As production needs change, existing stretch wrapping equipment may need to adapt to new products, load heights, and performance requirements. In many cases, targeted aftermarket upgrades can improve results without requiring a complete machine replacement.

That was the opportunity identified when an Orion distributor contacted our aftermarket team on behalf of a customer operating two Orion RTD rotary tower semi-automatic stretch wrappers.

The customer was experiencing inconsistent load retention and concerns with the appearance of finished pallets. Shorter loads had also been introduced into production after the machines were originally installed, creating wrapping conditions that were not part of the initial application requirements.

To provide additional stability, operators were manually applying straps to the pallets with a battery-powered hand strapping tool. While the straps added reinforcement, they also required extra material and an additional production step.

Evaluating the Application

The Orion aftermarket team worked closely with the distributor and end user to understand the full wrapping process. This included reviewing the customer’s products, load heights, film application, wrap patterns, operating requirements, and the specific loads causing the greatest challenges.

Based on the evaluation, Orion recommended adding a pneumatic roping retrofit and supplemental short-load detection sensors.

Pneumatic roping gathers stretch film into a concentrated band, allowing additional containment force to be applied to targeted areas of the pallet. For this application, the roping process offered the potential to improve load-to-pallet bonding, reduce product movement, and create a cleaner, more consistent finished load.

The additional sensors would allow the machines to more accurately detect shorter pallets and apply the appropriate wrap cycle. This would help the equipment accommodate the customer’s expanded product mix and improve film placement across a wider range of load heights.

Testing the Solution

Before moving forward, the customer wanted to see how the proposed solution would perform with their products. Orion invited the customer to send representative loads to the facility for testing, including some of the most challenging pallet configurations.

The Orion team tested the loads using the recommended wrapping techniques and documented the process with photos and videos. This gave the distributor and end user a clear comparison of the loads before and after the proposed changes.

The testing demonstrated meaningful improvements in load stability, containment, and overall appearance. It also showed that the enhanced stretch wrapping process could eliminate the need for the manually applied straps.

Extending the Capabilities of Existing Equipment

Following the successful testing, the customer moved forward with the retrofit solution for its existing Orion wrappers.

The project highlights the value of reviewing stretch wrapping equipment as production requirements evolve. The machines were still capable systems, but the customer’s load profiles and operational needs had changed since the original installation.

Through application analysis, retrofit engineering, and real-world product testing, Orion helped the customer improve load containment, support shorter pallets, enhance finished load appearance, and reduce reliance on manual strapping. The result was a more efficient wrapping process and expanded capabilities from equipment already in place.