4100H-FS Hercules FS Pallet Wrapper

Heavy-Duty Rotary-Arm Wrapping for Large Loads

The 4100H-FS pallet wrapper uses a rugged four-post frame and powered rotary arm to wrap large pallet loads while they remain stationary on the facility floor. Because the machine rotates the arm instead of the pallet, it can handle heavy, unstable, lightweight or irregular loads without exposing them to turntable movement.

Moreover, the Hercules model provides greater load clearance and faster rotary-arm operation than standard Cousins 4100T semi-automatic wrappers. Therefore, it offers a practical solution for facilities that need stationary-load wrapping, larger load capacity and production rates up to 40 loads per hour.

Benefits of the 4100H-FS Pallet Wrapper

• Large-load capacity: The standard frame accommodates loads up to 56 inches wide and 56 inches long.
• Stationary load wrapping: The pallet remains on the facility floor during the complete cycle.
• No machine-imposed weight limit: Instead, the floor and material-handling equipment determine practical capacity.
• Higher production speed: The rotary arm can process up to 40 loads per hour.
• Four-post construction: Consequently, the frame provides stable support around the wrapping zone.
• Powered pre-stretch: Meanwhile, the film carriage improves film yield and containment consistency.
• Programmable operation: Operators can adjust wrap counts, arm speed, film force and carriage movement.
• Upgradeable film handling: Finally, automatic film-start and film-cutting options can reduce forklift-operator involvement.

For additional guidance, review turntable versus rotary-arm stretch wrappers in the Ameripak Learning Center.

4100H-FS Pallet Wrapper Specifications

Production and Load Capacity

• Production speed: 1–40 loads per hour
• Maximum machine-supported weight: Unlimited because the facility floor supports the pallet
• Maximum load width: 56 inches
• Maximum load length: 56 inches
• Maximum load diagonal: 79 inches
• Maximum standard load height: 80 inches
• Top film overlap: Up to 4 additional inches

Although the machine does not impose a turntable weight rating, the building floor, pallet and forklift must safely support the load. Therefore, Ameripak should review unusually heavy applications before finalizing the system.

Heavy-Duty Four-Post Frame

The Hercules frame uses four structural posts to support the rotary-arm assembly and define the wrapping area. This arrangement provides a stable foundation for larger products and faster arm rotation.

• Frame design: Four floor-mounted posts surround the wrapping zone.
• Construction: Heavy-duty structural steel supports industrial operation.
• Load access: The frame accommodates forklift or pallet-jack loading through the designated opening.
• Floor mounting: Appropriate anchors secure the structure during operation.
• Protective finish: Finally, electrostatic powder coating helps resist corrosion and wear.

Because the frame surrounds the wrapping zone, Ameripak should review forklift approach, pallet orientation, floor anchoring and traffic flow before installation.

Higher-Speed Rotary-Arm System

The rotary arm travels around the stationary pallet while the film carriage moves vertically. Therefore, large or unstable loads avoid the centrifugal force that a turntable would apply.

• Arm support: A 20-inch-diameter ring bearing supports rotation.
• Drive system: An ANSI #60 direct chain drive includes a chain tensioner.
• Rotational speed: Operators can adjust the arm from 3–15 RPM.
• Acceleration: Soft-start control reduces sudden movement at cycle startup.
• Final positioning: Additionally, controlled deceleration provides positive stop alignment.
• Arm motor: A 3/4 HP DC variable-speed motor powers rotation.
• Dynamic braking: Finally, the braking system controls rotary-arm and carriage movement.

Powered Pre-Stretch Film Delivery

The 4100H-FS pallet wrapper 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 pallet.

• 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 power.
• Roller contact: Greater film coverage helps reduce slipping during operation.
• Pre-stretch rollers: Finally, Cousins provides a lifetime warranty on the rollers.

Consequently, the carriage can improve containment consistency while helping facilities manage stretch-film consumption.

Film-Carriage Elevator

• Elevator motor: A 1/2 HP AC variable-speed motor moves the carriage.
• Chain drive: An ANSI #40 direct drive provides controlled vertical movement.
• Shock dampener: In addition, the drive cushions carriage travel.
• Guidance system: Twelve maintenance-free points keep the carriage aligned.
• Speed adjustments: Independent raising and lowering settings control film overlap.
• Dynamic braking: Finally, controlled stopping supports repeatable positioning.

Touchscreen Wrapping Controls

Wrap-Pattern and Film Controls

The Panasonic PLC and touchscreen operator interface provide direct access to the semi-automatic wrapping functions.

• Cycle start: A single button starts or pauses the automatic cycle.
• Wrap direction: Operators can select an up-only or up-and-down pattern.
• Starting position: In addition, the program can apply base wraps or top wraps first.
• Top and bottom wraps: Separate settings provide from 1–12 revolutions.
• Film tension: Force-to-load control adjusts containment pressure.
• Carriage speed: Independent raising and lowering settings control overlap.
• Rotary-arm speed: Variable control helps match movement to load stability.
• Reinforcement: Finally, the mid-cycle reinforce function adds film to selected areas.

Operator and Safety Controls

• Top-sheet pause: Operators can pause the cycle to apply a protective sheet.
• Load-height detection: A triple-beam photo-eye recognizes dark or reflective products.
• Manual arm movement: Additionally, the rotary-arm jog switch assists with setup.
• Carriage positioning: Raise and lower controls allow manual adjustment.
• Power functions: Off, on and reset controls include a power indicator.
• Emergency stop: A dedicated button stops machine operation.
• Control enclosure: The NEMA 12 panel protects industrial components.
• Slip-ring protection: A dust-tight assembly supports dependable power transmission.
• Service components: Finally, non-proprietary UL/CSA-approved parts simplify maintenance.

Standard Semi-Automatic Operation

In the standard configuration, the forklift operator positions the load inside the frame and attaches the stretch film to the pallet. After the operator starts the cycle, the rotary arm and film carriage complete the programmed wrapping pattern.

Once the arm returns to its home position, the operator cuts the film and removes the wrapped load. Therefore, the standard Hercules provides powered wrapping while retaining manual film attachment and cutting.

Optional Automatic Film Start and Cutting

Cousins offers two options that can reduce the amount of time an operator spends outside the forklift.

Automatic Film Cutter

The automatic cutter separates the film at the end of the wrapping cycle. As a result, the operator does not need to dismount solely to cut the film after every pallet.

Automatic Film Start

The automatic film-start option reduces manual film-attachment steps and includes wireless remote operation. Consequently, it can reduce the number of times the operator must bend down and handle the film tail.

Ameripak should review the desired operating sequence with Cousins to confirm which options provide the required level of operator independence.

Rotary-Arm Safety System

The 4100H-FS includes an obstruction-sensitive emergency-stop sensor on the rotating arm. If the arm contacts an unexpected obstruction, the sensor stops rotation to help protect personnel, the load and the equipment.

However, the rotating arm still requires a controlled operating area. Optional side fences can close the spaces between the frame posts, while a rear fence can protect the back of the machine. Additionally, a front sliding gate with an interlock can prevent operation while personnel enter the wrapping zone.

Electrical and Installation Requirements

Electrical Input

• Voltage: 115 volts
• Phase: Single phase
• Frequency: 60 Hz
• Amperage: 20 amps
• Standard pneumatics: No compressed air required for basic semi-automatic wrapping

Certain optional devices, including pallet-lock roping or air-flow equipment, may require compressed air.

Installation Planning

Before installation, Ameripak should verify:

• Floor condition and anchoring requirements
• Forklift or pallet-jack approach
• Pallet orientation inside the frame
• Rotary-arm sweep clearance
• Ceiling height
• Pedestrian and vehicle traffic
• Safety-fence placement
• Electrical connection location
• Optional pneumatic connection

Therefore, a layout review can prevent interference with columns, walls, doors, conveyors or traffic aisles.

How the 4100H-FS Wrapping Cycle Works

First, a forklift or pallet jack positions the load inside the four-post frame. The operator then attaches the film and selects the appropriate wrap program. Next, the operator starts the cycle from the control panel or available remote configuration.

Meanwhile, the photo-eye detects load height while the rotary arm travels around the stationary pallet. The powered carriage applies film according to the selected wrap counts, overlap and tension. After the final revolution, the arm decelerates and returns to its aligned stop position. Finally, the operator or optional film cutter completes the film-handling step.

Best Applications for the Hercules

The 4100H-FS works particularly well when a facility handles larger loads or needs greater semi-automatic production capability.

Typical applications include:

• Large industrial components
• Heavy machinery parts
• Tall or top-heavy pallets
• Lightweight products that may shift
• Unstable or irregularly stacked goods
• Building products
• Bagged materials
• Large containers
• Fragile products
• Loads with a high center of gravity

In particular, floor-supported wrapping can accommodate products that exceed the capacities of many turntable wrappers. However, the facility floor and material-handling equipment must still support the total pallet weight safely.

Hercules Compared with the 4100T-FS3

The Hercules and 4100T-FS3 both use free-standing frames and keep pallet loads stationary. However, the Hercules supports larger loads and higher production rates.

The 4100T-FS3 pallet wrapper accommodates loads up to 50 × 50 inches with a 71-inch diagonal and processes up to 30 loads per hour. In contrast, the Hercules accommodates loads up to 56 × 56 inches with a 79-inch diagonal and processes up to 40 loads per hour.

Moreover, the Hercules uses a heavier ring-bearing and chain-drive rotary-arm system. Therefore, it better suits larger products and applications that require additional speed.

Semi-Automatic or Fully Automatic Rotary Arm?

The standard Hercules still requires manual film attachment and cutting. Consequently, it provides greater speed and capacity without the additional complexity of a fully automatic conveyorized system.

Operations requiring automatic pallet transfer and film handling should consider a system such as the 4100-45-OHA conveyorized automatic pallet wrapper. Ameripak can compare labor requirements, production speed, floor space and integration costs for both approaches.

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, installation planning and continuing support in addition to the machine.

Ameripak Support Advantages

• Load evaluation: Ameripak reviews dimensions, weight, stability and pallet condition.
• Equipment selection: Next, our team determines whether the Hercules or another rotary-arm model best fits the application.
• Capacity analysis: We compare load dimensions and required production speed.
• Layout review: Additionally, Ameripak evaluates frame clearance, arm sweep and forklift traffic.
• Mounting guidance: Our team reviews floor condition, anchoring and ceiling clearance.
• Guarding recommendations: We help select fencing, gates and safety controls.
• Automation review: Ameripak evaluates automatic film-start and cutting options.
• Film selection: Proper stretch film supports containment and powered pre-stretch performance.
• Cousins coordination: We communicate application requirements directly with the manufacturer.
• Startup support: Ameripak can assist with installation, commissioning and operator training.
• Continuing service: Finally, customers gain access to parts, technical assistance and preventative maintenance.

Available 4100H-FS Hercules Options

Available configurations may include:

• Automatic film cutter
• Automatic film-start system with wireless remote
• 48 × 48 × 4-inch pallet platform
• Side safety fences
• Rear safety fence
• Front sliding safety gate with interlock
• Cold-weather package for operation down to 32°F
• Freezer package for temperatures as low as -20°F
• Dust-protection package
• Broken-film and out-of-film detection
• 30-inch film carriage for 20- or 30-inch film
• AC variable-speed drives
• Height extension for loads up to 110 inches
• Frame extension for loads up to an 86-inch diagonal
• Four-foot or five-foot platform scale packages
• Upgraded digital scale indicator
• Automatic film slitting or roping equipment
• Pallet-lock roping device
• Recommended spare-parts kit

Because some options change the frame dimensions, wrapping height, utilities or operating sequence, Ameripak can verify the complete configuration before ordering.

Common Applications

The 4100H-FS pallet wrapper can support manufacturers, building-products operations, distribution centers and heavy industrial facilities. In particular, it suits larger stationary loads that require more clearance or faster wrapping than standard semi-automatic rotary-arm systems provide.

Ultimately, the Hercules combines a rugged four-post frame, higher-speed rotary-arm operation and powered pre-stretch in a flexible heavy-duty wrapping system.