An automatic strapping machine rarely operates in isolation on a fully automated production line. It needs to receive the pallet correctly, complete the required strapping cycle and release the load to the next stage without interrupting the overall production sequence.
Depending on the application, strapping can form part of a system incorporating palletisers, pallet conveyors, stretch wrapping or stretch hooding, labelling and other pallet handling equipment.
Integrating these processes requires the mechanical layout, controls and required throughput to be considered as one system.
Where Does Strapping Fit into an End-of-Line System?
The position of a strapping machine depends on what needs to happen to the pallet before and after the straps are applied.
A typical automated sequence could include:
Palletiser → Pallet Conveyor → Strapping Machine → Stretch Wrapper or Stretch Hooding Machine → Labelling → Outfeed
That sequence is not fixed for every application.
Some loads may only require strapping. Others may be strapped and subsequently stretch wrapped or stretch hooded. The order of individual processes needs to be established around the product, pallet configuration and required finished load.
Phoenix Handling Solutions considers the complete pallet handling sequence when integrating an automatic strapping machine rather than treating the strapper as a standalone part of the line.
Pallet Transfer into the Strapping Machine
The pallet needs to arrive at the strapping station in the correct position and orientation.
Pallet conveyors can be used to transfer loads between the palletiser, strapping machine and subsequent packaging equipment. The conveyor arrangement depends on pallet dimensions, load characteristics, direction of travel and the layout of the available production area.
The interface between the conveyor and strapping machine is particularly important. Conveyor levels and transfer points need to allow the pallet to enter, stop in the required position and leave the machine correctly.
Where the direction of pallet travel needs to change, additional pallet handling equipment may also form part of the system.
Phoenix supplies pallet and product conveyor systems for standalone applications and integrated automated lines.
Positioning the Pallet for Strapping
Once the pallet reaches the strapping machine, it needs to be correctly positioned for the required strapping cycle.
The exact process depends on the machine configuration.
TOSA strapping machines can incorporate features such as automatic pallet-height detection, service conveyors, pallet centring and different arrangements for positioning the strap around the load.
For vertical strapping, the relationship between the pallet and strap path is particularly important. The TOSA CAM 41, for example, uses a retractable bayonet to pass the strap through the pallet.
For horizontal strapping, the required strap heights need to be established so that the machine can apply straps in the correct positions around the load.
Integrating Strapping with a Palletiser
Where products are automatically palletised, the strapping machine can form part of the downstream pallet handling system.
Once the palletiser has completed the required pallet pattern, the finished load can be transferred onto the pallet conveyor and moved to the next packaging stage.
The interface between the palletising and strapping processes needs to account for the production rate of both machines.
If pallets leave the palletiser faster than the strapping process can accept them, the line may require sufficient conveyor capacity or accumulation between the two operations.
Equally, the strapping system should not unnecessarily restrict the output of the upstream equipment.
This is why individual machine throughput figures need to be considered as part of the complete line rather than in isolation.
Strapping and Pallet Wrapping on the Same Line
Strapping and stretch wrapping perform different functions and can both form part of the same end-of-line packaging system.
Where both processes are required, the production sequence needs to establish when the straps are applied and when the pallet is wrapped.
The appropriate arrangement depends on the load and packaging requirement rather than applying the same sequence to every product.
The transfer between the two machines also needs to be considered. Pallets need to leave the strapping station and enter the pallet wrapping machine in the correct position without unnecessary manual handling.
Where stretch hooding is used instead of conventional stretch wrapping, the same principle applies: the individual packaging processes need to operate as part of one coordinated pallet handling sequence.
Matching Throughput Across the Complete Line
The output of an integrated line is not determined by the fastest individual machine.
Palletiser cycle time, conveyor movements, number of straps, strapping cycle, wrapping process and any additional handling operations all contribute to the overall production rate.
For example, applying several straps to a pallet may require a different cycle from an application requiring a single strapping position. Pallet rotation or repositioning can introduce additional movements.
The required pallets per hour should therefore be established for the complete operating sequence.
Individual machine capacities can then be assessed against that requirement and the surrounding system designed accordingly.
Controls and Communication Between Machines
Mechanical integration is only one part of an automated strapping system.
The equipment also needs to operate in the correct sequence.
The control system needs to establish when a pallet is available, when it can enter the strapping station, which strapping cycle is required and when the completed pallet can be released.
Signals also need to be exchanged with surrounding equipment so that one machine does not send a pallet forward before the next position is available.
Phoenix Handling Solutions integrates equipment with PLC-based control systems and can incorporate machinery into wider automated systems connected with plant control infrastructure.
For an existing line, understanding the current controls is therefore an important part of assessing how a new strapping machine will be incorporated.
Handling Different Pallet and Product Formats
Not every production line processes one standard pallet load.
Different products may result in changes to pallet height, overall dimensions, strap positions or the number of straps required.
These variations need to be established when the integrated system is designed.
Depending on the specified equipment, automatic detection and machine adjustment can be used for some load variations. Other changes may require a different machine sequence or production setting.
The important point is to define the complete range of loads expected on the line rather than designing the system around one typical pallet.
Our guide to choosing an automatic pallet strapping machine explains the information required when specifying the strapping equipment itself.
Accumulation and Pallet Flow
Conveyors do more than move a pallet from one machine to another.
In an automated system they can also provide controlled space between processes, allowing pallets to be held until the next machine is ready to receive them.
The amount of accumulation required depends on the production process and the relationship between individual machine cycle times.
The available floor space also needs to be considered. Adding conveyor simply to create additional accumulation is not always practical, particularly when machinery is being integrated into an existing production area.
The line layout therefore needs to balance pallet flow, machine access and the available footprint.
Integrating a Strapping Machine into an Existing Line
Adding automatic strapping to an existing production line requires a different assessment from designing a new system from the outset.
Existing conveyor heights, available floor space, guarding and upstream and downstream equipment can all affect where the machine can be positioned.
Phoenix will also need to understand the current production sequence and control system.
Useful information for an existing installation includes:
- Pallet and product dimensions
- Required strap positions and number of straps
- Required production rate
- Existing conveyor type, dimensions and height
- Direction of pallet travel
- Available installation space
- Upstream and downstream machinery
- Existing control system
- Current pallet handling sequence
Line drawings, photographs and videos can also help establish the existing arrangement before a detailed system is developed.
Access, Guarding and Maintenance
An integrated system needs sufficient space for operation and maintenance as well as production.
The strapping head, strap reels and other serviceable components need to remain accessible once conveyors, guarding and surrounding machinery have been installed.
The same applies to the other equipment forming part of the line.
Planning these requirements during the system design stage avoids creating an installation where routine access is unnecessarily restricted by adjacent equipment.
Complete End-of-Line Strapping Systems
An integrated strapping system needs to be designed around the movement of the pallet through the complete end-of-line process.
The required strap pattern determines the strapping operation, while pallet dimensions, production rate, conveyor layout, surrounding machinery and controls determine how the machine fits into the wider system.
Phoenix Handling Solutions designs and integrates complete automated solutions incorporating pallet handling, palletising, strapping, wrapping and other end-of-line equipment.
Automatic strapping machines can also be supplied as standalone equipment where integration with a wider automated system is not required.
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Frequently Asked Questions About Integrated Strapping Systems
Can a strapping machine be added to an existing automated production line?
Yes. The existing conveyor arrangement, available space, pallet dimensions, required production rate, surrounding machinery and controls need to be assessed to determine how the strapping machine can be incorporated.
Does a pallet need to be strapped before it is stretch wrapped?
Not in every application. The required sequence depends on the product, pallet configuration and packaging process. Where both strapping and wrapping are required, the order should be established as part of the complete system specification.
How does a strapping machine communicate with conveyors and other equipment?
In an automated system, controls and signals coordinate pallet movement and machine operation. The precise control arrangement depends on the equipment and existing plant controls.
What happens if the strapping machine has a different cycle time from the palletiser?
The complete system needs to be designed around the required production rate. Conveyor capacity, accumulation and the operating sequence can be considered where individual processes have different cycle times.
Can an integrated strapping line handle different pallet sizes?
Yes, where the equipment is specified for the required range. The minimum and maximum pallet and load dimensions, strap positions and variations between products need to be established during system design.
Can pallet wrapping and strapping be automated on the same line?
Yes. Strapping and pallet wrapping equipment can form part of the same automated pallet handling line. The appropriate sequence and conveyor arrangement depend on the load and required packaging process.