packaging efficiency. Height detection control by means of a gauge is a must for multi-format loads such as in picking warehousing or logistics industries.

• Connection with other end-of-line systems: The stretch wrapper can be connected to other packaging or end-of-line systems, such as labeling systems.