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E-Series Stretchwrappers

Low profile machines, with round turntables 3" above the floor and the addition of a ramp from the floor to the turntable, are usually loaded by pallet-jack, or a mixture of pallet-jacks and fork-trucks.

Sometimes pallets are loaded while sitting on the machine’s turntable, a convenient lazy-susan, then wrapped and removed.  The low profile is usually preferred because the top of the load being stacked does not end up quite so high above the floor, making it easier and faster to load.

This structural steel machine is fabricated from 5.5" x 2.5" x 3/16" structural tubing.

Unlike almost all other low-profile machines, E-Series's low-profile systems are designed with a structural steel frame, not built by attaching components to a steel plate (warpable) laying on the (uneven?) floor.

The top of the turntable is an easy-to-use 3" from the floor, making the machine easily loadable/unloadable even by hand-jacks when the machine is ordered with E-Series optional 4' by 4' steel plate ramps.

The standard rotating capacity of the standard low profile is 4,400#.

The standard turntable is 65" diameter.

Maximum standard pallet size is 48" x 48”.

The 3-12 r.p.m. variable-speed turntable features Soft-start and Soft-stop.

The motors speed reducer and ALL reducers in this E-Series machine are covered by a LIFETIME warranty.

The turntable is rotated by a ANSI #50 roller chain with over 6200# tensile strength.

The turntable drive chain is enclosed for safety.

This machine is fork-truck portable from BOTH the front and rear.

WHY PRESTRETCH ?

When stretch wrapping you want to stretch the film as far as possible because this reduces the amount of film that must be taken from the roll to wrap a load, saving money.

If a 48" x 48" x 60" high load is spiral wrapped with 2 layers of film top and bottom, 4" of film over the top of the load, 4" film overlap between vertical (spiral) layers, and 1" of film neck-down (a typical wrap pattern), then the following annual film costs prevail, if we wrap 10 loads per hour single shift (2,000 hours per year), and pay $35 for a 20" x 5,000' roll of film:

                    10% stretch (as in handwrap or full web non-prestretch applications)                        $20,618

                    40% stretch                                                                                                          16,200

                    110% stretch                                                                                                         10,800

                    200% stretch                                                                                                           7,400

It is obvious that, given any wrap volume at all, stretching the film as far as possible will pay for the mechanical device necessary to do so with a single year's film savings.  It may pay for the whole machine.

Why not just use a thinner film rather than prestretch?  The tensile strength of a film is a result of its manufacturing, and is higher for thicker films.  Tensile strength does not change as the film is stretched.  If we used a thinner film to begin with, we sacrifice the load-holding abilities of the film.

Three major problems prevent achieving high stretch levels with a "conventional" brake system (a non-powered stretch device in which the pallet pulls on the restrained film to stretch it):

Most manufacturers use electromechanical brakes, or clutches, to restrain the roll of film for stretching.  These brakes are not precision parts and were not designed for the purpose for which they are being used.  They vary in effectiveness, just as the brakes on your car are more effective at slow speed, and vary dramatically when they are cold vs. when they are hot.  Film stretch levels change as the brake heats up with use and as the roll of film accelerates and slows (or stops) its rotation during the wrap cycle.  The end result is that these brakes cannot stretch film to high stretch levels because of their inherent inefficiencies.

Also, when the web width of film is not supported (usually between rubber rollers) when it is being stretched, much of its elongation is taken from the width of the film.  If the web width is supported by non-powered rubber rollers which are driven by the film being pulled through them by the product being wrapped, the film will "neck-down" after leaving the last rubber roller - though not nearly as much as if it were not supported at all.

Narrower film forces us to raise and lower the film elevator on a spiral stretch wrapper slower, so we lose in additional vertical layers and wrap time much of what we gained in film length.

Also, unless we use a motor to both stretch the film and relieve the stretch force from the load, the force required to stretch to high stretch levels will crush some loads and/or their boxes, or pull them from the stretch-wrapper.

LOAD-HOLDING FORCE

E-Series powered prestretch systems provide for independently adjusting the load-holding force of the film around the load - regardless of the amount of film stretch, load size, shape, position on turntable, or turntable speed selected.

The operator adjusts E-Series pre-stretch system, by turning a knob, to the proper load-holding ("Load Tension" or "Compression") force of the film around your product - adjustable from only two (2) pounds of force to as much as the film being used will allow - strong enough to hold the load together, but not so strong as to crush light or soft products or boxes or to topple unstable loads during the wrap process.

The importance of consistent load-holding force cannot be overstated.  Besides not allowing your products to ship undamaged, an inconsistent force-to-load, or too low a force can easily double the cost of film used by allowing the stretch in the film to be lost.

DLE-96PS POWERED PRESTRETCH SYSTEM

E-Series prestretch system stretches the film as it leaves the supply roll and travels between two rubber rollers in the prestretch unit.

Threading the unit is as simple as opening the pre-stretch unit’s door, placing a roll of film in the unit, pulling a tail of film outside the door, and closing the door.

DLE-96F FRICTION BRAKE SYSTEM

A manually adjustable friction brake system is employed, with the controls on the film elevator.

This system is best for the newer pre-stretched films. 

FILM MAST

The film mast on the DEL-96PS is formed from 11 ga. steel.

It has a rear door, with a lock, for accessing the internal components.

The film mast on the DEL-96F is 6” x 6” structural tubing.

The standard spiral tower height is designed to wrap loads to 96" in height   Additional wrap height, to 110”, is an option.

DLE-96PS SEMI-AUTOMATIC SPIRAL CONTROLS

OMRON PLC featuring:

Top & Bottom Wrap Counters (0 – 9 revolutions) & Up-Down Wrap Cycles Selector

Photo-eye automatic pallet height sensor with time delay for top of pallet overlap

Reinforce Wrap function to allow more wrap on the same location on the pallet (great for locking 2 pallet-loads

   together!)

Powered Pre-stretch Film Tension Control adjustment on the control panel

3-12 RPM variable turntable speed turntable with controlled-acceleration/deceleration.  Soft start with

   decelerate to low speed homing cycle for soft stop

Positive turntable alignment (turntable stops in the same place every time)

Variable Speed Film Elevator with separate Up & Down speed controls

Manual Film Elevator Up & Down switches

Cycle Pause capability

Separate Start & Emergency Stop buttons

Reset button sends Film Elevator & Turntable to starting positions & resets PLC to a new wrap cycle

Turntable jog button

Circuit Breaker Overload Protection  (NO FUSES)

Automatic shut-off if a foot is caught under the film elevator

DLE-96F SEMI-AUTOMATIC SPIRAL CONTROLS

OMRON PLC featuring:

Top & Bottom Wrap Counters (0 – 3 revolutions) & Up-Down Wrap Cycles Selector

Photo-eye automatic pallet height sensor

3-12 RPM variable turntable speed turntable with soft Start and Stop

Positive turntable alignment (turntable stops in the same place every time)

Variable Speed Film Elevator with separate Up & Down speed controls

Manual Film Elevator Up & Down switches

Cycle Pause capability

Turntable jog button

Circuit Breaker Overload Protection  (NO FUSES)

Automatic shut-off if a foot is caught under the film elevator

ELECTRICAL

Simple, reliable 115 V., 15 amp. AC electrics are used.  The power cord plugs into a standard wall outlet.

DOCUMENTATION

All E-Series customers receive full documentation on the products they purchase.  E-Series manuals include:

Complete equipment specifications, including all options.

An initial installation and start-up guide.

Complete operating instructions for each individual control, explaining what each does and how they are used, with location drawings.

A complete machine operations guide, explaining step-by-step how to use the equipment.

A complete equipment description, including indexed drawings, for all components of the machine, with manufacturer’s part numbers and quantity information.

A complete set of electrical schematics.

A complete preventative maintenance guide, explaining each task completely.

A complete troubleshooting guide, explaining step-by-step what needs to be checked if any part of the machine does not function.

A recommended spare parts list for the equipment.

A "Troubleshooting Assignment List" relating each electrical component to the electrical schematics by line number.

Major component manufacturers parts bulletins/manuals.

The final, signed, "Quality Control Check List".

FLOOR SPACE REQUIREMENTS and  SHIPPING WEIGHT

DLE-96PS

Max load size                                     48" x 48" x 96" H.

Turntable diameter                               65"

Turntable Height                                  3" above the floor

Turntable weight capacity                     4,400 lbs. (Standard)

Turntable speed                                   3-12rpm

Machine weight                                   1,540 lbs. (Standard machine)

Voltage                                               120V 60HZ 1Phase

Power                                                 12.5 Amps

Machine dimensions                           108" L x 65" W x 113” H (Standard).

Wrapping Speed                                20-30 loads/hour depending on load height and number of wraps

Max load size                                     48" x 48" x 96" H.

Turntable diameter                               65"

Turntable Height                                  3" above the floor

Turntable weight capacity                     4,400 lbs. (Standard)

Turntable speed                                   3-12rpm

Machine weight                                   1,320 lbs. (Standard machine)

Voltage                                               120V 60HZ 1Phase

Power                                                 12.5 Amps

Machine dimensions                           108" L x 65" W x 113” H (Standard).

Wrapping Speed                                20-30 loads/hour depending on load height and number of wraps

AVAILABLE OPTIONS

4’ x 4’ Access Ramp for pallet-jack loading & unloading    

Additional Wrapping height: 110"

Increased Turntable Diameter for larger loads: 70" or 78"

Additional Turntable Capacity: 5,500 lbs. or 6,600 lbs.

Motorized or Pneumatic top platen for holding down light or unstable loads 

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