“THE IMPULS MOTION”mediumoutputwww.ear-flap.comVERTICAL WRAPPINGPalletized loads wrapping machinesLoad protection with stretch film
Medium output vertical wrappingPalletized loads wrapping machines with stretch filmwww.ear-flap.comContentsStretch film 3Medium output semiautomatic wrapping machines 4Wrapping with stretch film for palletized loads protection from EAR FLAP 5One film carriage for each requirement 6Semiautomatic turntable wrapping machine model 100 7Semiautomatic turntable wrapping machine model 200 9Semiautomatic turntable wrapping machine model 600TP 11Semiautomatic turntable wrapping machine model 700 13“À-la-carte” machine 15EAR-FLAP® 21“THE IMPULS MOTION”
3Stretch filmThe most used option for protecting palletized loadsIn the last times, the industry evolutionhas aroused an ever growing demand ofglobal reach for materials that unitize,stabilize and protect palletized loads fromdust, water, dirt, etc. For this reason, stretchfilm keeps evolving as a consequence of thetechnical revolution, being the most usedoption for the vast majority of the arisingneeds.Polyethylene stretch film owes its qualitymainly to the raw material used in its pro-duction, which differs in its manufacturingfrom that of the ethylene polymer itself.The catalyst used for the polymerizationreaction confers better features in terms ofshine, stretch strength, puncture strength,and behavior at melting point.Stretch film is manufactured by blow-extru-sion processes (in case of PVC and low-quality PE) or flat layer extrusion, whichmay have up to five layers to better makethe most of each used polymer withoutharming the final quality.Among the innovations in that field, macroperforated sheets have been developed forthe wrapping of palletized loads to conferthem the benefit of free aeration. Speciallyconceived for loads that need to “breathe”due both to the product nature and its pro-cessing.Thanks to its piercing, the macro perfora-ted stretch film prevents the condensationproblems arising from differences betweeninner and outer temperature, thus achie-ving that cardboard cases do not deterio-rate, labels keep their legibility, metal cansdo not rust and a constant stability of thepalletized load during shipping and stoc-king.The use of macro perforated stretch filmis mostly for biological products (flowers,produce, fruits, eggs, cheese, flour, etc.),warm-palletized products (drinks, beer,canned food, fodder, sweets, etc.) andrefrigerated or frozen products (meat, fish,dairy, ice cream, etc.).There is also a small offer of dyed stretchfilm for special applications and UV-prooffilm to wrap those products that are sun-light sensitive. Special additives are usedto increase film cling for loads that are tobe stocked under open weather conditions.It is also possible to find printed films forload customization.
Medium output semiautomatic wrapping machinesOne model for each need4With over 3.000 wrappingmachines sold, we have lear-nt that there are plenty offactors that determine which semiau-tomatic vertical wrapper is the mostsuitable one for an installation.Features such as pallet dimensions,percentage of occupied pallet, loadheight, weight, product packaging aswell as hourly pallet output and areasize where the machine must be placeddefine which type of machine to install.Referring to the semiautomatic stretchfilm wrappers, the market offers 3 ty-pes of wrapping systems, all of them tobe considered after the formerly statedfactors.The most common, used for manyyears in small to medium size compa-nies has been the turntable wrapper,whose main feature is that the palleti-zed load spins on a turntable while astretch film reel travels up and downalong a mast wrapping the load.This is the most usual machine foroutputs of up to 10 loads/hour for the“nimble” operator to work with. Sincenot all loads are stable for a fast wra-pping, there is the well-known optionof a top platen, either pneumatic orelectric, which holds the load at the topwithout damaging it for a wrappingprocess without collapsing.Additional options like pit framesor access ramps allow avoiding theturntable height obstacle to access itwith a manual trolley. Furthermore,it is possible to choose among severalconfigurations of film carriages wheredifferent load features will determinethe most suitable one.
5Vertical wrapping according to EAR FLAPAll along the last years we have concen-trated our endeavours in Research andDevelopment for improving each oneof the elements that make up our wrappers, tothe point that we have become a reference inthis sector.In the same way as the emerging marketrequirements compel to improve the mecha-nical properties of the stretch film, so the loadwrappers must continually evolve to match themost recent stretch film specifications. Hence,our side film carriage has become one of themain components in our wrappers.Since each product is different and each needis different, EAR FLAP studies and analyzesevery installation taking into account all directand indirect factors that meet for the best wra-pper configuration.Some of the features we consider:• LOAD WEIGHT: we offer several types ofbase, depending on the weight to hold(2.000 kg, 3.000 kg, etc.)• LOAD HEIGHT: we manufacture customi-zed masts if the load is higher than thestandard (3.000 mm, 4.000 mm, etc)• SIDE CARRIAGE: we have several models offilm carriages (direct brake, electromagne-tic brake, pre-stretch)• CONTROL BOARD: it features a LCD screenwith an user friendly menu for configura-tion of the wrapper. Includes warnings andalarms• SPECIAL ENVIRONMENTS: we manufactu-re with different finishings and protectionsfor special conditions (stainless, ATEX,below oºC, etc)Some details we care for:• COLOURS: we integrate the machine intothe line painted in the colour the customerwants for a uniform visual aspect• UNIFORMITY IN PARTS AND COMPO-NENTS: we endeavour to use such ele-ments that the customer has approved, toprevent the need for extra spares• SIZES AND TYPES OF LOADS: we tailor thewrappers to the load, producing and fittingroller or chain conveyors,• or other components to the machines, de-pending on the needs• INTERCONNECTIONS: our electric controlcabinet allows for interconnections withthe rest of elements in a line, by signals,network, etc
A film carriage for each need6Direct brakeThis is the simplest and more economical system. It is fitted with a knobthat exerts a direct pressure against the reel mandrel to adjust the tensionon it.Its drawback is that the exerted pressure on the cardboard mandrel cau-ses it to wear, requiring constant readjustment. Besides, if attention is notkept on this fact, the loads do not get uniform wrapping tension along thedifferent cycles.“M” prestretchThis system offers several advantages as compared to the conventional“S” system. Safety at work: a door hides the rollers and the film, protec-ting the operators’ fingers from possible catching. Ease of use: no need tothread the film through the rollers, saving time in the reel changeover.Electromagnetic brakeAnother system to replace the direct brake. The difference as comparedwith the mechanical brake is that being electromagnetic, tension ad-justment is made from the control board. It’s more advantageous andcomfortable for film tensioning during the wrapping cycle.Mechanical brakeThis system solves the problem of the direct brake. It is fitted with anadditional roller around which the film passes and upon which pressureis exerted with a manual tension regulator. This system grants that thefilm tension is the same for every load, even when changing reels as itdoesn’t directly affect these.
7Semiautomatic turntable wrapper. Model 100Standard technical featuresLoad features• Type of wrapping: vertical• Maximum height: 2.400 mm• Pallet + load max. dimensions: 1.200 x 800 mm• Maximum weight: 1.500 kgMachine features• EAR-FLAP® profile• Hinged mast• 2.400 mm max. wrapping height• Powered film carriage with variable speed, placed sidewise• Adjustable mechanical brake with foot trapping detector• Automatic load height detection photocell• 1.500 kg max. load weight• 1.200 x 800 mm max load dimensions (L x W)• 1.500 mm diameter turntable, 10 mm thick• Soft start/stop and return to start position with frequency inverter• 4 wrapping programs: Single, Cross wrap, Cross-plus, Full• Independently adjustable top & bottom reinforcement wraps• PLC controlled with LCD screen• Ergonomic control panel• Single phase 220V, power supply• Variable output depending on operator’s ability and load features
8Options and machine dimensions1234Featured options1. Access ramp2. Pit frame3. Direct brake4. Adjustable mechanical brake with foot trapping detector (standard)Machine dimensionsDimensionsUpon request, they may be customizedto match the installation requirements.
9Semiautomatic turntable wrapper. Model 200Standard technical featuresLoad features• Type of wrapping: vertical• Maximum height: 2.400 mm• Pallet + load max. dimensions: 1.200 x 1.000 mm• Maximum weight: 2.000 kgMachine features• EAR-FLAP® profile• Hinged mast• 2.400 mm max. wrapping height• Powered film carriage with variable speed, placed sidewise• Adjustable mechanical brake with foot trapping detector• Automatic load height detection photocell• 1.650 kg max. load weight• 1.200 x 1000 mm max load dimensions (L x W)• 1.650 mm diameter turntable, 10 mm thick• Soft start/stop and return to start position with frequency inverter• 4 wrapping programs: Single, Cross wrap, Cross-plus, Full• Independently adjustable top & bottom reinforcement wraps• PLC controlled with LCD screen• Ergonomic control panel• Single phase 220V, power supply• Variable output depending on operator’s ability and load features
Featured options1. Access ramp2. Pit frame3. Direct brake4. Adjustable mechanical brake with foot trap-ping detector (standard)5. Electromagnetic brake with foot trappingdetector6. “M” prestretch with foot trapping detector7. Scale with display8. Powered top platen9. Flat boards holder powered kit10. “Celaire” kit10Options and machine dimensions12345678910Machine dimensionsDimensionsUpon request, they may be customizedto match the installation requirements.
11Semiautomatic turntable wrapper for side/front loadtrolley infeed Model 600TP-L/600TP-FStandard technical featuresLoad features• Type of wrapping: vertical• Maximum height: 2.400 mm• Pallet + load max. dimensions: 1.200 x 1.000 mm• Maximum weight: 1.000 kgMachine features• Hinged mast• 2.400 mm max. wrapping height• Single phase 220 V power tension• Powered film carriage with variable speed, placed si-dewise• Adjustable mechanical film brake with foot trappingdetector• Automatic load height detection by photocell• 1.000 kg max. load weight• 1.200 x 800 mm max load dimensions. Ø1.500 mm turn-table• Soft start/stop with return to start position. Variablespeed.• Slotted turntable for load trolley infeed (600TP-F, frontentry; 600TP-L side entry)• Several wrapping programs• Independently adjustable top & bottom reinforcementwraps• PLC controlled, with LCD screen• Reinforcement wraps at any point in the cycle• Wrapping cycles counter
12Machine dimensions1 2 3Options and machine dimensionsFeatured options1. Adjustable mechanical brake with foot trapping detector (standard)2. Electromagnetic brake with foot trapping detector3. “M” prestretch with foot trapping detector
13Semiautomatic rotating arm wrapper. Model 700Standard technical featuresLoad features• Max. length: 1.200 mm• Max. width: 1.200 mm• Max. height: 2.000 mm• Max. pallet diagonal: 1.800 mmMachine features• Rotating arm with obstacle detecting photocell• Variable arm rotation speed• Automatic wrapping cycle• 3 available cycles: Single, Cross, Top sheet• Control panel with user friendly icons• Electromagnetic brake for film stretching• Arm return to position upon cycle’s end• Automatic load height detection by photocell• Soft arm start/stop by electronic control• Inverter controlled arm speed, up to 12 rpm• Inverter controlled film carriage speed with independent settings for upwards/downwards• Automatic load height detection by photocell• Independently adjustable top & bottom reinforcement wraps• Floor height: 3.500 mm• Rotation diameter: 2.800 mm• Single phase+N+PE, 230V, 50 Hz. power supply
14Options and machine dimensionsMachine dimensions1 2 3Featured options1. Adjustable mechanical brake with foot trapping detector (standard)2. Electromagnetic brake with foot trapping detector3. “M” prestretch with foot trapping detector
15Standard powered top platenPowered top holder for flat loadsSquare platenFlat loads kitWe offer two types of top holders; dependingof the type of load, one or the other are to beused.Standard top platen. This is the most commonly used topplaten in the market. It is manually activated so that it isdisabled when the loads do not require it, thus makingthe wrapping process swifter. Its stroke is 2.000 mm andthe operation height is adjustable. The standard platenis round, although other shapes and dimensions may besupplied, to prevent it exceeding the load top edges.Powered top holder for flat loads. This system is thesolution for wrapping flat loads, such as doors, windows,ladders, etc. The system is fitted with top and bottomadjusting guides, to hold the load.
Special environments (explosive, corrosive, below 0ºC…)16Our goal being that of providing the best ser-vice in solutions for the semiautomatic wra-pping of palletized loads in the end-of-linepackaging, we have developed -and keep on evol-ving- special adaptations of our machines to specialenvironments. That’s why we present decade-longproven experienced solutions forexplosive conditions (ATEX), corrosive ones (STAIN-LESS STEEL) or freezing temperatures down to-30ºC.
17Special scale baseThere is an ever increasing request for identifyingthe palletized loads with their weight. Hence,the shipment dept. is burdened with the tedioustask of weighing the load prior to wrapping. In orderto speed up this process and make it user-friendly, weoffer the option of including a scale in the wrapperbase, composed of weigh cells and one display, withthe possibility of linking it to the company printer orlocal network.
Special platforms18We can manufacture any sort of platformdifferent from the standard one.Turntable sizeAlthough our standard disk size, Ø1.650mm, has been calculated for the “Ame-rican” pallets not to overflow, we maysupply larger ones to avoid corners oflarger pallets overflowing. Dependingon the dimensions of the larger disk, thesupporting structure and bearings mightrequire to be reinforced.Neck lengthThe neck is the section between the baseand the mast. Its standard length is 500mm, but there may be occasions whenthe load overflows the disk thus possiblyhitting the mast. For such cases we maysupply machines with longer necks.Types of baseAlthough the most usual option is the flatturntable, sometimes it is more purpo-seful that it is fitted with rollers, free orpowered, for line integration.WeightUsually, the highest taken weight of2.000 kg is enough. Anyway, it is possibleto reinforce the base and bearings forheavier loads.Turntable 3.000 mm diameterTurntable with powered rollers
19Special heightsAlthough the standard topload height is of 2.400 mm,me may supply masts withsuperior heights if the loads sorequire.Upon giving the chance to makeother heights, some customersseize the chance to change thepackaging mode of other products,shifting to stretch film wrappingto maximize the machine profita-bility.
Load infeed and outfeed.Access ramp, pit frame, lifting supports20Setting the load on the turntable is cru-cial, as there are different ways for theuser to move the palletized loads aroundand the turntable base, with its 75 mm thick-ness, is a hindrance to overcome.Access ramp (for manual trolleys). When theoperator uses a manual trolley, one of theoptions to overcome the turntable height isan access ramp 1.300 mm long. Such ramp isreinforced with underneath ribs, to hold thesame weight as the wrapper does.Pit frame (manual trolley). Another optionfor the same moving way is to embed themachine in the floor, so that the turntableis flush with it, thus avoiding the effort topush a heavy load up a ramp. For a perfectembedding, a metal frame in the shape of thewrapper is provided.Lifting supports (electric forklifts). Since these forklifts have four prongs, two forfloor propping and two for lifting the load, if the machine wouldn’t be raised, the fixedprongs would hit the turntable base, making it impossible to lift the load. In such cases,the machine must be raised with specific supports and the whole structure must bereinforced to withstand the 2.000 kg (max) to prevent deformation.
Ear Flap® counts with a professional knowledge and a broad experience in the world ofPackaging that go back to more than 20 years. This great professional experience togetherwith our commitment to offer bespoke solutions to our customers, based on our largerange of high quality packaging machines, all complemented with the support of an effi-cient and skilled after sales service, has made us worthy of our clients trust, placing us athe leader in Spain in the manufacturing of vertical wrappers.Our motto is service and within this commitment to the customer, Ear Flap® doesn’t stopat the machine supply only, but it goes beyond with its different technical departments forany doubt or query.Ear Flap® has a large showroom, open to all our customers, where we show our machinesworking. This showroom has been designed not only for demos and information to thecustomer, but also to check at the concerned machine the complexity of a named applica-tion, allowing us to refine the customization of each project.Our development and expansion are directly linked to our commitment in finding newpackaging solutions that will materialize in a machine range that anticipate the marketneeds.We are in full expansion, both at Domestic as well as International level, with two subsi-diaries in Europe and one in China.At Ear Flap® we base our activity and our growth on the excellence in Customer serviceand on the swift adaptation to his packaging needs.