Maintenance & Reliability · SOP

Automated Stretch Wrapping Machine Film Tension Adjustment

Proper film tension is critical for load containment, film cost control, and film breakage prevention. This SOP covers the standard method for adjusting tension on any automated stretch wrapper equipped with a pre-stretch carriage.

Estimated Time

15 min

Difficulty

Intermediate

Regulation

ANSI/ASME B20.1

Version

1.0

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Purpose

To provide a standardized procedure for adjusting film tension on an automated stretch wrapping machine. Adjusting tension within the manufacturer's specifications ensures consistent load integrity, reduces film waste, prevents film jams, and extends the life of the pre-stretch rollers and clutches.

Scope

This SOP covers tension adjustment on automated stretch wrappers with manual pre-stretch tensioners (bolt/spring type) commonly found in high‑speed distribution and manufacturing environments. It applies to all models in the Ryxen shop fleet; for specific torque values consult the machine's OEM manual.

Safety Precautions

LOTOLockout/tagout the machine at the main disconnect and verify zero energy with a qualified voltage tester before any adjustment.
PPEWear cut‑resistant sleeves and safety glasses when handling film roll and accessing the carriage. Film edges can cause severe lacerations.
PINCHKeep hands clear of moving rollers and pinch points during operation. Never adjust tension while the machine is running.

Required Tools & Materials

Torque wrench (in‑lbs range, 0–50 in‑lbs)
Digital film tension gauge (optional but recommended)
Allen key set (metric/imperial as per machine)
Replacement film roll of correct width and gauge
Lockout/tagout kit (padlock, hasp, tag, lockout device)
Cut‑resistant sleeves and safety glasses

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Procedure: Step-by-Step

1 Lockout/tagout. Shut off the main power disconnect and apply lockout/tagout. Verify zero energy using a voltage tester at the control panel and at the film carriage motor.

2 Remove existing film roll. Open the film carriage guard. Unspool any remaining film and remove the roll. Inspect idler rollers for wear, debris, or damage. Clean rollers with a lint‑free cloth if necessary.

3 Loosen tension adjustment bolts. Locate the tension adjustment bolts on the pre-stretch carriage (typically two bolts acting on a spring plate). Use the correct Allen key to back off the bolts until they spin freely — do not remove them completely.

4 Set initial tension. Using the torque wrench, tighten each bolt evenly to the manufacturer's specified torque (commonly 15–25 in‑lbs). For machines without a torque spec, tighten in 5 in‑lbs increments until the spring compresses by 3–5 mm. Alternate between bolts.

5 Load new film roll. Install the new film roll, ensuring the film unwinds in the correct direction (usually clockwise). Thread the film over all idler rollers and through the pre-stretch rollers according to the routing diagram on the carriage guard.

6 Perform test wrap and measure tension. Remove lockout/tagout and re‑energize the machine. Run a single test cycle on a pallet of representative weight. During the wrap, use a digital film tension gauge on the film span between rollers. Target tension is typically 15–25% of film break force (check film spec sheet).

7 Fine‑tune if needed. If film tension is too low (loose wrap, film wrinkling) or too high (film stretching white, breakage), repeat steps 3–6, adjusting torque in 2 in‑lbs increments. Document the final torque setting in the PM log.

Automated Stretch Wrapping Machine Film Tension Adjustment

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