You are on page 1of 24

THE IMPULS MOTION

VERTICAL WRAPPING
Palletized loads wrapping machines Load protection with stretch film

medium output
www.ear-flap.com

THE IMPULS MOTION

Medium output vertical wrapping


Palletized loads wrapping machines with stretch film
Contents
Stretch film

Medium output semiautomatic wrapping machines One film carriage for each requirement

Wrapping with stretch film for palletized loads protection from EAR FLAP Semiautomatic turntable wrapping machine model 100 Semiautomatic turntable wrapping machine model 200 Semiautomatic turntable wrapping machine model 700 -la-carte machine EAR-FLAP

3 4 5 6 11 21 13 15 7 9

Semiautomatic turntable wrapping machine model 600TP

www.ear-flap.com

Stretch film The most used option for protecting palletized loads

n the last times, the industry evolution has aroused an ever growing demand of global reach for materials that unitize, stabilize and protect palletized loads from dust, water, dirt, etc. For this reason, stretch film keeps evolving as a consequence of the technical revolution, being the most used option for the vast majority of the arising needs. Polyethylene stretch film owes its quality mainly to the raw material used in its production, which differs in its manufacturing from that of the ethylene polymer itself. The catalyst used for the polymerization reaction confers better features in terms of shine, stretch strength, puncture strength, and behavior at melting point.

Thanks to its piercing, the macro perforated stretch film prevents the condensation problems arising from differences between inner and outer temperature, thus achieving that cardboard cases do not deteriorate, labels keep their legibility, metal cans do not rust and a constant stability of the palletized load during shipping and stocking. The use of macro perforated stretch film is mostly for biological products (flowers, produce, fruits, eggs, cheese, flour, etc.), warm-palletized products (drinks, beer, canned food, fodder, sweets, etc.) and refrigerated or frozen products (meat, fish, dairy, ice cream, etc.).

Stretch film is manufactured by blow-extrusion processes (in case of PVC and lowquality PE) or flat layer extrusion, which may have up to five layers to better make the most of each used polymer without harming the final quality. Among the innovations in that field, macro perforated sheets have been developed for the wrapping of palletized loads to confer them the benefit of free aeration. Specially conceived for loads that need to breathe due both to the product nature and its processing.

There is also a small offer of dyed stretch film for special applications and UV-proof film to wrap those products that are sunlight sensitive. Special additives are used to increase film cling for loads that are to be stocked under open weather conditions. It is also possible to find printed films for load customization.

Medium output semiautomatic wrapping machines One model for each need

ith over 3.000 wrapping machines sold, we have learnt that there are plenty of factors that determine which semiautomatic vertical wrapper is the most suitable one for an installation.

Features such as pallet dimensions, percentage of occupied pallet, load height, weight, product packaging as well as hourly pallet output and area size where the machine must be placed define which type of machine to install. Referring to the semiautomatic stretch film wrappers, the market offers 3 types of wrapping systems, all of them to be considered after the formerly stated factors. The most common, used for many years in small to medium size companies has been the turntable wrapper, whose main feature is that the palletized load spins on a turntable while a stretch film reel travels up and down along a mast wrapping the load.

This is the most usual machine for outputs of up to 10 loads/hour for the nimble operator to work with. Since not all loads are stable for a fast wrapping, there is the well-known option of a top platen, either pneumatic or electric, which holds the load at the top without damaging it for a wrapping process without collapsing. Additional options like pit frames or access ramps allow avoiding the turntable height obstacle to access it with a manual trolley. Furthermore, it is possible to choose among several configurations of film carriages where different load features will determine the most suitable one.

ll along the last years we have concentrated our endeavours in Research and Development for improving each one of the elements that make up our wrappers, to the point that we have become a reference in this sector.

In the same way as the emerging market requirements compel to improve the mechanical properties of the stretch film, so the load wrappers must continually evolve to match the most recent stretch film specifications. Hence, our side film carriage has become one of the main components in our wrappers. Since each product is different and each need is different, EAR FLAP studies and analyzes every installation taking into account all direct and indirect factors that meet for the best wrapper configuration. Some of the features we consider:

Vertical wrapping according to EAR FLAP

Some details we care for:

COLOURS: we integrate the machine into the line painted in the colour the customer wants for a uniform visual aspect UNIFORMITY IN PARTS AND COMPONENTS: we endeavour to use such elements that the customer has approved, to prevent the need for extra spares SIZES AND TYPES OF LOADS: we tailor the wrappers to the load, producing and fitting roller or chain conveyors, or other components to the machines, depending on the needs INTERCONNECTIONS: our electric control cabinet allows for interconnections with the rest of elements in a line, by signals, network, etc

LOAD WEIGHT: we offer several types of base, depending on the weight to hold (2.000 kg, 3.000 kg, etc.) LOAD HEIGHT: we manufacture customized masts if the load is higher than the standard (3.000 mm, 4.000 mm, etc) SIDE CARRIAGE: we have several models of film carriages (direct brake, electromagnetic brake, pre-stretch) CONTROL BOARD: it features a LCD screen with an user friendly menu for configuration of the wrapper. Includes warnings and alarms SPECIAL ENVIRONMENTS: we manufacture with different finishings and protections for special conditions (stainless, ATEX, below oC, etc)

A film carriage for each need

Direct brake This is the simplest and more economical system. It is fitted with a knob that exerts a direct pressure against the reel mandrel to adjust the tension on it. Its drawback is that the exerted pressure on the cardboard mandrel causes it to wear, requiring constant readjustment. Besides, if attention is not kept on this fact, the loads do not get uniform wrapping tension along the different cycles. Mechanical brake This system solves the problem of the direct brake. It is fitted with an additional roller around which the film passes and upon which pressure is exerted with a manual tension regulator. This system grants that the film tension is the same for every load, even when changing reels as it doesnt directly affect these. Electromagnetic brake Another system to replace the direct brake. The difference as compared with the mechanical brake is that being electromagnetic, tension adjustment is made from the control board. Its more advantageous and comfortable for film tensioning during the wrapping cycle.

M prestretch This system offers several advantages as compared to the conventional S system. Safety at work: a door hides the rollers and the film, protecting the operators fingers from possible catching. Ease of use: no need to thread the film through the rollers, saving time in the reel changeover.

Semiautomatic turntable wrapper. Model 100

Standard technical features


Load features Type of wrapping: vertical Maximum height: 2.400 mm Pallet + load max. dimensions: 1.200 x 800 mm Maximum weight: 1.500 kg

Machine features

EAR-FLAP profile Hinged mast 2.400 mm max. wrapping height Powered film carriage with variable speed, placed sidewise Adjustable mechanical brake with foot trapping detector Automatic load height detection photocell 1.500 kg max. load weight 1.200 x 800 mm max load dimensions (L x W) 1.500 mm diameter turntable, 10 mm thick Soft start/stop and return to start position with frequency inverter 4 wrapping programs: Single, Cross wrap, Cross-plus, Full Independently adjustable top & bottom reinforcement wraps PLC controlled with LCD screen Ergonomic control panel Single phase 220V, power supply Variable output depending on operators ability and load features

Options and machine dimensions

Featured options 1. Access ramp 2. Pit frame 3. Direct brake 4. Adjustable mechanical brake with foot trapping detector (standard)

3 4 2

Machine dimensions

Dimensions Upon request, they may be customized to match the installation requirements.

Semiautomatic turntable wrapper. Model 200

Standard technical features


Load features Type of wrapping: vertical Maximum height: 2.400 mm Pallet + load max. dimensions: 1.200 x 1.000 mm Maximum weight: 2.000 kg

Machine features

EAR-FLAP profile Hinged mast 2.400 mm max. wrapping height Powered film carriage with variable speed, placed sidewise Adjustable mechanical brake with foot trapping detector Automatic load height detection photocell 1.650 kg max. load weight 1.200 x 1000 mm max load dimensions (L x W) 1.650 mm diameter turntable, 10 mm thick Soft start/stop and return to start position with frequency inverter 4 wrapping programs: Single, Cross wrap, Cross-plus, Full Independently adjustable top & bottom reinforcement wraps PLC controlled with LCD screen Ergonomic control panel Single phase 220V, power supply Variable output depending on operators ability and load features

Options and machine dimensions

Featured options
1. 2. 3. 4.

Access ramp Pit frame Direct brake Adjustable mechanical brake with foot trapping detector (standard) 5. Electromagnetic brake with foot trapping detector 6. M prestretch with foot trapping detector 7. Scale with display 8. Powered top platen 9. Flat boards holder powered kit 10. Celaire kit 1

10 3

4 5 6

Machine dimensions

Dimensions Upon request, they may be customized to match the installation requirements.

10

Semiautomatic turntable wrapper for side/front load trolley infeed Model 600TP-L/600TP-F

Standard technical features


Load features Type of wrapping: vertical Maximum height: 2.400 mm Pallet + load max. dimensions: 1.200 x 1.000 mm Maximum weight: 1.000 kg

Machine features

Hinged mast 2.400 mm max. wrapping height Single phase 220 V power tension Powered film carriage with variable speed, placed sidewise Adjustable mechanical film brake with foot trapping detector Automatic load height detection by photocell 1.000 kg max. load weight 1.200 x 800 mm max load dimensions. 1.500 mm turntable Soft start/stop with return to start position. Variable speed. Slotted turntable for load trolley infeed (600TP-F, front entry; 600TP-L side entry) Several wrapping programs Independently adjustable top & bottom reinforcement wraps PLC controlled, with LCD screen Reinforcement wraps at any point in the cycle Wrapping cycles counter

11

Options and machine dimensions

Featured options

1. Adjustable mechanical brake with foot trapping detector (standard) 2. Electromagnetic brake with foot trapping detector 3. M prestretch with foot trapping detector

Machine dimensions

12

Semiautomatic rotating arm wrapper. Model 700

Standard technical features


Load features Max. length: 1.200 mm Max. width: 1.200 mm Max. height: 2.000 mm Max. pallet diagonal: 1.800 mm

Machine features

Rotating arm with obstacle detecting photocell Variable arm rotation speed Automatic wrapping cycle 3 available cycles: Single, Cross, Top sheet Control panel with user friendly icons Electromagnetic brake for film stretching Arm return to position upon cycles end Automatic load height detection by photocell Soft arm start/stop by electronic control Inverter controlled arm speed, up to 12 rpm Inverter controlled film carriage speed with independent settings for upwards/downwards Automatic load height detection by photocell Independently adjustable top & bottom reinforcement wraps Floor height: 3.500 mm Rotation diameter: 2.800 mm Single phase+N+PE, 230V, 50 Hz. power supply

13

Options and machine dimensions

Featured options

1. Adjustable mechanical brake with foot trapping detector (standard) 2. Electromagnetic brake with foot trapping detector 3. M prestretch with foot trapping detector

Machine dimensions

14

Standard powered top platen Powered top holder for flat loads

Standard top platen. This is the most commonly used top platen in the market. It is manually activated so that it is disabled when the loads do not require it, thus making the wrapping process swifter. Its stroke is 2.000 mm and the operation height is adjustable. The standard platen is round, although other shapes and dimensions may be supplied, to prevent it exceeding the load top edges. Powered top holder for flat loads. This system is the solution for wrapping flat loads, such as doors, windows, ladders, etc. The system is fitted with top and bottom adjusting guides, to hold the load.

e offer two types of top holders; depending of the type of load, one or the other are to be used.

Square platen

Flat loads kit

15

Special environments (explosive, corrosive, below 0C)

ur goal being that of providing the best service in solutions for the semiautomatic wrapping of palletized loads in the end-of-line packaging, we have developed -and keep on evolving- special adaptations of our machines to special environments. Thats why we present decade-long proven experienced solutions for explosive conditions (ATEX), corrosive ones (STAINLESS STEEL) or freezing temperatures down to -30C.

16

Special scale base

here is an ever increasing request for identifying the palletized loads with their weight. Hence, the shipment dept. is burdened with the tedious task of weighing the load prior to wrapping. In order to speed up this process and make it user-friendly, we offer the option of including a scale in the wrapper base, composed of weigh cells and one display, with the possibility of linking it to the company printer or local network.

17

Special platforms

We can manufacture any sort of platform different from the standard one. Turntable size Although our standard disk size, 1.650 mm, has been calculated for the American pallets not to overflow, we may supply larger ones to avoid corners of larger pallets overflowing. Depending on the dimensions of the larger disk, the supporting structure and bearings might require to be reinforced.
Turntable 3.000 mm diameter

Neck length The neck is the section between the base and the mast. Its standard length is 500 mm, but there may be occasions when the load overflows the disk thus possibly hitting the mast. For such cases we may supply machines with longer necks.

Types of base Although the most usual option is the flat turntable, sometimes it is more purposeful that it is fitted with rollers, free or powered, for line integration. Weight Usually, the highest taken weight of 2.000 kg is enough. Anyway, it is possible to reinforce the base and bearings for heavier loads.

Turntable with powered rollers

18

Special heights

lthough the standard top load height is of 2.400 mm, me may supply masts with superior heights if the loads so require. Upon giving the chance to make other heights, some customers seize the chance to change the packaging mode of other products, shifting to stretch film wrapping to maximize the machine profitability.

19

Load infeed and outfeed. Access ramp, pit frame, lifting supports

etting the load on the turntable is crucial, as there are different ways for the user to move the palletized loads around and the turntable base, with its 75 mm thickness, is a hindrance to overcome. Access ramp (for manual trolleys). When the operator uses a manual trolley, one of the options to overcome the turntable height is an access ramp 1.300 mm long. Such ramp is reinforced with underneath ribs, to hold the same weight as the wrapper does.

Pit frame (manual trolley). Another option for the same moving way is to embed the machine in the floor, so that the turntable is flush with it, thus avoiding the effort to push a heavy load up a ramp. For a perfect embedding, a metal frame in the shape of the wrapper is provided.

Lifting supports (electric forklifts). Since these forklifts have four prongs, two for floor propping and two for lifting the load, if the machine wouldnt be raised, the fixed prongs would hit the turntable base, making it impossible to lift the load. In such cases, the machine must be raised with specific supports and the whole structure must be reinforced to withstand the 2.000 kg (max) to prevent deformation.

20

Ear Flap counts with a professional knowledge and a broad experience in the world of Packaging that go back to more than 20 years. This great professional experience together with our commitment to offer bespoke solutions to our customers, based on our large range of high quality packaging machines, all complemented with the support of an efficient and skilled after sales service, has made us worthy of our clients trust, placing us a the leader in Spain in the manufacturing of vertical wrappers. Our motto is service and within this commitment to the customer, Ear Flap doesnt stop at the machine supply only, but it goes beyond with its different technical departments for any doubt or query. Our development and expansion are directly linked to our commitment in finding new packaging solutions that will materialize in a machine range that anticipate the market needs. Ear Flap has a large showroom, open to all our customers, where we show our machines working. This showroom has been designed not only for demos and information to the customer, but also to check at the concerned machine the complexity of a named application, allowing us to refine the customization of each project. We are in full expansion, both at Domestic as well as International level, with two subsidiaries in Europe and one in China.

At Ear Flap we base our activity and our growth on the excellence in Customer service and on the swift adaptation to his packaging needs.

www.ear-flap.com - info@ear-flap.com t. +34 938 449 616

EVMP-11/10 EN

An IMPULS Corporation company