Double Press
Precision Block Former & Automatic Stretch Wrap System
(AWS)

The System The Precision Block Former & Automatic Stretch Wrap System (AWS) is a fully automatic and highly flexible system that forms precise blocks, delivers them to an automatic wrap station where the stretch wrap is applied, and then stacks them two-high in a staging area ready to be loaded into a container.
(Click on photos for larger views.)

Loading In the typical application, the AWS is integrated with one of our presses for continuous, hands-free operation. The photo above shows half-cut bales coming from a 3-tie press, but the AWS will also work with the Cut Down Bale Press.

The accumulator pushes a layer of bales into position, and the AWS stacks them into a predetermined configuration. Moving on an overhead gantry, the AWS clamp can move in a three-axis space simultaneously, speeding output considerably.

Squaring Before moving to the stretch-wrapping station, the clamp releases the stack, rotates 90o and squeezes again to square the block load before placing it on one of two stretch-wrapping stations. Accuracy of placement is within 1/4 inch.

Stretch-wrapping The AWS features two fully automatic wrapping stations on a moving treadle. As one block is being wrapped, the clamp is stacking and placing the second block in the ready position.  The stretch wrap is held to the stack until it is trapped by the next layer. The tail is clipped and heat sealed to the block automatically.  The number of wraps is software configurable. The only operator involvement is replacing full rolls of stretch wrap material.

Stacking Once the wrapping is complete, the clamp takes the completed block and moves it to the staging area, ready for a lift truck operator. The AWS has the capability of stacking two blocks high and five wide. If  the staging area becomes full and an lift truck operator is not available , the system will pause automatically.

A variety of block configurations are software controlled, including a five-layer half-cut block stacked on top of a four-layer block to optimize the fit into a high cube shipping container.

 

Control The system is controlled by the press operator via the Auto Wrap System control panel and the Press Panel View. Operation typically involves turning the system on, selecting the type and number of blocks or combination of blocks desired, starting automatic, and making sure that the wrapper has film.

Alternate Uses For loads not requiring blocks or wrapping, the block former is simply moved to its shutdown position and the hay can be accumulated up to 5 wide for pick up with a forklift clamp or grapple.

What's In It For You? The system eliminates virtually all man-hours and forklift/clamp wear and tear associated with removing pressed bales from the press, forming blocks to be wrapped, delivering the blocks to the stretch wrapper, operating the stretch wrapper and stacking the blocks prior to loading them in the container. It also results in tighter and more consistent finished blocks than the traditional forklift/clamp approach by doing each step exactly the same every time.

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Specifications

Speed: 30 Blocks (12 bales each) per hour for standard blocks with single layer accumulation. Unique block configurations may reduce speed, and two layer accumulation will increase speed. (see stacking accumulator)

Block Size: 32" to 52" wide X 32" to 52" deep X 24" to 60" high.

Block Types: Virtually any block configuration within the block size limitations can be programmed. New block configurations can be added at any time with program changes; no hardware changes are required.

Label Application: Labels are manually applied by the forklift driver when the blocks are picked up for loading into the container.

Space Requirements: 40 feet long X 21 feet wide X 20 feet high, with some flexibility in length and layout to fit existing facilities. (Footprint)

Control System: Computerized control with direct communication to the Press computer system for fully coordinated operation. Full manual operation is possible via the Auto Wrap System Control Panel located on the Press Operator's platform.

Power Requirements: One 480VAC, 3-phase, 40 horsepower pump power circuit and one 120VAC, single phase, 20 amp control power circuit.

Hydraulic Oil Source: The Press Reservoir. No additional reservoir, cooling or filtering is required.