Abstract: The present invention provides a method and apparatus for dispensing a predetermined fixed amount of pre-stretched film based upon load girth. A non-rotating ring carries a belt. A film dispenser is mounted on a rotating ring, and the rotating ring includes a pulley that connects to the belt. Based upon the girth of the load to be wrapped, an amount of pre-stretched film to be dispensed for each revolution made by the rotating ring is determined. Good wrapping performance in terms of load containment (wrap force) and optimum film use is obtained by dispensing a length of pre-stretched film that is between approximately 100% and approximately 130% of load girth. Once the amount of film to be dispensed per revolution is determined, a mechanical ratio of ring drive to final pre-stretch surface speed (i.e., number of pre-stretch roller revolution/ring rotation) can be set. Thus, for each revolution of the rotating ring and dispenser, a predetermined fixed amount of film is dispensed and wrapped around the load.

Abstract: An apparatus and method for wrapping a palletized load are provided. The apparatus preferably includes a film dispenser for dispensing a film web, at least one guide rollers configured to engage the width of the film web, and at least one roping element. The at least one roping element may be a cable rolling roper configured to roll a portion of the film web into a rolled cable of film. The apparatus may also include means for providing relative rotation between the load and the dispenser to wrap a roped portion of the film web around a base of the load/top portion of a pallet supporting the load.

Abstract: A film dispenser for a stretch wrapping apparatus is provided. The film dispenser includes a pre-stretch assembly having a top portion mounted to and extending downwardly from a drive plate of a roll carriage frame. The pre-stretch assembly includes two pre-stretch rollers having first ends connected to the roll carriage frame and second ends connected to one another. The pre-stretch rollers may be coated. The pre-stretch assembly further includes a cantilevered idle roller mounted to the drive plate and positioned between the pre-stretch rollers. A film path is defined by the space between the pre-stretch rollers and the idle roller. The film path is easily accessible via the bottom end of the pre-stretch assembly.

Abstract: A side seal assembly for a shrink wrap packaging system is located downstream in the feed direction from a wrapping station to join first and second plies together and enclose each of the products in individually wrapped packages. The side seal assembly includes a heated side seal mechanism to form the side seal weld and separate the selvage film. The assembly includes an indexing mechanism to index the side seal mechanism and expose a clean surface to the film without removal or extensive servicing of the assembly and the heretofore requisite downtime for the system. The sealing and cutting functions are combined into a single, stationary component thereby reducing the number of movable parts. Moreover, indexing the side seal mechanism operatively exposes a clean, free of resin build-up, peripheral edge of the side seal mechanism to the plies, without the need to stop production for extended periods of time while consistently producing a thin side seal weld on the package.

Abstract: A heat sealing device for sealing layers of plastic film together is provided. In a preferred embodiment, the heat sealing device is incorporated into a stretch wrapping apparatus for wrapping a load. The heat sealing device includes a heater element, an air compressor or blower, and a sealing head in fluid communication with the heater element to distribute the heated air. The sealing head is preferably flexible and includes a plurality of convection ports configured to apply heated air to a portion of the packaging material without being completely covered by the packaging material. At least one insulated film contact portion is provided to distance the convection ports from the plastic film.

Abstract: An apparatus and method for wrapping a palletized load is provided. The apparatus includes a non-powered conveyor load wrapping surface, at least one non-powered conveyor load storage surface, and a pusher assembly for moving the load between the wrapping and storage surfaces. The non-powered conveyor load wrapping surface is provided on a surface of a rotatable turntable and is isolated from any electrical or fluid power source by the rotatable turntable. The pusher assembly includes at least one pusher arm rotatable between an upright home position and a horizontal pushing position. The apparatus may also include a load building surface in a hand palletizing area. Hand palletized loads are pushed from the load building surface onto either a load storage surface or the load wrapping surface.

Abstract: A leading end of packaging material is grasped in a packaging material holder while a load is wrapped. Packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material holder may be positioned on the rotating surface of a turntable but isolated from any electrical or fluid power source of a rotatable surface of the turntable. During the wrapping cycle, the packaging material holder moves downstream along the turntable, automatically releasing the leading end of the packaging material and automatically grasping a trailing end of the packaging material. The packaging material is weakened and then severed between the packaging material holder and the load. The packaging material holder is mounted to permit it to move upstream due to force exerted by the packaging material held in the holder.

Abstract: A method and apparatus for securing an initial tail of film to a load while wrapping the load with packaging material are provided. The method includes holding a leading end of packaging material while providing relative rotation between the load and the dispenser to wrap film around the load. A portion of the leading end of film is secured to a fixed wrapping structure while the leading end of the film is held. After the leading end is secured to the fixed wrapping structure, the leading end of the film is released. The released leading end of the film is then secured to the load. The apparatus holds a leading end of packaging material and provides relative rotation between the load and a dispenser to dispense packaging material. The apparatus also secures a held leading end of packaging material and secures a released leading end of packaging material between two layers of packaging material. A method and apparatus for securing a final tail of film to the load also are provided.

Abstract: A method and apparatus for providing corners of a load with cornerboards prior to wrapping the load is provided. The method may include providing a load on a load transport surface, removing a cornerboard from within a magazine by a gripper, and transporting the cornerboard to a corner of the load with the gripper. Relative rotation may be provided between the stretch wrap packaging material dispenser and the load to wrap the stretch wrap packaging material around the cornerboard and the load. If the cornerboard is not pre-formed, it is folded prior to transport to the load. The cornerboard is secured to the corner of the load with the stretch wrap packaging material. In a preferred embodiment, four magazines and four grippers are provided, such that four cornerboards can be carried to the load at the same time.

Abstract: Loads on pallets are often wrapped with a plastic film for shipping. The present invention relates to top platen devices used to maintain stability in loads while the load is wrapped for shipping. The top platen device applies a compressive force to the load to stabilize the load while it is being wrapped. The top platen includes a shaft supporting platen pad which is placed on top of the load. The shaft and platen pad are configured to rotate eccentrically with respect to the geometric center of the top platen in order to rotate with the load about the load's center of rotation.

Abstract: The present invention relates to an apparatus and method for stretch wrapping a load in an efficient manner so as to tightly and securely wrap the load at a desired tension without rupturing the packaging material. The method and apparatus compensate for variation in demand rate as the load is wrapped so as to apply the wrapping material to a load at a desired force, maintain the desired containment tension on the wrapping material on the load after wrapping, and prevent the wrapping material from rupturing during wrapping. The apparatus combines two systems, power assisted roller stretch (“PRS”) and roller stretch (“RS”) to vary the supply rate of the packaging material as the demand rate varies. The apparatus automatically switches between the two types of prestretch to achieve “high” and “low” wrapping force dependent upon the demand rate. Changes in the demand rate are sensed by monitoring changes in the payoff angle of the packaging material extending between the dispenser and the load.

Abstract: A method and apparatus for providing corners of a load with cornerboards prior to wrapping the load is provided. The method may include providing a load on a load transport surface, removing a cornerboard from within a magazine by a gripper, and transporting the cornerboard to a corner of the load with the gripper. Relative rotation may be provided between the stretch wrap packaging material dispenser and the load to wrap the stretch wrap packaging material around the cornerboard and the load. If the cornerboard is not pre-formed, it is folded prior to transport to the load. The cornerboard is secured to the corner of the load with the stretch wrap packaging material. In a preferred embodiment, four magazines and four grippers are provided, such that four cornerboards can be carried to the load at the same time.

Abstract: An apparatus and method for wrapping a top and bottom of a load with packaging material is provided. The apparatus includes at least one non-driven packaging material guide is provided for use in combination with a powered conveying surface. The non-powered packaging material guide includes at least one row of non-driven wheels attached to a rail. The force applied by the packaging material as it is wrapped around the guide is supported by both the rail and the at least one row of non-driven wheels. The rail also serves to bridge any gaps between the non-driven wheels, thereby preventing capture of packaging material between the non-driven wheels. Preferably, the packaging material guide includes two rows of non-driven wheels, one on each side of the rail. Further, it is preferable that the rail connect the two rows of wheels such that the two rows of wheels form an angle of 60 degrees between them.

Abstract: A leading end of packaging material is attached to a retainer to hold the leading end of the packaging material as the retainer moves toward the load. The retainer is positioned adjacent the load and packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material is released from the retainer in response to force applied to the retainer to withdraw it from the wrapped load.

Abstract: A leading end of packaging material is grasped in a packaging material holder while a load is wrapped. Packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material holder may be positioned on the rotating surface of a turntable but isolated from any electrical or fluid power source of a rotatable surface of the turntable. During the wrapping cycle, the packaging material holder moves downstream along the turntable, automatically releasing the leading end of the packaging material and automatically grasping a trailing end of the packaging material. The packaging material is weakened and then severed between the packaging material holder and the load. The packaging material holder is mounted to permit it to move upstream due to force exerted by the packaging material held in the holder.

Abstract: An automatic high-speed wrapping system for wrapping packages in heat sealable thermoplastic film includes a film delivery unit wherein the film is dispensed and wrapped around the packages at a high rate of speed as the packages travel through the system. The packages travel continuously in a straight line through the system and are delivered at the input end of the system by a feed conveyor into a wrapping station where the packages are surrounded by the film, thence to the side sealing mechanism which forms a seal while severing the salvage from the packages, then into an end sealing mechanism where both ends of the packages are sealed and the film web connecting succeeding packages is severed. The film is delivered to the wrapping station in two plies and subsequently inverted for wrapping around the products. The positions of the wrapping station and film delivery units are adjustable to efficiently accommodate a variety of product heights while providing proper film delivery geometry.

Abstract: An automatic high-speed wrapping system for wrapping packages in heat sealable thermoplastic film includes a film delivery unit wherein the film is dispensed and wrapped around the packages at a high rate of speed as the packages travel through the system. The packages travel continuously in a straight line through the system and are delivered at the input end of the system by a feed conveyor into a wrapping station where the packages are surrounded by the film, thence to the side sealing mechanism which forms a seal while severing the salvage from the packages, then into an end sealing mechanism where both ends of the packages are sealed and the film web connecting succeeding packages is severed. The film is delivered to the wrapping station in two plies and subsequently inverted for wrapping around the products. The positions of the wrapping station and film delivery units are adjustable to efficiently accommodate a variety of product heights while providing proper film delivery geometry.

Abstract: A method and apparatus for providing corners of a load with cornerboards prior to wrapping the load is provided. The method may include providing a load on a load transport surface, removing a cornerboard from within a magazine by a gripper, and transporting the cornerboard to a corner of the load with the gripper. Relative rotation may be provided between the stretch wrap packaging material dispenser and the load to wrap the stretch wrap packaging material around the cornerboard and the load. If the cornerboard is not pre-formed, it is folded prior to transport to the load. The cornerboard is secured to the corner of the load with the stretch wrap packaging material. In a preferred embodiment, four magazines and four grippers are provided, such that four cornerboards can be carried to the load at the same time.