4100-45-OHA Conveyorized Automatic Pallet Wrapper

Conveyorized Automatic Rotary-Arm Wrapping

The 4100-45-OHA pallet wrapper automatically indexes pallet loads into a protected wrapping zone, holds them stationary while the rotary arm applies stretch film and then transfers them to the exit conveyor. Because the pallet does not rotate, the system can wrap stable, unstable, lightweight or top-heavy loads without exposing them to turntable movement.

Moreover, the standard system includes powered infeed, process and exit conveyors. Pneumatic components automatically attach and cut the film, while PLC controls coordinate pallet movement and the programmed wrap cycle. Therefore, the 4100-45-OHA provides a complete automatic wrapping solution for production rates up to 45 loads per hour.

Benefits of the 4100-45-OHA Pallet Wrapper

• Stationary-load wrapping: The pallet remains still while the rotary arm applies film.
• Automatic pallet movement: Powered conveyors index loads into and out of the wrapping zone.
• Up to 45 loads per hour: Actual production depends on load dimensions, wrap counts and conveyor timing.
• Automatic film handling: Pneumatic mechanisms attach, cut and wipe the film without operator involvement.
• Powered pre-stretch: Meanwhile, the film carriage improves film yield and containment consistency.
• Flexible load handling: The rotary-arm design suits stable, unstable and lightweight products.
• Integrated safety system: Wire-mesh barriers and interlocked gates control access to the wrapping area.
• Production-line integration: Finally, PLC logic can coordinate the wrapper with upstream and downstream equipment.

Ameripak’s guide to how conveyorized stretch wrappers increase throughput provides additional information about automated pallet flow and labor reduction.

4100-45-OHA Pallet Wrapper Specifications

Production and Load Capacity

• Production speed: Up to 45 loads per hour
• Maximum dynamic load weight: 4,000 pounds
• Maximum static load weight: 12,000 pounds
• Maximum load width: 50 inches
• Maximum load length: 50 inches
• Maximum load diagonal: 71 inches
• Maximum load height: 80 inches
• Top film overlap: Up to 4 additional inches
• Minimum load dimensions: 30 inches wide × 30 inches long × 24 inches high

Because load height, wrap revolutions and material-flow timing affect throughput, Ameripak can calculate a realistic production range for the application.

Stationary Rotary-Arm Wrapping Zone

The 4100-45-OHA stops the pallet inside the process conveyor while the rotary arm travels around it. Therefore, the load avoids the centrifugal force associated with turntable wrapping.

This arrangement provides advantages for:

• Tall or top-heavy loads
• Lightweight products
• Unstable pallet configurations
• Fragile goods
• Loads with loose upper layers
• Products that may shift during rotation
• Consistently palletized production-line loads

In addition, the stationary load position can reduce the risk of products leaning, shifting or separating during high-production wrapping.

For a detailed comparison, review turntable versus rotary-arm stretch wrappers in the Ameripak Learning Center.

Standard Power Roller Conveyor System

The standard 4100-45-OHA includes three powered conveyor sections:

• Five-foot powered infeed conveyor
• Eleven-foot powered process and wrapping-zone conveyor
• Five-foot powered exit conveyor

Conveyor Construction and Performance

• Section capacity: Each conveyor section handles loads up to 4,000 pounds.
• Roller construction: The system uses 2-1/2-inch-diameter, 11-gauge rollers with 11/16-inch hex axles.
• Roller spacing: Three-inch centers provide consistent pallet support.
• Roller drive: ANSI #40 chains transfer power from roller to roller.
• Effective width: The conveyor provides 54 inches of usable roller width.
• Conveyor speed: Additionally, customers can specify a speed between 20 and 50 feet per minute.
• Acceleration: Electronic soft start provides controlled pallet movement.
• Pass-line height: The tops of the rollers sit 18 inches above the floor.
• Infeed and exit motors: Each section uses a 1/2 HP AC variable-speed reversible TEFC motor.
• Process motor: A 3/4 HP AC variable-speed reversible TEFC motor powers the wrapping zone.
• Pallet positioning: Finally, photo-eyes and PLC logic automatically index and center each load.

Consequently, the conveyor package can connect the wrapper with palletizers, accumulation conveyors and other material-handling equipment.

Automatic Film Clamp and Cut/Wipe System

The 4100-45-OHA pallet wrapper uses pneumatic components to manage the film tail automatically. First, the clamp captures and holds the stretch film at the beginning of the cycle. The rotary arm then applies the programmed wrap pattern.

After the final revolution, the film carriage and arm return to their finishing positions. Next, the pneumatic cut/wipe arm moves toward the load. A ni-chrome impulse hot wire cuts the film, and the arm wipes the remaining tail against the pallet.

Moreover, the automatic cleaning cycle helps maintain dependable hot-wire performance. As a result, the machine can complete successive wrapping cycles without requiring manual film attachment or cutting.

Powered Pre-Stretch Film Delivery

The 4100-45-OHA includes the Cousins Super Rapid Thread II™ 20-inch powered pre-stretch carriage. Its threading path increases film contact with the rollers and correctly positions the film’s cling side toward the load.

• Pre-stretch range: Fixed ratios extend from 33% to 313%.
• Ratio adjustment: Simple sprocket changes match pre-stretch to the selected film.
• Corner compensation: Additionally, electronic dynamic dancer control regulates film delivery around load corners.
• Carriage motor: A 1/2 HP AC variable-speed motor controls film output.
• Rapid threading: The special device simplifies film-roll installation.
• Safety interlock: Opening the Rapid Thread™ door interrupts carriage power.
• Roller contact: Greater film coverage helps reduce slipping during operation.
• Pre-stretch rollers: Finally, Cousins provides a lifetime warranty on the rollers.

Therefore, the carriage supports consistent containment while helping facilities control stretch-film consumption.

Film-Carriage Elevator

• Elevator motor: A 1/2 HP AC variable-speed motor moves the carriage.
• Drive system: A direct flat belt provides smooth vertical travel.
• Guidance system: Twelve maintenance-free points keep the carriage aligned.
• Speed adjustments: Meanwhile, independent raising and lowering controls determine film overlap.
• Dynamic braking: Controlled stopping supports repeatable carriage positioning.

PLC and Touchscreen Controls

Wrapping and Film Controls

The Panasonic FP-X PLC and HMI touchscreen provide access to production settings, manual functions and machine status.

• Wrap counts: Separate controls provide from 1–12 top and bottom revolutions.
• Film tension: Force-to-load control adjusts containment pressure.
• Carriage speed: Independent raising and lowering settings control film overlap.
• Height detection: Additionally, a triple-beam photo-eye recognizes dark or reflective loads.
• Rewrap function: A dedicated cycle-start button allows an additional wrap cycle.
• Dynamic braking: Controlled stopping supports precise arm and carriage positioning.
• Bypass mode: Finally, the selector allows pallets to travel through the system without wrapping.

Manual and Diagnostic Controls

• Rotary-arm jog: Operators can manually move the arm during setup or maintenance.
• Carriage movement: Raise and lower controls position the film carriage.
• Film clamp: In addition, manual open and close functions assist with setup.
• Conveyor direction: Forward and reverse controls help position pallets.
• Film monitoring: Broken-film and out-of-film detection identifies a loss of film tension.
• Automatic reset: The PLC can reset the system after a detected film fault.
• Fault beacon: A visible signal communicates machine status.
• Emergency stop: Finally, a dedicated button allows personnel to stop operation quickly.

Safety and Guarding System

The 4100-45-OHA includes several standard safety features:

• Arm obstruction sensor: Contact with an unexpected obstruction stops rotary-arm movement.
• Wire-mesh barriers: Guards enclose the wrapping zone and restrict personnel access.
• Interlocked access gates: Opening a gate disables machine operation.
• Emergency-stop circuit: Hard-wired controls provide direct shutdown.
• Dual-channel relays: Category 3 safety relays monitor the gate and emergency-stop circuits.
• NEMA 12 enclosures: Control panels and junction boxes protect electrical components.
• Dust-tight slip ring: Finally, the protected assembly supports reliable rotary-arm power transmission.

Because every production layout creates different access points, Ameripak should review guarding, light curtains, forklift traffic and pedestrian routes before installation.

Electrical and Pneumatic Requirements

Electrical Input

• Standard service: 208Y/120 volts
• Phase and frequency: Three phase, 60 Hz
• Amperage: 30 amps
• Alternate voltages: 230- or 460-volt three-phase configurations remain available.

Pneumatic Input

• Air volume: 3 CFM
• Air pressure: 80 PSI
• Air quality: Clean, dry compressed air
• Included equipment: Filter/regulator with gauge and lockout valve

Because optional conveyors, controls and voltage packages can change utility requirements, Ameripak should confirm the final electrical and pneumatic specifications before ordering.

Structural Specifications and Footprint

• Frame construction: Structural steel supports demanding production environments.
• Machine tower: Structural tubing supports the rotary-arm assembly.
• Protective finish: Electrostatic powder coating helps resist corrosion and wear.
• Typical length: Approximately 252 inches
• Typical width: Approximately 148 inches
• Typical height: Approximately 157 inches

These dimensions include the standard conveyors and control-panel position. However, additional conveyors, taller frames, larger load clearances or light curtains will increase the overall footprint.

How the 4100-45-OHA Cycle Works

First, upstream equipment transfers a pallet onto the powered infeed conveyor. Photo-eyes then index and center the load before moving it into the eleven-foot wrapping zone. Next, the pneumatic film clamp captures the stretch film.

Meanwhile, the rotary arm travels around the stationary pallet while the powered carriage follows the programmed wrap pattern. After the final revolution, the arm and carriage return to their finishing positions. The pneumatic mechanism then cuts and wipes the film tail. Finally, the exit conveyor transfers the completed load from the wrapping zone so the next pallet can enter.

4100-45-OHA Compared with the 6100-45-CTA

Both systems provide automatic conveyorized wrapping for up to 45 loads per hour. However, they move the stretch film around the pallet differently.

The 4100-45-OHA keeps the pallet stationary and rotates an overhead arm around it. In contrast, the 6100-45-CTA conveyorized automatic pallet wrapper rotates the load on an 80-inch turntable.

Therefore, the OHA often makes more sense for unstable, lightweight or top-heavy products. The CTA may provide a more compact solution for stable loads that can rotate safely. Ameripak can compare load characteristics, floor space and production requirements for both systems.

When to Choose Conveyorized Rotary-Arm Automation

The 4100-45-OHA works well when an operation needs:

• Fully automatic pallet movement
• Automatic film attachment and cutting
• Repeatable wrap patterns
• Consistent load containment
• Reduced operator handling
• Production-line integration
• Stationary wrapping for unstable loads
• Up to 45 loads per hour

In particular, the system suits automated facilities where pallet loads arrive continuously from production or palletizing equipment.

Why Purchase Cousins Equipment Through Ameripak?

Ameripak is a Cousins Packaging Master Distributor with more than 40 years of packaging-equipment experience. Therefore, customers receive application guidance, system coordination and continuing support in addition to the machine.

Ameripak Support Advantages

• Load evaluation: Ameripak reviews dimensions, weight, stability and pallet condition.
• Throughput analysis: Next, our team compares present production with projected growth.
• Technology selection: We determine whether rotary-arm or turntable wrapping best fits the loads.
• System layout: Additionally, Ameripak evaluates conveyor direction, accumulation and floor space.
• Utility review: Our team confirms electrical and pneumatic requirements.
• Guarding recommendations: We review fences, gates, light curtains and traffic flow.
• Equipment configuration: Ameripak helps select conveyors, controls and film-handling options.
• Film selection: Proper stretch film supports powered pre-stretch and containment performance.
• Cousins coordination: We communicate application requirements directly with the manufacturer.
• Startup support: Ameripak can assist with installation, commissioning and training.
• Continuing service: Finally, customers gain access to parts, technical assistance and preventative maintenance.

Available 4100-45-OHA Options

Available configurations may include:

• Tower extension for loads up to 110 inches high
• Frame extension for loads up to a 92-inch diagonal
• Additional five-foot powered conveyor sections
• Conveyor-ready configuration without the standard conveyor sections
• Alternate powered infeed or exit arrangements
• Load or unload forklift safety photo-eyes
• Muting light curtains with conveyor and fence extensions
• 230-volt three-phase electrical configuration
• 460-volt three-phase electrical configuration
• Automatic film slitting or roping equipment
• Pallet-lock roping device
• Recommended spare-parts kit

Because some options change the system footprint, guarding or utility requirements, Ameripak can verify the complete configuration before ordering.

Common Applications

The 4100-45-OHA pallet wrapper can support food and beverage facilities, consumer-goods manufacturers, distribution centers, warehouses and automated production lines. In particular, it suits unstable or lightweight pallets that need to remain stationary during wrapping.

Ultimately, the machine combines automatic conveyors, stationary-load rotary-arm wrapping and powered pre-stretch in a complete high-production system.