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: 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: 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.

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 includes means for holding a leading end of packaging material and means for providing relative rotation between the load and a dispenser to dispense packaging material. The apparatus also includes means for securing a held leading end of packaging material and means for securing a released leading end of packaging material between two layers of packaging material.

Abstract: A pallet dispenser and a method for stripping a lowermost pallet from a vertical stack of at least two pallets is disclosed. The pallet dispenser includes a pallet magazine for containing the vertical stack of pallets and a platform disposed below the pallet magazine. The platform is configured to support the vertical stack of pallets such that the lowermost pallet rests on the platform. The pallet dispenser also includes a cantilevered pusher bar configured to push the lowermost pallet from under the vertical stack of pallets and out of the pallet magazine. In another embodiment, the pallet dispenser may include motion means for providing motion to the stack of pallets.

Abstract: A palletizer for automatically building a load with product from an infeed area is disclosed. It includes means for defining a desired volume of a load including a length sensor, a width sensor, and a height sensor. It also includes means for transporting product from an infeed area to the load. A controller is associated with means for defining the desired volume, the controller being configured to receive signals from the sensors and to automatically control movement of the means for transporting. The controller is configured to automatically determine when the volume is filled. In another aspect, a method of building a load with product from an infeed area is provided. The method includes defining a desired volume of the load using a length sensor, a width sensor, and a height sensor. It also includes automatically filling the volume with product, and determining when the volume is filled.

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: 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: 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.

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 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: A method and apparatus for wrapping the load at a desired wrap force are provided. The apparatus includes a dispenser for dispensing packaging material and means for providing relative rotation between the load and the dispenser. The dispenser has a prestretch portion and a post-stretch portion. The prestretch portion is configured to prestretch the packaging material within the dispenser to a point below the yield point of the packaging material. Preferably the packaging material is prestretched between first and second unpowered prestretch rollers. The post-stretch portion is configured to further stretch the prestretched packaging material to a point above the yield point of the packaging material as the packaging material moves from the dispenser to the load. Preferably, the post-stretch portion includes a friction element, such as a brake, to apply friction to one of the prestretch rollers.

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: 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 non-powered packaging material transporting surface for use in combination with a load support surface of a wrapping apparatus for wrapping a top and bottom of a load is provided. The non-powered packaging material transporting surface includes non-driven rollers aligned in an inline configuration, and a packaging material support guard adjacent to the non-driven rollers. The packaging material support guard bridges gaps between the inline rollers, thereby preventing capture of packaging material between the non-driven rollers. The non-driven rollers rotate as packaging material, wrapped around a load on a top surface of the load support surface and around the non-powered packaging material transporting surface on the underside surface of the load support surface, is moved along the transporting 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 stretch wrapping apparatus is provided for stretch wrapping a load with a stretch wrapping material. The apparatus includes a dispenser for dispensing stretch wrapping material and a mechanism for rotating the dispenser around an axis of rotation to wrap the stretch wrapping material around the load. A conveyor transfers the load to and from a wrapping area, the conveyor having two sides and defining a centerline therebetween intersecting the axis of rotation. A frame supports the dispenser including at least one upright leg, only one leg of the frame being disposed on one of the sides of the conveyor and being spaced from a line perpendicularly intersecting the conveyor centerline at the axis of rotation.

Abstract: A load is stretch wrapped with a sheet of stretch wrap packaging material by adhering a leading end portion of the sheet to a holding member, dispensing the sheet from a stretch wrap dispenser, and providing relative rotation between the dispenser and the load to wrap the sheet of stretch wrap packaging material on a load. The leading end portion of the sheet is released from the holding member, and a trailing end portion of the sheet is adhered to the holding member. The packaging material between the load and the holding member is severed while being held by the holding member. The sheet of stretch wrap packaging material is held in place against the holding member with a vacuum or by a tacky surface. The severing is accomplished by a hot wire on the holding member.

Abstract: A process and apparatus for pre-stretching a plastic film material above its yield point in a roller assembly comprising at least two rollers connected for rotation at different speeds during a load wrapping operation. The downstream roller is at least partially driven by the film web connected to a turntable while the upstream roller rotates at a predetermined speed slower than that of the downstream roller to induce film elongation between the rollers. The force on the film between the roller assembly and the load is reduced by a powered constant torque device connected to the rollers to bring the force to the load down to a level permitting the film elongation between the roller assembly and the load to be equal to (balanced) or less than the elongation incurred between the rollers.