macrack Perfect Unmanned Packaging System Pallet Wrapping Machine Use, Maintenance And Spare Parts HandbookData‘The machine should be exclusively operated by previously trained personnel. General safety regulations Before using the machine or carrying out maintenance operation read the following instructions very carefully: Before > > vy During Carefully read the instructions about the machine; Check all the safety guards on the machine and immediately replace any worn or broken parts with original spares; Make sure that no tools or other objects have been left ying on the machine and that the machine itself is perfectly clean; Read the Use,Maintenance and Spare Parts Handbook very carefully Read all the labels and plates applied to the machine, Do not wear clothing that could get tangled up in the moving parts of the machine; Do not carry on maintenance operation barefoot; Do not put the hands or any kind of object inside the field of operation of the machine; Do not load the machine with boxes heavier than those recommended by the manufacturer. ‘Turn the master switch to OFF to stop the whole machine.‘The machine should be exclusively operated by previously trained personnel. Safety regulations for maintenance > Follow the maintenance regulations given in this handbook; > Never repair. |ubricate or adjust the machine while itis in movement; > Always turn off the power supply before opening the safety guards; > Do not use any parts other than the originals without the written permission of MACPACK MACHINERIES; ) > Always use original spare parts. Useful hints. > Always use appropriate electrical connection systems; > Do not remove or ccver up the labels and plates on the machine; > Consult the Use and Maintenance Handbook whenever necessary.The machine should be exclusively operated by previously trained personnel Warning For normal operation of the machine we recommend periodically lubricating the machine where necessary, checking pneumatic device, and always keeping the machine clean,‘The machine should be exclusively operated by previously trained personnel. Analysis of residual risks > Take care with rotation of the turnplate; > Take care with movements of the roll carriage or of the presser unit,INDEX | 21 | Preliminary operations Page 10 ‘Space required for setting up the machine Page 12 Installation for upright stanchion Electrical connections Manual operation E u Debug Page 25 ‘Adjusting reel downstroke limit Page 26 34 List of possible troubles Page 27 ‘Operation of the machine Page 34 5A Maintenance Page 38, 64 Parts list Page 42 7A Electrical ilustrative diagram Page 53PART 1. SPECIFICATION 1. description operation steps operation can be mainly divided into the following phases: 1. put the object together with its tray onto the tumplate; 2. put the film around the surface of the object; 3. start the machine, the machine will automatically run and wrap the object. Baers 1P, AC220V, S0Hz, 1KW/anti-stretoh) / pply 4.25KW(pre-stretch) | Liftingunit | Photoelectric switch controls the height ‘Max package weight:2000Kg. >2000kg (custom-made is Packaged object avaiable) Max | Mxmcere near neon eran | height: total height of upright | Mxmcere near neon eran | ‘S75DB [awachment | amp (opion) |3. film data the machine can use different types of film reel with the following dimensions(FIG1):, A. internal diameter of reel: @50~q76mm external diameter of reel: the machine is supplied with three-phase motors, with different voltages and frequencies(see attached drawing for the wiring diagram) > make sure that the voltage of the machine corresponds to that of the mains. The voltage is indicated in the rating plate(FIG2-2) > check to ensure that the turnplate is rotating in the right direction when operating in the manual mode. If a three-phase motor is rotating in the wrong direction, invert two of three-phases in the plug. Voltage three-phase plus neutral FIG2-15 Power | —_____} , wee | suppl: ((20] Vi(60] He | Year: [ Phase’ Single Serial Rate 2 Serial ‘ated power: Netweight: [800 |ko | CE ene En | GE ere js ) KWSetting up the machine before use a4 82 fitting the film reel ‘A. loosen the tightening screw A and remove the tightening ring B and the locating plate C; B. fit the film reel to the lower locating plate D, fasten the upper locating plate c: CC. fasten the tighting ring B and tighten A. threading the film and adjusting film tension. threading the Pre-stretch type (see FIG2-16, 2-17) ‘Shown as FIG2-16, pull down the rail fo turn the transition roller seat by a certain angle, then thread the film following the arrow direction shown as FIG2-17 and lastly close the transition roller seat. Adjust the rotation speed of the turnplate and the pre-stretch motor to achieve different flm tension, actually by dialing the lack knob on the frequency convertor which controls the tumplate and pre-stretching. Faster the turnplate rotates, slower the pre-stretch motor rotates, ‘more tight the film is, on the contrary more loose the FIG2-17 19f Anti-stretch type (see FIG218, 2-19) fit proper resistance for the anti-stretch roller, push down the handle of the eccentric wheel(1); then revise the adjusting screw (2) ;pull up the handle of the eccentric wheel, pull the film out of the reeiraround handle of the eccentric ‘wheel the anfi-stretch roller (3) —-around the transition roller (4) —stick the film to the object, and pull down the handle of the eccentric wheel. 2 + fO tS © FIG2-18 FIG2-19 important: special care should be taken when using reels of single-sticking extensible film to ‘ensure that the reel is fit onto the reel-holder of the machine facing in the right direction, so that the STICKY side is in contact with the tray. 209. machine start-up location of the operator is shown as FIG2-20; tum the main switch to “ON” (FIG2-21 POS1); deactivate ary EMERGENCY by turning the button clockwise(FIG2-21 POS2) press the button to supply the power circuit(FIG2-21 POS4), and wait a few seconds for the power indicator to ight(FIG2-21 POS3) Vey At this point the machine is ready to start the work cycle! FIG2-20 FIG2-21 ‘.main switch 2. emergency pushbutton 3. power indicator 4. start pushbutton a10. carriage of the machine use forklift or crane to carry the machine (see FIG2-22) insert the two forks of the forklift into the relevant slots in the machine(see FIG2-23), then the machine can be easily carried. wen 211, manual operation > if you want to operate the machine manually, select manual mode in the text; > press the numeric key 2 in the main menu after machine starts(FIG2-24,POS1); > presst|keys(FIG2-24,POS3)to select functions; > press ENT key or ESC key(FIG2-24,POS6,2) to enter or escape. With manual function of the machine the following operations can be carried out: automatic cycle restart; reset of wrapping machine positions; carriage rise/descent; ‘manual rotation; movement of film carriage device; wrapping machine transport forwards/backwards. Viveve 212, automatic cycle > You can select the high and low revs and up&down numbers by relevant settings, ‘Actuate the automatic cycle by means of the relevant selector and the machine is ready for receiving the objects to be wrapped horizontally. Check to make sure the objects have been correctly stacked on the tray. Make sure the weight and height of the objects donot exozed beyond the machine allows. ‘The oyole operations are the following: > put the objects onto the tumplate, actuate the turplate by the photoelectric switch; > clockwise rotation of the turnplate starts. At the end of the first rotation, the film carriage rises unt the photoelectric cell reads the en¢ of the tray; the high revs already set are actuated, then the film carriage descends; ‘once in the lower position, the low revs reset is enabled, followed by deceleration and stopping in posit > the wrapped pack is taken away and the wrapping machine is ready to receive the next object. > > PyPART 3. ADJUSTMENTS 4. debug check before operation 1. check whether the tightening items are loose or not; 2. check whether the motor and other electrical devices are under dry condition and good insulation or not; 3. check whether the power supply corresponds to the power needed for the machine, idle running switch to manual mode after power connection, press button 5 to start the turnplate rotation to check the tension of chains, normally chains swing less than 6mm; ifmore, please make some adjustment. Press button 9 or 3 to check whether the lifting unit ‘moves up and down continuously; if not continuous, check whether the lifting chains get stuck or not. A,B,C in FIG3-1 respectively means chain cover, turnplate motcr and chain adusting screw. Detailed adjustment is as following: open the chain cover A to check whether the chain is loose, if yes, please make some adjustment. Loosen the 4 pes of tightening screw of the turnplate motor B; regulate the chain adjusting screw C clockwise to tighten the chain or anti-clockwise to relax the chain. After proper regulation, (normally chains swing around +3mm), tighten the 4 pes of screw on the motor motherboard. A B FIG3-1 2sadjusting ree! downstroke limit to limit ree!-carrier downstroke, act as follows: > > > > > loosen screw nuts(FIG3-2 POS3) slide the travel switch along the guide, upwards to shorten or downwards to lengthen stroke tighten the loosened screws, screw(FIG3-2 POS2) can adjust the left and right touch point of travel switch screw(FIG3-2 POS1), on the limit block, used for locating when replacing the travel switch FiG3-23. disabling caution decommissioning and demolition must be carried out by staff specialised in electrics/pneumatics and mechanics. Before starting work, create around the machine a sufficiently large and clear space in order to allow operatives to work ‘without additional risks created by the surrounding area. ‘To decommission the machine proceed as follows: > stop the machine > disconnect power by tuming the main switch to'OFF" > remove inner electrical wire connected to the panel > loosen the four M10 screws > lay down the stanchion and place it on the base, backed with two wooden battens > prepare the machine for possible transport, clamping the stanchion and the ‘moving parts for possible demolition of the machine, repeat the same operations described for decommissioning: > separate various parts according to type(metal, plastic, rubber etc) and send them for selective waste collection note: in the event of demolition of the machine, the laws in force in the user's country must be observed. 4, list of possible troubles 4.1 the machine does not start 4.2 the power indicator does not light 4.3 the turnplate does not rotate 44 the lifting unit does not move 45 tensile failure of the stretch film 46 the automatic cycle stops4.1 trouble description:the machine does not start, 4.1 trouble description:the machine does not check electrical ‘mechanical t current on fine t emergency disabled q main switch set to “ON” q start pressed 2%4.2 the power indicator does not light 4.2 trouble description:the power indicator does not light start 1 check o———_ electrical pneumatic. mechanical L current on line q ‘emergency disabled y ‘main switch set to “ON’ ——————— start pressed ower indicator lights4.3 the turnplate does not rotate 4.3 trouble description:the pallet does nol rotate + check ——S electrical pneumatic mechanical current on line chain connection L ‘emergency disabled t main switch set to “on” L frequency-convertor adjusted to proper frequency q motor ¥ control button ¥ frequency convertor/controller 3044 the lifting unit does not move 44 trouble description:the lifting unit does not move. + check = electrical pneumatic mechanical current on tine lifting chain emergency disabled lifting unit & upright stanchion q main switch set to “ON" q limit switeh/count travel switch frequency convertor/controller q frequency-convertor adjusted to proper frequency 34.5 tensile failure of the stretch film 4.5 trouble description: tensile failure of the stretch film + check electrical pneumatic mechanical others pre-steich stretch fim speed of motor T pre-stretch motorfpallet ¥ pre-stretch cen Microswitch / chain extension chainwhee! spring46 the automatic cycle stops 4.6 trouble description: the automatic cycle stops y check during operation, the protection switch at the bottom of the lifting unit is actuated q one of the cases described previously y in the event of other troubles, call the technical assistance department 33PART 4. OPERATION OF THE MACHINE 4. operation of the machine AMP E[ text controller ‘Tur on the power, the machine will directly enter auto mode. 1. When_you want to wrap the object manually, turn on the power, pressSCkey, enter the mair|MENUpscreen; as shown on the screen, press to enterkJob modelscreen; press Bj to enterflanualscreen, then pull out ‘appropriate section of the film and wrap it to the object following the rotation ction of the tumplate, pres] to rotate the tumplatesafter the object is wrapped with appropriate circles, press 9 for upper continuous wrapping; after finishing upper wrapping, press@] for lower continuous wrapping. Adjustment for the thickness of wrapping: accordingly adjust speed of the tumplate and the lifting motor to fulfil appropriate thickness of wrapping. Faster the turnplate rotates, more slowly the lifting action is, thickness of ‘wrapping will increase; decrease in contrary case. MMenu : @Paran set@Job node ° @Yield — @Paran show © Password @Langua Job wode Menu. (5) fem x O BAL HO Fah @aAuto ::: @Manual @ HEI KO© WBS @Single : @ Top-wait: Manual >: Menu ; (J Stop @ © oO } @lable @Up * @Down 2. Automatic wrapping: turn on the power, the text will show auto mode screen, if not, press ESC to enter main menu;press2 to enter job mode, select! to ‘enter auto mode; then pull out appropriate section of the film and wrap it to the object following the rotation direction of the tumplate, press 0 to ‘automatic operation. After finishing the wrapping cycle, cut off the film. If the brake device for stretching film is too tight, the film will easily break; adjust, the magnetic powder brake, relax the tension, to fulfil perfect wrapping result. AUTO MODE, [auto :- No: 12: Menu: &3 7 Pause © ©--O ‘Stop: @ Table Up Down Start © Single No:12:. Menu - Pause © }:O:O:: O°: stop -@ |Table Up- Down | Start ©4. Top-wait: In the job mode soreen, select4 to enter top-wait mode;press 0 to start; when wrapping to the top position, the turnplate and the lifting unit both stop; wait until the roof is completed, then press start button, the machine will automatically complete remaining actions. TOP-WAIT MODE 5. Yield inquiry : pressSCkey, switch tfMENUbsreen , pressf] to fcreen, appears current yield and sum yield, press (D> to clear current yield to zero. YIELD INQUIRY Null yield: ®) Menu @) Current yield: 123456) Ree, 1234567890, Sum yield: _ 1234567890 6. Param setinffENUsoreen, press] to enter ARAM SETsorcen; if you need to adjust the top cycle, press 1 to entefMIODIFY SETscreen, first press SET], then select [Aor [7] to achieve appropriate number, pressENT] to confirm; same method for modifying bottom cycle and up8&down number. PARAM SET ‘TOP CYCLE MODIFICATION (with sensor) Modify SET Back Top cycle 2 0 | ENT positioning time 30 (0nSET | A EENT 1B TB: 2° REACAT TA]: 30 (Position time is used to the height of the lifting unit.) BOTTOM CYCLE MODIFICATION Modify SET ‘eexseT BREENT “ae Bottom cycle: 2 JASE: 2UP&DOWN NUMBER MODIFICATION (BoUSET WEENT 12) DEFOR: 7. Param inquiry: in(ENUscreen, press to entefPARAM SHOWscreen, then appears relative parameters. Top cycle Bottom cycle 2 Up&down num 8. Set password: inMENUscreen, press5 to enter Set password screen, passwrod can be set between one figure to sik figures. BABE: os: : Set password: 123456 : 123456 9. Select language: inMENUscreen, press 6 to enterSelect Languagescreen. Select Languagei 5 it## ‘© English 0 PHPART 5 MAINTENANCE 4. routine SAA 513 14 12 & maintenance requirements ‘safety warnings for repairing make sure that the mains power maintenance personnel should proceed with maintenance under good protective condition periodic maintenance and cleaning periodically check whether the screws of each part are loose Peridically lubricate the important parts of the machine keep clean for the surface of the machine Usual and proper maintenance for the machine can extend its durability and avoid some troubles, thereby enhancing production efficiency. Periodically check the main parts of the machine(lifting frame, chain, tumplate, etc) open the motor hood, carefully lubricate the chain(wheel)A with appropriate grease, and brush the whole chain transmission organization with the grease(FIG5-1) . (recommended maintenance once every three months) lubricate the slide rail of the lifting unit B (travel range of the slider C) with appropriated grease (FIGS-1) . recommended maintenance once every month) 382.1. open one cover plate between the tumplate and the upright stanchion(fixed by four screws), carefully lubricate the transmission chain of the tumplate with approprate grease, and brush the whole chain transmission organization with the grease (FIGS-2) . (recommended maintenance once every three months) ry Fics-2 3.1. open the cover plate at the bottom of the lifting unit, carefully lubricate the transmission chain with appropriate grease (FIGS-3) . Crecommended maintenance once every month) FIGS-3 42 ithe wrapping machin is ant.stetch ype, when the brake adjustment of @ the stretching organization is debased, please check whether the triangle rubber band is badly wom, if yes, please replace(FIGS-4). (recommended maintenance once half a month) »5.1.4 check to make sure no loose screw for any part of the machine at any time 5.1.8 if the diameter of the roller body under the turnplate(see FIG5-6) is less than 83mm, or noise abnormal, replace the whole roller. 2, parts which should be repaired or replaced by the operator [A Fiit-locating plate F-13258 jo [3 __| Micro-active switch (pre-stretch) | LXW5-11G1 | [5 | Batt Canitestraton) M-L105 jo 3. parts which should be repaired or replaced by professional personnel [1 | Bearing (antistretch) [eoor | a Piezoresistance caution: Please replace the old parts following correct order shown in figures. To avoid possible trouble or damage, please use original spare parts. 40attention: all maintenance work should be processed by professional personnel under the condition that all power supply and air pressure devices are disconnected. 41PART 6. PARTS LIST su/a940/ 221025002400 200/200 100/165 [3 [iting combinationDetailed parts list [rune rca || [a | Rolerconbinaton [FOTIA || [sl Tinelevichioun bio [rece | [7 Tensenchanonedd root 2 | = [it onerpaet [rar tT | [19 wanmoorvese [roost || [is [Tunpatemoor | cvIs0g0s 1 500/120 — | [ir oearrg(etmetp) eo2. roller combination 1 Detailed parts list [1 | spacerng | Fa.o1sausgs |2 | |s_ | Rollerbody |rcoiga | FG-7000-193. roller combination 2 detailed parts list [1 [spacering rccorsalezs 2 || [3 [Rotervoy roona ft | 46Detailed parts list [1 | Ungntstnction cover reo [1 | [3__| Steatrame soting plate roost | Litting motor NMRvo040/60- ‘YS6334/814 [7 [Transtontramerccorsa 1 [o [iting ocnizaionerecing tue [Foss tT [it |Dwensnat Goss) [ia [chan oss [is |sippece coe s | ‘Motor chainwheel ae5. lifting combination (pre-stretch)detailed parts list Pre-stretch upper cover Tightening sorew Film shaft Locating pallet ‘Transition roller seat Locating pin Driven chainwheel Lower hinge Travel switch touch block Left connecting block ‘Transition roller shaft (short) FG-119 Micro-active switch MQS-216 06. lifting combination (anti-stretch) q INDetailed parts list Hand grip Indicate block FG-167 1 Film shaft Roller shaft Mirco adjustable block Bearing Micro-active switch frame 1060.180.1.PL ‘Transition-roller outer cover ‘A50-106.1 2 ‘Transition-roller inside cover 32fava avs] sae - Sat] otal son t cocac| oon alma mom i, PART 7. ELECTRICAL ILLUSTRATIVE DIAGRAM 90h) ypjans-eid Jo spied feuoRIPpeE sue JEYEU » wy Wed oY f sou aei I E I 2d Ayoiio9|90}0ud Jo syed leuoRIPpE a1e yas YAM Hed oUN -Z df Jossaid jo syed reuonippe ove ,, unm ved ou Z 2edhy wsiens-o1d Jo syed jevonippe axes yim ued 4 “| . r9}0u Teen SMT TORSQ ° T I Tull I z I [eos] 1 Seer] a | ns] aewel mere | / eso] anno [al eran > O —=— 18s doe O —=s— zas Q—»io Gar TareraearaToean| wm] am ej |_MP PO wee iisco/bes/e/Seor!| 9] eo Fae I z I I £ I i €. r i E T z r Ee aves] we ee ee ee Bao> Beie oS] tore npg 0 a panes out indPallet Wrapper Control Setting Recommendations HOW-TO INSTRUCTIONS: What should my pallet wrapper settings be to properly secure my loads for shipment and reduce my stretch film costs? Goals: To properly secure the load for transport (keep loads from falling apart in the truck) To provide protection against dirt and moisture (helps to keep products clean and dry) To provide theft deterrence (make it harder for people to steal products) To minimize packaging costs (save money on the cost of film by preventing needless over wrapping of your loads) Applicability: This guidline describes the most common wrap type, a Wrap Up Down pattern. Other patterns, such as Wrap Up Only, Bottom Wraps First, etc, encompass the same wrapping philosophies, with obvious differences. This guidline is suitable for use with any industry standard pallet wrapper, conventional film dispenser, non-prestretch carriage, powered pre-stretch film carriage, semi- automatic, fully automatic, high profil, low profile, rotary tower, etc. There are many differences in the way these settings are changed, that vary from one machine to the next. Reference the manual for your model machine for instructions on how make the noted acjustments, Before you start: Produce a skid of product to use as the primary test load that is representative of the largest load in terms of width and length. ideally this load should be composed of product that you can afford to get damaged if something doesn't go well. For example: a load gets toppled over, or boxes get squeezed from being wrapped too tightly. In order to set up the overwrap settings, this load should be shorter than the maximum wrap height capacity of the wrapper, ensuring that the Auto Height Photoeye will be used. Produce a skid of product to use as the secondary test load that is representative of the smallest load. Set the wrap pattern (type) to a Wrap Up Down program. Load the stretch film into the machine. NOTE: Have a knife ready to cut off the stretch wrap that will be put on the test load. a) The test load will eventually be over-wrapped and need the film to be cut offb) also, the muttiple layers of stretch film might get white and shiny enough to cause the Auto Height Photoeye to fail to reliably recognize the top of the load, leading to set up issues. Quick Steps: Start a wrap cycle ‘Adjust the turntable speed to approximately 2/5 to 7/8 of maximum speed. ‘Adjust the film force to the desired tension. ‘Adjust the film carriage up (raise) speed of the film carriage until there is an overlap of approximately 4” (100 mm) ‘Adjust the overwrap height such that the film folds over the top of the load and creates a band around the top of the load that is approximately 4" (100 mm) wide. Set the top wraps count to at least two (2) revolutions. ‘Adjust the film carriage down (lower) speed to a fast rate. Set the bottom wraps count to at least two (2) revolutions. Repeat wrapping loads as necessary until satisfied with all settings. o BERS ane Detailed Steps: 1. Start Wrap Cycle 1, Attach the film tail to the bottom of the load. (Typically Its tied it to the pallet, tucked between boxes, or pulled under the load.) 2. Start the wrap cycle 3. Proceed to the next step. Comments: a) In semi-automatic wrappers, there is a typically a ‘Start’ pushbutton, b) In automatic equipment, select ‘Auto’ on the main control panel, or ifa load is already in place, push the 'Rewrap' pushbutton, 2. Set Turntable Speed 4. Adjust the turntable speed to approximately 2/3 to 7/8 of maximum speed. 2. Proceed to the next step. Comments:2) The turntable speed is the first thing to be set in the controls because several of the following steps are affected by this setting and all would need to be re-set if this is changed. b) Most wrappers have a maximum turntable speed of anywhere from 10 to 15 RPM. ©) Some wrappers come with this value preset from the factory, while others use a speed dial or operator selector of some kind on the control panel of the machine. d) Some wrappers (typically automatics) have this speed controlled by settings directly on the drive board or in the PLC program e) We recommend not running the turntable at full speed unless the loads are very stable (before being wrapped) ) Rotary arm wrappers do not run the risk of loads falling apart due to rotation speeds, but something less than full speed is still 2commended, 3. Set im Force / Tension 4. Adjust this setting unti the film is tightly being applied to the load, but not so much as to come close to breaking the film. 2. Proceed to the next step ‘Comments: a) This setting controls the amount of tension (aka. post-stretch) that is put on the load after the film ‘comes out of the film carriage. b) Ina machine equipped with pre-stretch, the film has already been stretched inside the film carriage, and will naturally tighten on the Joad as it sits there over the next few hours, so this setting doesn't usually need to be set to a very high value. ) Establish this setting before proceeding to the next step because as the tension is increased, the film will ‘neck down’ more and more, narrowing the film web, and affect the amount of flm coverage ‘on the load with each revolution d) Check the loads after they have been wrapped and been sitting in storage for a few hours (or days). If the product is susceptible to crushing, and this setting is too high, there may be damage to the load. If so, reduce this setting. Trial and error with the settings of the wrapper, and the proper selection of film, will help to produce satisfactory long term results, 4. Set Film Carriage Up / Raise Speed 1. While the film carriage is raising, look at the amount of film overlap that occurs from one layer of film to the next as the load (or tower) rotates.2. Adjust the up speed of the carriage unti there is an overlap of approximately 4" (100 mm), 3. Proceed to the next step. Comments: 22) The intent of this setting is to completely cover the product for cleanliness and theft deterrent purposes but apply as little film as possible. ') Setting this speed as high as possible (while maintaining overiap) minimizes the time it takes to reach the top of the load (decreasing cycle time, increasing load throughput, and minimizing film costs). Set Overwrap Height 4. Adjust the overwrap height such that the film folds over the top of the load and creates a band around the top of the load that is approximately 4" (100 mm) wide 2. Proceed to the next step. Comments: 12) This setting controls how much extra time the film carriage raises above the top of the load after the Auto Height Photoeye senses the top of the load, ) Many film carriages have a means to mechanically adjust the position of the photoeye to adjust this. ¢) Other film carriages use a timer in the control system to cause the flim carriage to keep raising after the photoeye senses the top of the load. In semi-automatic wrappers this timer is usually operator adjustable using the control panel. In automatic wrappers, this value is often programmed into the PLC. d) Many wrappers have both of the above means to make this adjustment. e) Ona turntable style wrapper, if the load is taller than the wrapper is built for, the film carriage will stop raising when the film carriage reaches the maximum upper limit of travel possible, and the fim will not wrap over the top of the load. In this case, the settings for overwrap have no effect, and the wrap cycle will carry on without issue. 1) ifthe top layer of a load is not complete, and there are extra boxes (products) left over, build the top layer of these loads such that these extra boxes (products) are placed in the comers and/or the outside edges of the load. Then, increase the overwrap setting (beyond the 4" recommendation) such that the film carriage raises an amount sufficient to catch these extra boxes (products) and secure them with the wrap. 6. Set Top Wraps Count 4. Set the Top Wraps Count to at least two (2) revolutions.2. Proceed to the next step. Comments: a) This setting controls how many revolutions the load (or the tower) will continue to rotate after the film carriage is at the top of the load, and before the film carriage starts to lower. bb) Two (2) top wraps is the recommended minimum for this value because it guarantees at least one full revolution of film at the top. (Explanation - Considering that there is a delay in time for the stretch film to actually reach the top of the load after the film carriage stops raising, if this value & set to only one (1), itis conceivable that the film carriage could count one revolution and start lowerng before one complete wrap has actually occurred at the top of the load.) ©) Note that a significant portion of the load unitization that keeps the loads from falling apart during transport is provided by the top wraps on the load. Therefore, if extra load retention is required, the single most significant setting to be changed is the top wraps count. 4) Most wrappers allow up to nine (9) top wraps to be applied, however, rarely is there ¢ need to go beyond a count of four (4) top wraps. Industry practice finds that four (4) top wraps is farly significant, and applying any more than that simply drives up the packaging costs, increasing wrapping time, and reducing throughput. 7. Set Film Carriage Down / Lower Speed 1, Adjust the film carriage down speed to a fast rate. 2. Proceed to the next step. Comments: 2) This setting controls how fast the fim carriage lowers to the bottom of the load, following the completion of the tap wraps. b) Since the load has already been secured by the wrap during the film carriage raise portion of the cycle, and structurally secured during the application of the top wraps, there is no need to manage ‘overlap, and the film carriage can go to the bottom as fast as possible in order to minimize wrap cycle time, and reduce fim usage. «c) However, if extra load retention in the middle of the load is required, slowing the film carriage down with this seting will apply extra film to the midale ofthe load and improve the integrity of the toad. Note that slowing this down more than necessary only increases packaging costs and slows, down the cycle time of the wrapper. 4) Changing this setting (instead of changing the film carriage up speed) to improve load retention in the middle of the load is preferred because changing this setting does not force the overwrap settings to be re-set.8. Set Bottom Wraps Count 4. Set the Botiom Wraps Count to at least two (2) revolutions 2. Proceed to the next step. Comments: a) This setting cont ols how many revolutions the load (or the tower) will continue to rotate at the bottom of the load after the film carriage has reached the lower limit, and before the turntable (or tower) shifts into slow speed to park at the start (home) position. bb) Two (2) bottom wraps is the recommended minimum for this value because it guarantees at least Cone full revolution o* film at the bottom, ©) These wraps help to secure the load to the pallet so it doesn't shit in transit 4d) Most wrappers ellow up to nine (9) bottom wraps to be applied, however, rarely is there a need to go beyond a count of four (4) bottom wraps. Industry practice finds that four (4) bottom wraps is fairly significant, and appying any more than that simply drives up the packaging costs, increasing ‘wrapping time, and reducing throughput. 9. Repeat (as necessary) 4, Repeat wrapping the test load muitiple times until everything is set your satisfaction and needs. 2. Cut the film and tuck the tail under the wrap. 3, Repeat fron step 1.1 as necessary. Comments: a) After the largest test load has been satisfactorily set up, then repeat the process with the smallest test load, ) Adjustments to the settings may be required and through trial and error the best settings can be found ) If the wrapper is equipped with a ‘quick select, ‘wrap program, ‘independent settings switch’, ‘pattern selector switch’, ‘multiple wrap settings’, ‘recipes’, etc, feature, it could be possible to set up another wrap program to better suit this smaller load size. Final Comments: Do not assume that all settings are necessarily optimized to your needs after your initial set up. Monitor your leads on a regular basis, from the time of wrapping, while they sit in your warehouse, to when they are put onto trucks for shipment, and after they have arrived at your customer's locator. ‘The type of stretch film that you are using may also be optimized. Work with your film supplier on trial and error basis to optimize your wrapping efficiency, and reduce your materials costs whle maintaining load integrity during transport