Technology

CircleLine-Wrapping machines: Construction of a wrapping unit

The central element of our wrapping machines is the wrapping unit.

We build the wrapping units in different sizes, adapted to the application and the dimensions of the products:
 

  • wrapping ring inner diameter from 290 mm to 3,590 mm (or larger)
  • intended for wrapping material widths from 30 mm to 500 mm


 

Closed ring systems

We differentiate between the single ring and the double ring system in the structure of the wrapping rings.

The wrapping machines are constructed in our usual compact design. The closed housing system ensures enormous machine rigidity and safety. This guarantees the high wrapping ring speeds. 

The ring bearings as well as the drive are designed for the high loads. The combination of materials ensures minimum wear and reduces maintenance and downtimes.

Even at the machine design stage, we attach great importance to ensuring a high level of service-friendliness.
 

Open ring system
The C-frame is designed as a rigid housing in which the bearings for the ring guide and drive rollers are accommodated.

The constructive design allows direct access to the components subject to wear. The entire machine design is very service-friendly. The service intervals are reduced to a minimum due to the selected materials and components.

CircleLine Wrapping Machines: Ring Centering

By adjusting the wrapping unit in vertical and/or horizontal level, the wrapping ring axes can center themselves on the product cross sections and thus ensure an even load (tension) of the wrapping material. This guarantees a trouble-free packaging process and optimum packaging quality.

At the same time, the flexibility of the wrapping machine is exploited to the optimum. 

The ring is moved electrically to its working position.

Depending on the degree of automation required, the adjustments can be moved by pressing a push button or automatically adjusted to the required positions. For this purpose, a measurement of the products (height and or width) takes place in front of the wrapping machine or the data are transmitted to our machine control system in advance by a higher-level control system. 

Depending on the requirements, we differentiate between the following positioning systems: 

  1. Ring adjustment with three height and/or width positions
  2. Ring adjustment infinitely variable between minimum and maximum adjustment distance
  3. Ring adjustment stepless, contour following

CircleLine-Wrapping machines: Presentation of the different roll changing systems

Depending on the application, our wrapping unit constructions enable the reel exchange of the wrapping material from the front or from the side.

CircleLine-Wrapping machines: Wrapping material holder and cutter

We offer different systems which automatically grip and cut the wrapping material. 

Linear cutter

The applied wrapping material is pulled by a driver onto a knife blade and cut off. 

The linear cutter is primialy suitable for cutting PE stretch film.
 

Swivel cutter

The wrapping material is placed on the upper swivel arm, the lower swivel arm swivels in and reaches upwards. The wrapping material is gripped straight across its width and separated cleanly. A brush presses the cut film end from below against the previously wound layers.

The swivel cutter is available with a knife cutting system or a thermal cutting system.
Knife cutting system:

  • fast cutting process 
  • suitable for different wrapping materials, e.g. PE stretch film, crepe paper, nonwovens, adhesive tapes etc.

Thermal cutting system:

  • low-maintenance cutting system
  • safe cutting process for plastic films such as PE stretch film, flat films, etc.
  • enables the use of a sealing unit

CircleLine-Wrapping machines: Sealing unit

If films, e.g. PE stretch films, are used as wrapping material, these can be welded to the previously wrapped layers parallel to the cutting process. 

For this purpose, a unit with a thermally heatable sealing wire swivels under the straight and smooth film. The material layers are melted together by a heating impulse. 

CircleLine-Wrapping machines: Film tensioning and stretching system

Depending on your requirements, we can offer you different systems that stretch the film during the wrapping process with the aim of achieving the desired wrapping result.

External brake role

The external brake roller is provided with a special rubber coating to prevent the wrapping material from slipping through. This coating is adapted when using different wrapping materials such as adhesive tape. 

The external brake role is equipped with resistance braking. The resistance can be infinitely adjusted via a spring pack, thus optimally adjusting the film tension. 
 

Dual-reel stretching

The film is guided over two rolls which are connected to each other by a gear stage. Thus the second roll rotates faster and the film is stretched between the first and second rolls. The stretching distance can be defined by the ratio in the gear stage. If this is to be adjusted, a new gear stage must be mounted. 

Return tensioning device

If the wrapping ring cannot move into the centre of the product cross-section in order to ensure uniform film tension all round, a film accumulator can compensate the loss of tension arising during the wrapping process.

CircleLine-Wrapping machines: Wrapping method

The wrapping rings can be equipped with one material reel system or with two material reel systems. This allows different wrapping processes:

One wrapping material reel holder on the wrapping ring

This is the standard procedure.
A catchy helix is created around the product. 

Two wrapping material reel holders on the wrapping ring – doubled

This version is used to be able to use more material (e.g. double film layer) or to process different wrapping materials (e.g. crepe paper and stretch film) in one wrapping process.
The result is a single, double-layer helix around the product.
 

Two wrapping material reel holders on the wrapping ring – isolated

This method is used in order to be able to line up higher packaging speeds (doubling of the maximum feed speed).
A double helix is created around the product.
 

CircleLine-Wrapping machines: Control technology - manual, - semi-automatic or - fully automatic

Manual machine control 

The operator pushes the product to the beginning of the wrapping and starts the wrapping process via the foot switch. If the operator gives a short impulse to the foot switch, the wrapping machine automatically executes the bundle program and winds the wrapping material around the product with a fixed number of revolutions. Three different numbers of revolutions can be selected via a switch. If the operator stops on the foot switch, the machine wraps until he removes the foot from the switch again. The product can be wrapped lengthwise.

Semi-automatic machine control 

The products are manually pushed to the beginning of the wrapping process by the operator and the wrapping process is started with the foot switch. The foil overhang, the number of wrappings at the beginning of the product as well as the foil pitch of the approx. first 200 mm product length are carried out manually by the operator. Once the products have been pushed approx. 200 mm through the wrapping unit, the rear conveyor takes over the further packaging process. The further sequence is now automatically carried out and completed.

Fully automatic machine control

The products can be fed to the wrapping machine automatically or manually. The processing of the products is automatically started and carried out. The machine parameters set by the user are taken into account. After the automatic wrapping process, the packaged products are discharged and the machine can pick up the next products. The machine works independently, but can also be integrated into a line. 

CircleLine-Wrapping machines: Wrapping programs

Wrapping:

The products are wrapped longitudinally from the start of wrapping to the end of wrapping.

The following parameters can be specified:

  • Position of the wrapping start measured from the beginning of the product in [mm]
  • Position of the wrapping end measured from the product end in [mm]
  • Number of wrappings at the position of the start of wrapping in [piece]
  • Number of wrappings at the position of the wrapping end in [piece]
  • Product feed per ring revolution in [mm] (film pitch)
  • Wrapping ring speed in [%]

Wrap/Bundle:

This is a combination of wrapping and bundling.

The following parameters can be specified:

  • Position of the wrapping start measured from product start in [mm]
  • Position of the wrapping end measured from the product end in [mm]
  • Number of wrappings at the position of the start of wrapping in [piece]
  • Number of wrappings at the position of the wrapping end in [piece]
  • Product feed per ring revolution in [mm] (film pitch)
  • Distance between the bundling points in [mm] (equal to the distance between the following bundling points)
  • Number of wrappings per bundling point in [pcs]
  • Wrapping ring speed in [%]

Bandages:

Different areas are defined over the length of the product, which may be wrapped at stretch (max. 5 areas).

The following parameters can be specified:

  • Position of the wrapping start for the first bandage measured from the product start in [mm]
  • Position of the wrapping end for the first bandage measured from the beginning of the product in [mm]
  • Number of wrappings for the first bandage at the position of the start of wrapping in [piece]
  • Number of wrappings for the first bandage at the position of the wrapping end in [piece]
  • Product feed per ring revolution in [mm] for the first bandage (film pitch)
  • Wrapping ring speed for the first bandage in [%]
  • etc. for the following bandages (each bandage can have its own parameters)

 

 

Bundle:

The products are bundled at specified points (wrapping on the spot).

The following parameters can be specified:

  • Position of the first bundling point measured from the beginning of the product in [mm]
  • Position of the last bundling point measured from the end of the product in [mm]
  • Distance between the bundling points in [mm]
  • Number of wrappings per bundling point in [pcs]

Step wrapping:

Different ranges are defined over the length of the product and different stretching parameters can be assigned.

The following parameters can be specified:

  • Position of the wrapping start measured from the product start in [mm]
  • Position of the wrapping end measured from the beginning of the product in [mm]
  • Number of wrappings at the position of the start of wrapping in [piece]
  • Number of wrappings at the position of the wrapping end in [piece]
  • Product feed per ring revolution in [mm] (film pitch)
  • Wrapping ring speed in [%]
  • First change position of the wrapping area measured from product start in [mm]
  • Product feed per ring revolution in [mm] (film pitch)
  • Wrapping ring speed in [%]
  • Second change position of the wrapping area measured from product start in [mm]
  • Product feed per ring revolution in [mm] (film pitch)
  • Wrapping ring speed in [%]
  • Third change position ...........etc.

CircleLine-Wrapping machines: Conveying and guiding systems

We supply you with complete concepts, i.e. depending on your requirements, we offer you a wide range of conveyor systems that are tailored to your products and applications.

  • Roller conveyors (gravity or driven)
  • Vroller conveyors (gravity or driven)
  • Apron conveyors
  • Belt conveyors
  • Chain conveyors
  • Corner converter
  • Accumulating and buffer conveyors
  • etc.

We also supply the required guide systems.

  • Side guides in a wide variety of designs
  • Holdingdown system in a wide variety of designs
  • Transfer systems
  • etc.

Special tasks are also planned and solved by our team of engineers.

Do you have questions or do you require further information?

Our employees will be glad to help you any time: +49 5731 860 01-0


Now - Inquire individual machine and get quote.

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