Why is it worth automating pallet wrapping?
Automatic securing of loads on pallets is an important stage of production, warehouse, and logistics processes. The wrapping method affects not only the stability of products during transport, but also the efficiency of the entire line, the consumption of packaging materials, and the safety of further load handling. In plants handling a large number of pallets, manual film wrapping often proves insufficient due to limited efficiency, difficulties in maintaining repeatability, and a heavy workload for employees. The solution is an automatic pallet wrapper working with a rotary roller conveyor. The device takes over the pallet from the previous section of the line, positions it correctly, carries out the programmed wrapping cycle, and then transfers the secured load to the next stage. Such a combination also facilitates the integration of the wrapping process with a palletizer, an internal transport system, and other machines operating within one line. As a result, the entire process can run smoothly without the need to manually rotate the pallet or stop the remaining devices. How exactly does such a solution work in practice? We explain it in the following part of this article!
How does the pallet enter the automatic wrapping zone?
The process begins with transporting the finished pallet to the working zone of the wrapper. The load can be transferred directly from a palletizer, conveyor system, or another section of the technological line. Rotating rollers allow it to move smoothly without the need to use a forklift each time. After entering the wrapper, the pallet is stopped in a precisely defined position, which allows the programmed cycle to start correctly. Appropriate sensors monitor its presence, positioning, and the possibility of safely starting the machine. Only after all required conditions have been confirmed does the controller issue the command to begin wrapping. Synchronizing the conveyor operation with the remaining elements of the line also makes it possible to maintain proper spacing between subsequent pallets and reduce the risk of jams. Such a solution reduces the likelihood of load displacement, incorrect film application, or machine start-up with the pallet positioned improperly. The rotary roller conveyor therefore performs both a transport and working function, as it not only delivers the load to the machine, but also participates in rotating it during the application of the securing material.
Why does the entire pallet rotate during wrapping?
During automatic wrapping, the pallet rotates on the roller conveyor, allowing the film to be applied evenly around the entire circumference of the load. The material feeding unit moves vertically or remains at a specific height according to the selected operating program. This makes it possible to gradually secure successive parts of the load – most often starting from its lower section, which requires a stable connection with the pallet base. The first wraps limit the possibility of product movement, while the subsequent layers connect the individual levels of packages into a compact whole. The number of rotations, the degree of overlap between successive layers, and the method of guiding the film can be adjusted to the height, weight, and type of transported products. Thanks to proper configuration, the automatic AWP-30 wrapper handles various pallets – regardless of whether they contain regularly arranged cartons, bags, lightweight packages, or goods more prone to shifting. Adjusting the cycle parameters helps avoid both wrapping that is too loose and excessive pressure that could deform delicate packages. Rotating the entire pallet eliminates the need to move an extensive working unit around the load, which streamlines the process and helps maintain repeatable securing quality for subsequent pallets.
How does the controller select the course of the entire cycle?
The operation of the wrapper is managed by a control system operated via a touchscreen operator panel. The operator can select a program adapted to the type of pallet, the height of the load, and the required level of securing. Depending on the machine configuration, settings include, among others, the number of wraps in the lower and upper sections, the pallet rotation speed, the movement speed of the film unit, and the film tension force. The most frequently used settings can be saved, so changing the type of load being wrapped does not require entering all parameters from the beginning each time. After the selected program is started, individual operations are performed automatically and in a strictly defined order. Sensors provide information about the pallet position, drive operation, and the course of subsequent operations, while the controller continuously checks whether the entire cycle is running correctly. If the system detects an irregularity, it can stop the machine and display a message that helps determine the cause of the problem. Automation therefore does not only involve replacing manual work, but also precise control of each stage of wrapping. The ability to repeat the same settings for subsequent pallets helps maintain a uniform securing standard for the entire product batch.
How does the PRE STRETCH system reduce film consumption?
Reducing film consumption is possible thanks to its controlled stretching before it is applied to the load. This function is performed by the PRE STRETCH system, which allows a larger pallet surface to be secured using the same amount of material. The system should maintain properly selected tension so that subsequent layers adhere closely to the products, while at the same time not crushing cartons, deforming packages, or disturbing the structure of the entire load. Too little tension will not provide the required stability, while excessive tension may damage delicate goods or cause the material to tear. Therefore, the PRE STRETCH system in pallet wrappers should be properly configured, taking into account the type of packaging, the weight of the load, and the conditions of its later transport and storage. Precise tension control also makes it possible to maintain a similar level of securing regardless of the number of pallets wrapped one after another. Controlled stretching improves process repeatability and reduces the differences typical of manual film application. It can also reduce the amount of waste and lower the cost of consumable materials. However, savings should not be based on using the smallest possible number of layers, but on using exactly the amount of film needed to secure the load effectively and safely.
When is it worth using additional top film?
Standard wrapping effectively stabilizes the sides of the load, but it does not provide full protection for its upper surface. If products require protection against dust, fine particles, dirt, or water running down from above, the wrapper can be equipped with a top film application unit. Before the actual cycle begins, the machine unwinds an appropriate section of material and precisely places it on top of the pallet. Then the stretch film applied to the sides presses the edges of the sheet against the load, creating a tighter and more stable cover. This solution works well, among others, in plants where pallets are temporarily stored in conditions with increased dust levels, transported between buildings, or exposed to short-term contact with precipitation. An additional protective layer can be particularly important for food products, loose materials, and goods sensitive to contamination. When selecting top film, its width, thickness, and fit to the pallet dimensions should be taken into account. The method of guiding and cutting the material is also very important, because an improperly positioned sheet may shift even before the first wraps are made. The automatic unit increases the repeatability of this operation and allows it to be included in the entire cycle without the need to create a separate workstation.
What happens to the pallet after wrapping is completed?
After the required number of layers has been applied, the wrapper completes the cycle, cuts the film, and secures its end. Depending on the design of the device, the material may be pressed down or heat-sealed so that it does not unwind during later transport. The roller conveyor then positions the pallet correctly and transfers it to the next section of the line. Before leaving the working zone, the system can also check whether the cycle has been completed correctly. The secured load can be directed to a pickup point for a forklift, an automated warehouse, a labeling system, or further internal transport. The entire process takes place without the need to manually move the pallet within the machine. This is particularly important in advanced lines where individual devices should operate at a similar pace. The wrapper’s capacity should therefore be matched to the capabilities of the palletizer and conveyors in order to reduce the risk of jams. It is equally important to properly plan safety zones and use guards, sensors, and switches that stop the device in the event of danger. The automatic nature of operation does not eliminate the need for supervision, but it helps limit the operator’s direct contact with the moving parts of the machine.
What does the use of a rotary conveyor in a wrapper provide?
Combining a wrapper with a rotary roller conveyor makes it possible to automate the transport, positioning, rotation, and securing of the load within one coherent process. The pallet enters the working zone without the need for manual repositioning, is wrapped according to saved parameters, and is then automatically transferred to the next stage of the line. Controlled rotation of the load enables even film application around its entire circumference, which improves product stability and reduces the risk of shifting during transport. The repeatable course of the cycle also means that subsequent pallets can be secured in a similar way – regardless of the operators’ work pace. Such a solution streamlines the work of the plant, reduces the share of manual operations, and allows packaging materials to be used more effectively. Additional equipment, such as a top film application unit, makes it possible to adapt the device even more precisely to the type of loads and the conditions in the plant. However, the efficiency of the installation depends not only on the machine itself, but also on its proper integration with the palletizer, conveyors, and other elements of the line. A properly configured wrapper with a rotary conveyor thus becomes an important link in the process of preparing pallets for safe storage and further transport.
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