6100-45-CTA Conveyorized Automatic Pallet Wrapper

High-Production Conveyorized Pallet Wrapping

The 6100-45-CTA pallet wrapper provides fully automatic, conveyorized stretch wrapping for production environments processing up to 45 pallet loads per hour. Its standard system includes a five-foot powered infeed conveyor, an 80-inch turntable conveyor and a five-foot powered exit conveyor.

Moreover, automatic indexing moves each pallet into position and centers it through photo-eye and PLC logic. The machine then attaches the film, wraps the load, cuts the film and transfers the completed pallet toward the next production stage. As a result, the 6100-45-CTA reduces manual handling while delivering repeatable wrapping performance.

Benefits of the 6100-45-CTA Pallet Wrapper

• High-production performance: The system processes up to 45 loads per hour under the appropriate operating conditions.
• Complete conveyor package: Standard equipment includes powered infeed, process and exit sections.
• Automatic pallet positioning: In addition, photo-eye and PLC controls index and center each load.
• Automatic film handling: Pneumatic mechanisms attach, cut and wipe the film without operator intervention.
• Powered pre-stretch: Meanwhile, the film carriage improves film yield and containment consistency.
• Reduced downtime: Film monitoring, machine diagnostics and adjustable controls support production continuity.
• Heavy-duty turntable: A ring-gear drive supports loads up to 4,000 pounds during rotation.
• Integrated safety system: Finally, barriers, an interlocked access gate and dual-channel safety relays protect the wrapping zone.

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

6100-45-CTA 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 dimensions: 50 inches wide × 50 inches long × 82 inches high
• Maximum load diagonal: 71 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, conveyor speed and upstream product flow affect actual throughput, Ameripak can calculate a realistic production range for the application.

High-Speed Turntable

• Turntable diameter: 80 inches
• Turntable design: A protective skirt surrounds the rotating platform.
• Dynamic capacity: The turntable handles loads up to 4,000 pounds.
• Support system: A 29-inch ring gear supports the platform.
• Drive method: Direct pinion-to-gear power transfer provides controlled rotation.
• Rotational speed: Operators can adjust the turntable from 1–20 RPM.
• Cycle movement: Additionally, soft-start acceleration reduces sudden load movement.
• Final positioning: Controlled deceleration brings the turntable to a positive stop.
• Lubrication: Finally, a remote centralized system simplifies ring-gear lubrication.

Standard Power Roller Conveyor System

Unlike smaller automatic wrappers that require optional conveyor additions, the standard 6100-45-CTA includes three powered conveyor sections.

Included Conveyor Sections

• Five-foot powered infeed conveyor
• 80-inch powered turntable 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.
• Drive system: ANSI #40 chains transfer power from roller to roller.
• Effective roller width: The conveyor provides 54 inches of usable width.
• Conveyor speed: Additionally, customers can specify a speed between 20 and 50 feet per minute.
• Acceleration: Electronic soft start provides smooth pallet movement.
• Pass-line height: The tops of the rollers sit 18 inches above the floor.
• Conveyor motor: A 1/2 HP AC variable-speed reversible TEFC motor powers each section.
• Load positioning: Finally, photo-eyes and PLC logic automatically index and center the pallet.

Therefore, the conveyor package can connect the wrapping process with upstream palletizing and downstream material-handling equipment.

Automatic Film Clamp and Cut/Wipe System

The standard 6100-45-CTA pallet wrapper uses pneumatic components to control the film tail. First, the film clamp captures and holds the stretch film. The machine then completes the programmed wrapping cycle.

After the final revolution, the turntable decelerates and aligns with the film-handling assembly. Next, the pneumatic cut/wipe arm moves toward the wrapped load. A ni-chrome impulse hot wire cuts the film between the clamp and pallet. Finally, the arm wipes the remaining film tail against the load.

Moreover, the automatic cleaning cycle helps maintain reliable hot-wire performance. This arrangement supports continuous production without requiring an operator to attach or cut film manually.

Powered Pre-Stretch Film Delivery

The 6100-45-CTA includes the Cousins Super Rapid Thread II™ 20-inch powered pre-stretch carriage. Its film path maximizes contact with the pre-stretch rollers and positions the film’s cling side toward the load.

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

Consequently, the carriage can improve containment consistency while helping reduce unnecessary stretch-film consumption.

Film-Carriage Elevator

• Elevator motor: A 1/2 HP AC variable-speed motor moves the film carriage.
• Chain drive: An ANSI #40 direct drive provides controlled vertical movement.
• Shock protection: In addition, the drive includes a dampener that cushions carriage movement.
• Anti-fall device: A dedicated mechanism protects against an uncontrolled carriage drop.
• Guidance system: Finally, 12 maintenance-free guidance points keep the carriage aligned.

PLC and Touchscreen Controls

Wrap-Program Controls

The Panasonic FP-X PLC and HMI touchscreen give operators 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 speeds: Independent raising and lowering settings control film overlap.
• Turntable movement: Dynamic braking supports controlled deceleration and positioning.
• Height detection: Additionally, a triple-beam photo-eye detects dark or reflective loads.
• Rewrap function: A dedicated cycle-start button allows an additional wrapping cycle.
• Bypass mode: Finally, the selector lets pallets travel through the system without wrapping.

Manual and Diagnostic Controls

• Turntable control: Operators can manually jog the turntable 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 film loss.
• Automatic reset: The control system can reset the machine 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.

Electrical and Pneumatic Requirements

Electrical Input

• Standard service: 208Y/120 volts
• Phase and frequency: Three phase, 60 Hz
• Amperage: 30 amps
• Alternate voltages: Cousins offers other voltage configurations after factory review.

Pneumatic Input

• Air volume: 3 CFM
• Air pressure: 80 PSI
• Air quality: Clean, dry compressed air
• Included preparation equipment: Filter/regulator with pressure 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 and Safety Systems

Heavy-Duty Construction

• Machine structure: Structural steel supports demanding production environments.
• Base design: Forklift pockets allow relocation when the system permits safe movement.
• Machine tower: A structural steel H-beam supports the film-carriage assembly.
• Protective finish: Finally, electrostatic powder coating helps resist corrosion and wear.

Wrapping-Zone Protection

• Safety barriers: Physical guards enclose the turntable section.
• Access gate: An interlock disables machine operation when personnel open the gate.
• Emergency-stop circuit: Hard-wired controls provide direct machine shutdown.
• Safety relays: Category 3 dual-channel relays monitor the gate and emergency-stop circuits.
• Control enclosures: Additionally, NEMA 12 panels and junction boxes protect electrical components.
• Slip-ring protection: A dust-tight assembly supports reliable turntable operation.
• Service components: Finally, non-proprietary UL/CSA-approved parts simplify replacement and maintenance.

Typical System Dimensions

• Overall length: Approximately 202 inches
• Overall width: Approximately 143 inches
• Overall height: Approximately 100 inches

These measurements represent the standard system. However, additional conveyors, extended towers, guarding packages and light curtains will increase the overall footprint.

How the 6100-45-CTA Wrapping Cycle Works

First, upstream equipment transfers a pallet onto the powered infeed conveyor. Photo-eyes then index and center the load before releasing it onto the 80-inch process turntable. Next, the pneumatic film clamp captures the film, and the turntable begins rotating.

Meanwhile, the triple-beam photo-eye detects load height while the powered carriage follows the programmed wrap pattern. After the final revolution, the turntable decelerates and stops in the correct position. The pneumatic arm then cuts and wipes the film tail. Finally, the powered exit conveyor removes the completed pallet so the next load can enter the wrapping zone.

6100-45-CTA Compared with the 3300-CTA

Both systems provide conveyorized turntable wrapping with automatic film attachment and cutting. However, the 6100-45-CTA offers a more complete standard conveyor package and greater production capability.

The 3300-CTA conveyorized automatic pallet wrapper processes up to 40 loads per hour and includes the powered turntable process section, while its infeed and outfeed conveyors remain optional. In contrast, the 6100-45-CTA processes up to 45 loads per hour and includes powered infeed and exit sections as standard equipment.

Moreover, the 6100-45-CTA uses faster turntable operation, wider conveyors and automatic load indexing. Therefore, it better suits integrated production lines with continuous pallet flow.

Standard Film Clamp or Optional A-Arm?

The standard 6100-45-CTA uses a pneumatic clamp and cut/wipe arm. However, Cousins also offers its patented A-Arm technology as an optional replacement for that assembly.

The A-Arm starts and finishes the wrap process near the top of the load. As a result, it eliminates the traditional turntable clamp and changes how the machine captures and cuts the film. A 30-inch film carriage cannot accompany the A-Arm option.

Facilities considering A-Arm technology can also review the 3300-A Conveyorized A-Arm automatic pallet wrapper.

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 throughout the equipment’s service life.

Ameripak Support Advantages

• Application evaluation: Ameripak reviews load dimensions, weights, pallet condition and stability.
• Throughput analysis: Next, our team compares present production with projected growth.
• System layout: We evaluate pallet flow, conveyor direction, accumulation and available floor space.
• Utility review: Additionally, Ameripak confirms electrical and pneumatic requirements.
• Equipment configuration: Our team helps select film handling, conveyors, controls and guarding.
• Cousins coordination: Ameripak communicates application details directly with the manufacturer.
• Installation planning: We can assist with placement, startup and operator training.
• Stretch-film selection: Proper film supports powered pre-stretch performance and containment.
• Continuing support: Finally, customers gain access to replacement parts, technical assistance and preventative-maintenance support.

Available 6100-45-CTA Options

Available configurations may include:

• Cousins patented A-Arm film-control technology
• 20-inch or 30-inch Super Rapid Thread II powered pre-stretch carriage
• Tower extension for loads up to 110 inches high
• Additional powered infeed or outfeed conveyor sections
• Gravity outfeed conveyor with tapered end stop and full-conveyor detection
• 230-volt three-phase electrical configuration
• 460-volt three-phase electrical configuration
• Allen-Bradley PLC upgrade
• Enhanced 78-inch wire-mesh safety guarding
• Muting light curtains with conveyor and fence extensions
• Automatic film slitting or roping equipment
• Pallet-lock roping device
• Recommended spare-parts kit

Because some options conflict with one another, Ameripak can confirm compatibility during system configuration.

Common Applications

The 6100-45-CTA pallet wrapper can support food and beverage operations, consumer-goods manufacturers, distribution centers, warehouses and automated production facilities. In particular, it suits stable pallet loads that can rotate safely at higher turntable speeds.

Ultimately, the system provides a practical step into high-production conveyorized wrapping without moving immediately to a faster or more complex automatic wrapping line.