Baling is enhanced by wrapping

Setting a New Standard in Square Bale Wrapping

Designed and manufactured with a focus on high throughput and reliability, Rotowrap bale wrappers set a new standard in wrapping performance and efficiency    for square bales.

To effectively wrap a cube or square bale, the bale must be rotated along more than one axis. These rotations must be exact and relative to each other in order to ensure the correct amount and placement of the film around the bale – particularly in relation to the corners. Unlike most traditional bale wrapping units (which rotate on one axis at a time) Rotowrap’s design allows the unit to function through both axes simultaneously, improving efficiency and productivity by reducing the total time taken to wrap the bale. In addition, this simultaneous rotation capability also results in a significant reduction the energy required, the amount of film required and equipment wear and tear.

The fixed Rotowrap units are designed to be installed directly behind the baler. When the bale is ejected and pushed towards the Rotowrap, the automatic bale wrapping cycle starts, with the bale transported into the wrapper between the two oscillating rollers. These rollers lift the bale into the wrapping position, and then rotate it along its horizontal axis during the wrapping procedure. At the same time, the Rotowrap’s wrapping arm assembly – which is fitted with two 750mm wide rolls of film – rotates around the bale, applying the film.

Importantly, the Rotowrap process has been designed with a focus on eliminating material loss from the compacted MSW bales. The bale rotation process is extremely smooth, exact and controlled, and can be even be used with loose or weak bales without material loss.

Rotowrap’s automatic Film Break Control system constantly monitors the wrapping operation. In the event of a film breakage on one of the two rolls, or if one of the rolls runs out, the machine automatically switches to ‘single roll’ mode to finish the job – maximising productivity and minimising downtime by eliminating the need to stop the baling process due to a single breakage. In the unlikely event of both film rolls breaking, the Rotowrap halts the bale wrapping process until the problem is rectified.

The Rotowrap units can cater for a wide variety of bale dimensions and wrapping requirements. As an example, when compared to a cube or ‘Square Bale’ an elongated rectangular shaped bale will have significantly differing rotation speeds between the corner of the bale and the middle of the bale. By always knowing where the bale is positioned on the rollers, Rotowrap’s intelligent bale handling system is able to control the speed and rotation of the bale to ensure that the wrapping arms are able to apply the film correctly to all areas, including the corners of the bale. In addition, the Rotowrap units allow for adjustments to be made to the amount of overlap between layers, as well as the total number of layers, thereby allowing the bale wrapping procedure to be optimised to suit specific conditions and requirements. 

Rotowrap’s patented roller measuring device delivers consistent, high quality wrapping regardless of the bale size. Rotowrap models are available to suit bale sizes ranging from 27" x 27" x 32" right through to 55" x 47" x 79" and bale weights up to 5300 lb..

Once the wrapping procedure is complete, the film is automatically cut in readiness for the next bale. Compared to many traditional bale wrapping systems – which use additional film to create a ‘knot’ for a controlled break between bales - this ‘Cut & Tie’ system results in a significant reduction in total film usage. The wrapped bale is then transported out of the wrapping section onto the collection conveyor, from where it can be picked up by a forklift.

The finished result is a tightly wrapped bale which is easy to lift, transport and store until required. The quality of the wrap prevents odours, litter problems and leachate issues, whilst also minimising the risk of attracting vermin. Furthermore, once the baled MSW is required for use, the polyethylene stretch film can either by recycled or used in the ‘Waste to Energy’ process.