Gantry Online Pallet Wrapper
Fully automatic gantry-style online pallet wrapper for high-volume unmanned operation. Wraps 20-40 pallets/hour, 1200×1200×2000mm capacity, ~3KW power. Rotary arm 15rpm, integrates with conveyor lines for continuous unattended wrapping.
Overview
The PW-GO1200 is our fully automatic gantry-style online pallet wrapper, designed for high-volume facilities that require continuous, unmanned pallet wrapping at 20-40 pallets per hour. The gantry frame houses a rotary wrapping arm that orbits around stationary pallets on the conveyor, eliminating the need for a rotating turntable and enabling seamless inline integration.
Accommodates pallets up to 1200×1200×2000mm, with the rotary arm spinning at 15rpm for fast, consistent wrapping. The entire system consumes approximately 3KW of power at 380V, making it energy-efficient for continuous operation. The film carriage automatically attaches, wraps and cuts the film — no operator intervention required between cycles.
Integrates directly with existing conveyor lines, case sealers and strappers for a fully automated end-of-line system. The gantry design allows pallets to flow through continuously without stopping for turntable rotation. CE certified, with optional top sheet dispenser, label applicator and custom conveyor configurations available.
Get a Quote for PW-GO1200
Send us your product size and daily output. We’ll confirm the right configuration and send a detailed quote within 24 hours. Free factory test with your products before you commit.
PW-GO1200 Specifications
Standard configuration parameters from factory documentation. Custom modifications available for product size, wrap dimensions, voltage and film type.
| Parameter | Specification |
|---|---|
| Maximum Pallet Size (L × W × H) | 1200mm × 1200mm × 2000mm |
| Wrapping Efficiency | 20-40 pallets/hour |
| Rotary Arm Speed | 15rpm |
| Power Consumption | ~3KW |
| Power Supply | 380V, 50/60Hz (customizable) |
| Film Pre-Stretch Ratio | Up to 250% |
| Film Width | 500mm standard |
| Operation Mode | Fully automatic, conveyor-integrated |
| Film Attachment & Cutting | Automatic |
| Conveyor Integration | Standard, for inline production |
| Certification | CE / ISO 9001 |
| Warranty | 12 months comprehensive, lifetime remote support |
Built for Reliable Daily Operation
Every component is selected for industrial durability and ease of maintenance.
Variable Frequency Drive
Inverter-controlled rotation with programmable soft start and stop. Eliminates sudden jerks that can damage unstable loads.
Pre-Stretch Film Carriage
Mechanical pre-stretch system stretches film up to 250% before application. Cuts film cost per unit by 40-60%.
Reinforced Steel Frame
Heavy-gauge steel construction with reinforced supports. Industrial bearings for continuous operation in demanding environments.
Intuitive Control Panel
Simple push-button controls with adjustable wrap cycles and film tension. No specialized training required for operators.
Low Maintenance Design
Accessible components, standard industrial parts, and lubrication points. Most routine maintenance performed by in-house team.
48-Hour Run Test
Every machine runs continuously for 48 hours at rated speed before shipment. Tested with your actual product samples when provided.
Built for Gantry Online Pallet Wrapper Applications
Trusted across industries where specialized wrapping is critical for product protection.
High-Speed Manufacturing
Perfect for production lines exceeding 40 pallets/hour requiring fully automated gantry-style wrapping.
Automated Warehouses
Ideal for AS/RS systems and automated storage facilities requiring unmanned wrapping operation.
Beverage Bottling
Designed for high-speed bottling lines where consistent wrapping at line speed is essential.
Canned Food Production
Reliable inline wrapping for canned goods lines with strict hygiene and throughput requirements.
Personal Care
Gentle but fast wrapping for cosmetic and personal care product pallets in high-volume production.
Pharmaceutical
Validated wrapping process suitable for pharmaceutical manufacturing with full documentation.
Automotive Assembly
Handles heavy and irregular automotive component pallets with robust gantry structure.
Food Processing
Stainless steel options available for food processing environments requiring wash-down.
Understanding the Wrapping Process
Step-by-step operation designed for reliability and consistent results.
Pallet Arrives at Gantry Station
The pallet automatically enters the gantry wrapping station via powered conveyor. Advanced sensors detect pallet dimensions, height, and position, automatically adjusting the wrapping program for each unique load. No manual setup required.
Gantry Positions Over Pallet
The gantry frame precisely positions the rotary wrapping arm over the center of the pallet. The film carriage descends to the base of the load. The gantry design eliminates the need for a rotating turntable, making it ideal for very heavy or fragile loads.
Automatic Film Attachment
The film tail is automatically attached to the pallet using a mechanical clamp and welding system. The operator never needs to touch the film or the moving load, significantly improving workplace safety. The system verifies film attachment before starting the wrap cycle.
Rotary Arm Wrapping Cycle
The rotary arm revolves around the stationary pallet at speeds up to 25rpm. The film carriage moves up and down in a programmed pattern, wrapping the entire load with consistent tension. Because the pallet remains stationary, even very tall or unstable loads wrap perfectly without risk of tipping.
Film Cut & Pallet Exits
Once the wrapping program completes, the film is automatically cut and clamped for the next cycle. The gantry returns to home position. The conveyor discharges the fully wrapped pallet. The system immediately resets for the next pallet, achieving throughput of 60-120 pallets/hour depending on load height.
How to Choose the Right Gantry Online Pallet Wrapper
Key factors to consider for your specific operation.
| Factor | Recommendation |
|---|---|
| Throughput Requirement | Rated 60-120 pallets/hour. For lower volumes (20-40/hour), the Online Pallet Wrapper PW-OL2000 may be more cost-effective. |
| Load Weight Capacity | Standard 2000kg, optional up to 3000kg. Because pallet remains stationary, ideal for very heavy loads that would be difficult to rotate on a turntable. |
| Load Height Range | Standard 500-2000mm, optional up to 3000mm. Gantry design accommodates very tall loads that would be unstable on rotating turntable. |
| Floor Space | Footprint approximately 4000×4000mm including conveyor. Requires adequate ceiling height of 4000mm minimum for gantry structure. |
| Automation Level | Fully automatic with PLC control. Integrates with factory automation systems via Ethernet/IP, Modbus, or Profibus. Can be part of fully automated packaging line. |
| ROI Timeline | Typical ROI 4-8 months for high-volume operations replacing manual or semi-automatic wrapping. Labor savings of 2-3 operators per shift. |
Expert Selection Tips
- Gantry wrappers require more floor space than turntable models — plan layout carefully before installation
- For very tall loads (>2000mm), confirm gantry clearance and film carriage vertical travel
- Request factory acceptance test (FAT) with your actual pallets before shipment
- Gantry wrappers are ideal for unstable loads — the stationary pallet eliminates tipping risk
- Consider adding automatic top sheet dispenser for dust and moisture protection
- Evaluate existing conveyor system height — gantry wrappers can be customized to match
Real Results from Real Customers
See how companies improved efficiency with our specialized wrapping solutions.
Bottling Plant Doubles Line Speed with Gantry Wrapper
Challenge: A major beverage bottling plant producing 1.2 million bottles/day was limited by their turntable wrapper max speed of 40 pallets/hour. The production line could output 80 pallets/hour, creating a major bottleneck at wrapping.
Solution: Installed PW-GO1200 gantry online pallet wrapper integrated directly into the production conveyor. Added automatic top sheet dispenser and connected to plant SCADA system for real-time monitoring and production reporting.
Results: Wrapping throughput increased from 40 to 100 pallets/hour (150% improvement). Line bottleneck eliminated. Labor reduced by 4 operators across 3 shifts. Film consumption reduced by 22% due to precise rotary arm wrapping. Complete ROI achieved in 4 months. Plant OEE improved by 18%.
Auto Parts Manufacturer Eliminates Load Tipping
Challenge: An automotive parts manufacturer wrapping very tall (2400mm) and heavy (1800kg) pallets experienced periodic load tipping with their turntable wrapper. Each tipping incident caused $5,000-15,000 in damaged parts and production downtime.
Solution: Replaced turntable wrapper with PW-GO1200 gantry wrapper where pallet remains completely stationary during wrapping. Customized conveyor height to match existing line. Added load height detection for automatic program adjustment.
Results: Load tipping incidents eliminated completely — zero in 18 months of operation. Damaged parts cost savings of $80,000/year. Production downtime from wrapping issues reduced by 95%. Operator confidence and satisfaction significantly improved. Machine handles the tallest, heaviest loads with perfect stability. Payback period: 6 months.
Pharmaceutical Company Achieves Validated Wrapping
Challenge: A pharmaceutical manufacturer needed a fully validated wrapping process for FDA compliance. Their semi-automatic wrapper could not provide the documentation and consistency required for pharmaceutical product pallets.
Solution: Installed PW-GO1200 with full validation documentation package (IQ/OQ/PQ). Implemented electronic batch recording for every pallet wrapped. Added barcode scanning for pallet tracking and traceability. Stainless steel construction for cleanroom compatibility.
Results: Wrapping process fully validated and FDA compliant. 100% electronic documentation for every pallet — no manual recordkeeping. Audit preparation time reduced by 80%. Product quality consistency improved to 99.9%. System integrates seamlessly with existing pharmaceutical production line. Complete validation achieved in 3 months. Customer audit results: zero findings related to wrapping process.
Keep Your Gantry Online Pallet Wrapper Running at Peak Performance
Regular maintenance ensures years of reliable operation.
Maintenance Schedule
| Frequency | Tasks |
|---|---|
| Daily | Clean gantry frame and rotary arm. Check film roll quantity. Inspect all photo-eye sensors. Verify emergency stops. Check conveyor operation. Lubricate chain tensioners. |
| Weekly | Inspect rotary arm drive belt tension. Clean film carriage guide rails. Check all limit switches. Inspect electrical cabinet. Verify gantry alignment. Tighten structural bolts. |
| Monthly | Lubricate all bearing points. Inspect pre-stretch rollers. Check rotary arm bearing. Inspect film cutting blade. Verify safety guards. Test PLC communication. Clean motor vents. |
| Quarterly | Replace rotary arm drive belt if worn. Inspect gearbox oil levels. Calibrate sensors. Inspect film clamp mechanism. Verify grounding. Check conveyor rollers. |
| Annually | Complete gearbox oil change. Replace rotary arm bearings. Full gantry system inspection. Electrical insulation test. Update PLC firmware. Performance validation with actual load. |
Common Troubleshooting
Symptom: Rotary arm does not rotate
Cause: Drive motor overload, VFD fault, drive belt broken, or safety guard interlock triggered.
Solution: Check VFD display for error code. Reset motor overload. Inspect drive belt. Verify all safety guards closed and interlocks engaged. Check rotary arm bearing for seizure. Contact support if VFD error persists.
Symptom: Film carriage does not move vertically
Cause: Vertical drive motor fault, guide rail obstruction, limit switch malfunction, or belt broken.
Solution: Check for obstructions on vertical guide rails. Test upper/lower limit switches. Inspect vertical drive motor and belt. Verify carriage is not overloaded. Clean photo-eye sensors. Check VFD for vertical motor errors.
Symptom: Gantry frame vibrates excessively during operation
Cause: Floor mounting bolts loose, rotary arm unbalanced, or bearing wear.
Solution: Check and tighten all floor anchor bolts. Verify rotary arm balance and counterweight. Inspect rotary arm bearings for wear. Ensure floor is level and can support dynamic loads. Check gantry frame for structural damage. Contact support if vibration persists.
Symptom: Pallet not detected by sensors
Cause: Sensor misalignment, dirty lens, faulty sensor, or pallet outside detection range.
Solution: Clean sensor lenses. Realign photo-eye sensors. Check sensor output with multimeter. Verify pallet is within detection zone. Check sensor mounting brackets. Adjust sensor sensitivity settings. Replace faulty sensor if necessary.
Engineered for Reliability, Tested for Excellence
Every Gantry Online Pallet Wrapper undergoes rigorous quality control and 48-hour testing.
CE Certified
Meets EU safety, health, and environmental standards.
ISO 9001:2015
Quality management system for consistent manufacturing.
48-Hour Run Test
Continuous testing at rated speed before shipment.
EN ISO 12100
Machinery safety standard for risk assessment and ergonomic design.
EN 60204-1
Electrical equipment safety standard for wiring, grounding, and emergency stop.
EMC Directive
Electromagnetic compatibility for emission and immunity performance.
Four-Stage Quality Control
Incoming Inspection
All materials verified against specifications.
In-Process Checks
Welding, machining, assembly verified at each stage.
Performance Testing
48-hour continuous run test with actual load.
Final Verification
Complete inspection including documentation and packaging.
Compliance Documentation Available
Every Gantry Online Pallet Wrapper comes with complete technical documentation for your compliance records:
- EU Declaration of Conformity — Signed declaration confirming compliance with EU Machinery Directive 2006/42/EC
- CE Certificate — Issued by accredited Notified Bodies (UDEM, SGS, ICR)
- Technical File — Design drawings, risk assessments, electrical schematics, and component lists
- Test Reports — 48-hour run test data, electrical safety test results, and noise measurements
- Operation & Maintenance Manual — Detailed instructions for installation, operation, and maintenance
Third-party certified by UDEM, SGS, and ICR — all accredited Notified Bodies under the EU Machinery Directive. View all certifications and patents →
Common Questions
Ready to Automate Your Packaging?
Send us your product size, daily output and floor layout. Our engineers will confirm the PW-GO1200 is the right fit and send a detailed quote within 24 hours. Free factory test with your actual products before you commit.