For many years, a major UK manufacturer of ceramic wall tiles have used semi automatic machines to stretch wrap their pallets of tiles. Following major investment in production capacity and a new VNA warehouse it was decided to install an automatic wrapping system to speed the flow of pallets from the manufacturing area to the new warehouse.
Against fierce competition Atlanta UK won the contract to supply an automatic machine capable of top sheeting and wrapping 25 pallets per hour.
The automatic system had to accept pallets from the various production lines using ride on trucks so a low level infeed was supplied with heavy duty guides to help centering of the pallets.
After the loading station Atlanta also supplied a profile checking system to prevent oversize loads entering the warehouse – the profile checker inspects all four vertical faces of the load for overhang and the overall height of the pallet – if any parameter is broken, the pallet is rejected and sent for remedial work by an operator.
The wrapping machine is a Revolution rotating arm unit with integral top sheet dispenser. As the client did not want any pits in the floor, the infeed conveyor slopes upward to allow the pallet to reach the required wrapping height. As the slope is very gentle, there is no risk of disturbing the load before it reaches the wrapping station.
During wrapping, the conveyors each side of the wrapper move down, out of the way of the film carriage, to allow the film to be wrapped down the pallet base without the need for an independent lifting unit which is the normal solution. This greatly increases the load security as it ties the pallet securely to the load.
The top sheet is applied mid cycle and due to its advanced design, the unit is capable of handling a sheet of only 40 micron thickness – offering substantial savings over the more traditional 60-80 micron sheet.
In addition to the Revolution, the project also included the supply of four semi automatic wrappers to wrap part loads. These machines are equipped with a unique mast design which means the traditional tall mast with slides, bearings, chains or belts is completely eliminated. The sealed for life screw jack requires no maintenance, which can be vital in a warehouse environment where engineering resources are usually very limited. The short mast design also makes the machine ideal for installations where headroom is limited.
All the machines are equipped with power pre stretch film carriages which maximise the yield from every roll of film and return savings of about 50% against traditional hand wrapping or basic wrapping machines. The film carriage is fully closed during operation eliminating the dangers associated with open roller systems.