In the 1900s, the plastics industry boomed, and with that came a particular change in the way the packaging industry operated forever: stretch wrap. Today, this revolutionary product continues to be intrinsic to the success of the industrial packaging industry. Since its introduction, stretch wrapping has become the prevailing method of unitising products on pallets for safe shipment to their destinations. But what would stretch wrap be without the pallet wrapping machine? Like most of our most-loved products, we take technology for granted and often don’t think about their origins. Pallet wrapping machines are probably the most numerous pieces of packaging equipment in the industry. So, let’s look into the history and mechanics of this essential piece of wrapping machinery.
Before the invention of the pallet wrapping machine in the 1970s, companies had no choice but to load trucks with their products individually or use metal strapping or shrink bags to unitise loads. These practices were labour-intensive, expensive, and physically draining. Surely there had to be another way?
The first stretch wrapper came to fruition in 1973; Brothers Pat and Bill Lancaster unveiled the invention at the Packaging Machinery Manufacturer’s Trade Show. This machine showcased a way to unitise products on pallets by wrapping them in layers of plastic film. Not only was this a less labour-intensive method of palletisation, but it was also cheaper. Now, instead of taking many working hours to floor load a truck, a forklift driver could load an entire truck in less than 30 minutes. Typically, wrapping with steel strapping would take a long time to complete, whereas utilising a pallet wrapper would mean the load is secured in just over one minute. Not only could it wrap pallets more cheaply, but it was also mobile.
This was a well-thought-out solution to yesterday’s wrapping needs. Three of its features are still being used today: It’s mobile, has a rectangular turntable, and is a mechanical brake machine. Development in extruders and film technology means that the film is now only 500mm wide, so it must travel up and down the mast. The right machine stretch is crucial for securing and shipping palletised goods efficiently.
How do pallet wrappers work?
They have two or three motors: one/turns the turn table, two lifts the film carriage up and down the mast, and three stretch and lay the film onto the loaded pallet. (power stretch variety)
Pallet wrapping has been made more convenient by the use of machines. Pallet wrapping machines reduce the amount of time spent packing products and make businesses more productive. What’s more, less waste material is created due to inefficient human error. Pallet-wrapping machines protect your company’s load by wrapping multiple layers of film over it. Pallet wrap machines are known for their efficiency, reliability, and cost-saving benefits, making them an essential tool for any business. Pallets are loaded into position, and the turntable is rotated until the load is completely covered. There are many models to choose from, and there are three fundamental styles to consider: turntable, straddle, and robot.
- A turntable stretch wrapper spins the load on a turntable while the film delivery system moves up and down the mast and dispenses the film around the pallet. Typically, these turntables spin around at up to 12 revolutions per minute. This type of wrapper can handle most wrapping needs. 8 out of 10 pallet wrappers sold are turntable systems. They are cheaper than using labour.
- A straddle stretch wrapper works oppositely; the load remains static, and the film delivery system rotates and moves up and down to distribute the film. This type of machinery is used more often for light loads and unstable loads, which may fall over on a turntable when it starts to rotate. Because it is fed with a conveyor belt, its throughput is far higher than a stand-alone turn table. They do not require labour as they will wrap and move pallets unattended.
- It has advantages where the environment is dirty or very cold; it keeps the main pallet wrapper out of harms away, suspended in the air.
- The robot can go anywhere (wrap anything; it has all the sophisticated programs of the static turntable). Utilizing pallet wrapping machines eliminates the need to manually transport unwrapped pallets to the stationary pallet wrapper within the factory. Apart from moving the robot to the place of work, it wraps pallets unaided.
The three methods of wrapping pallets
- Before purchasing a pallet wrapping machine, there are several factors to consider. Straddle stretch wrappers, with their rotating arm and supporting frame, require more floor space compared to turntable machines but offer high throughput. Additionally, straddle wrappers need to be securely anchored to the floor. On the other hand, turntable machines are more compact and convenient for businesses dealing with various load sizes or limited floor space.
- When it comes to operation, semi-automatic pallet wrapping machines are recommended for companies wrapping low to high volumes. These machines offer a safe and efficient method where an operator simply needs to place the load on the machine, secure the film, and start the wrapping cycle. In contrast, automatic pallet-wrapping machines operate without any manual intervention. Pallets are automatically fed into the machine via a conveyor system while sensors calculate the optimal wrapping height for each load. The film is cut and secured before the conveyor belt releases the wrapped pallet for loading and repeats the cycle seamlessly.
- The latest technology in wrapping pallets is the robot. It operates by going self-propelled around the pallet to apply the film. It can travel to where the load needs to be wrapped. The use of pallet wrapping machines eliminates the need to transport unwrapped pallets around the factory for static wrapping. Using a stretch wrapping machine enhances efficiency, ensures precise wrapping, and reduces costs significantly.
Types of pallet wrappers
Core Break Pallet Wrappers
Core break pallet wrappers are entry-level turntables machines; there are only two working motors, one to turn the turn table and the other to lift the film carriage up and down the mast. The load is placed on the turntable with the aid of a forklift or pallet truck. The film is attached, the turntable revolves, and the film is pulled off the roll. Once the cycle is complete, the operator cuts the film, and the load is removed. Minimal machine stretch is applied to the film with this type of machine, which is crucial for securing the load during shipping. A light sensor controls the assent height on all pallet wrappers.
Power Pre-Stretch pallet wrappers
Depending on the machine’s age, model, and make, they will stretch the film from 100% to 300%. The difference between the core break and power stretch pallet wrapper is that the latter has a 3rd motor in the film carriage head. It performs three functions: 1/pulls the film from the roll, 2/stretches the film, and 3/controls the lay-on tension of the film to the load. They have multi-functional control panels so that almost any loaded pallet can be wrapped. The best of these machines will turn one meter of film from the roll into four meters to wrap the pallet. Stretch wrap machines, including robotic pallet wrapping machines and entry-level semi-automatic stretch wrap machines, are known for their efficiency and versatility. The real savings start here at 250/300% stretch.
Cut and clamp semi-automatic Power stretch pallet wrapper
These are the ultimate technology in stand-alone turn table wrapping machines. All that the operative has to do is place the loaded pallet onto the turn table. Press the start switch on their handheld console and walk /drive away. The stretch film is then applied to the pallet; it then rotates to wrap the load and stops when it’s done. The film is cut, and an arm secures/pats the tail securely to the wrapped pallet.
The advantage of this type of pallet wrapper is that it can save the company time in the wrapping cycle. The average wrapping cycle by pump truck is one minute to load and one minute to unload. Then, one minute to wrap on the machine, ie 3 minutes. (em for further details)
The cut and clamp saving are on the loading, unloading and applying film to the load then cutting the film before moving the pallet away for despatch. Different types of pallet wrap machines, such as robotic pallet wrapping machines and automatic pallet wrap machines, offer benefits like increased production speed, ensuring product security, and handling various pallet sizes.
Super Power Stretch pallet wrappers
With the recent vast developments in film extruders and, to a lesser degree, in polymer engineering, stretch films can now be stretched up to 400% or even more. When stretched to 300%, twelve-micron films are only 3 microns thick when laid onto the pallet. The Power Pre Stretch pallet wrapper had to reinvent itself to take advantage of the extruder and film development. The superpower stretch or variable stretch wrappers are different in that they have two motors in the film carriage head with various developments in the film handling part of the carriage head. This makes it possible to stretch with more than 400 % pre-stretch; i.e. one meter of the film now becomes five meters. These machines are easy to operate from a control panel, producing a pre-stretch which can range from 10% to 400%. High pre-stretch reduces film consumption, enabling companies to achieve the best results at the lowest possible costs with optimal pallet stabilisation, which is crucial for product protection.
Inline Turn Table pallet wrapper
Inline is when a turn table wrapper is placed into a conveyor system and is integrated into the production line, which is ideal for those needing a fast pallet wrapping operation. These machines easily fit into or at the end of an existing conveyor system. The stretch film is applied automatically; it then wraps automatically and stops at the end of the cycle. The stretch film is automatically cut, and the tail is then pasted into place before the pallet moves off. Placing a turn table wrapper into a production line will offer the opportunity to reduce labour on each shift that it works. The automated wrapping process enhances efficiency and precision, ensuring consistent and cost-effective pallet wrapping.
Robot Pallet Wrapper
The latest technology in wrapping pallets is the robot. It operates by going self-propelled around the pallet to apply the film. Unlike a turn table or straddle machine, the robot will wrap a load that is larger than 1000 x 1200 pallets, i.e., 4 feet wide and 8 feet long. It could even wrap a portacabin or a load too heavy to be picked up by a forklift truck. It is very mobile, so it can easily go to where the load needs wrapping, thereby eliminating the need to move unwrapped loads through the factory to the pallet wrapper. One operator can work two or three machines simultaneously.
Robot pallet wrappers significantly improve efficiency within the supply chain by streamlining the wrapping process and reducing the need for manual labour.
Stand Alone Overhead Pallet wrapper.
These overhead pallet wrappers have their electrics and motors in the gantry above the wrapping arm, which rotates around the pallet. They are ideal for light, unstable loads, or very heavy loads. Pallet wrap machines, including automatic, manual, and mobile systems, offer significant benefits such as increasing production speed, accommodating different pallet sizes, and enhancing load stability. Food processing industries such as meat, poultry, or dairy, where the floor has to be hosed down, chilled or freezer plants, and dusty or dirty industries such as sawmills, brick & cement yards, or recycling plants. Anywhere
In-Line Overhead arm wrapper
Overhead straddle wrapping machines are ideal for unstable loads because this type of stretch wrapper allows loads to be quickly wrapped while moving on the conveyor. Overhead stretch wrappers are versatile. They can be employed in various ways: 1/ in a conveyor line, 2/ attached to the wall, and 3/ as a stand-alone unit. This technology is very versatile compared to a ring wrapper. It is swift at wrapping. The arm can be fitted with one or two film dispenser units. A stretch wrapping machine offers versatility and speed, making it an efficient solution for various warehouse operations.
In-Line Ring wrapper
Rotary ring wrappers straddle the pallet; they are unique because the film dispensers are fixed to a ring that allows them to rotate around the pallet. This type of wrapping machine is beneficial when wrapping unstable loads, including heavy and liquid loads, because the product remains static whilst being wrapped. The ring can be fitted with one or two film dispenser units. Stretch wrap machines, including robotic pallet wrapping machines and entry-level semi-automatic stretch wrap machines, offer efficiency and versatility for wrapping unstable loads.
Vertical ring wrappers
Loads can often be long and narrow (mouldings and extrusions), making them difficult to wrap by hand. Vertical Orbital wrappers are designed to wrap these products effectively and efficiently.
Vertical Orbital Wrappers can be semi or fully automatic. These machines enhance the wrapping process by providing greater efficiency and precision. The vertically positioned stretch wrap dispenser rotates the film around and under the load as it passes through the ring, significantly reducing the time it takes to wrap the loads by hand.
Hollow wrappers
These are designed to wrap endless products, such as car tyres, window frames and wound coils of flexible tubing.
Pallet wrap machines are highly efficient and flexible. They accommodate various pallet sizes and ensure the safe shipment of items.
Summary
The stretch wrap machine has revolutionised the way the packaging industry works by ensuring consistency and efficiency throughout the packaging process. Once, hand wrapping was the only option, but this was not cost-effective due to the time each load took to wrap and the ununiformed look of the end result. Today, every company has different operations and different packing machinery needs. Thanks to the wide range of pallet wrappers available today, every company can now choose a machine that is ideally suited to their individual needs. Pallet wrap machines, including automatic, manual, and mobile systems, offer increased production speed, accommodate different pallet sizes, enhance load stability, and come with various finance options, including renting and maintenance programs.
If you have any questions about your pallet wrapping project or requirements, we shall be happy to help you and answer any questions that you may have, not only about the pallet wrapping machine but the stretch film as well and the project that you have to wrap so that your product can travel and arrive to your customer without mishap.