How to pack heavy cargo pallets?

Intelligent Upgrade! The new generation of Pallet Wrapping Machines solves packaging pain points for businesses.

With a 300% increase in efficiency and a 22% reduction in film costs, these innovative technologies are reshaping the packaging industry.

Driven by the wave of manufacturing automation and improved logistics efficiency, Pallet Wrapping Machines are undergoing an unprecedented intelligent transformation. In August 2025, several companies released innovative technologies, offering new solutions to address efficiency bottlenecks and cost challenges in the packaging process.

Technological Breakthrough: Triple Upgrades in Quietness, Intelligence, and Automation

Shandong Keepway Machinery Technology's newly developed wrapping production line utilizes a silent motor and precision gear transmission technology, along with shock-absorbing pads and a soundproof enclosure, keeping operating noise to below 70 decibels, well below the national industrial workplace limit of 85 decibels.

This technological breakthrough has directly improved the work environment. After implementing this production line in the packaging workshop of an electronics factory, employee ratings of the work environment increased by 45%, noise-related leave rates decreased by 40%, and the company saved significant labor and training costs.

Even more noteworthy is the deep integration of AI technology. KABWAY's production line has been embedded with an adaptive algorithm. Through machine learning, the system accumulates packaging data for different goods and automatically optimizes wrapping parameters (such as speed, number of wraps, and stretch ratio). For fragile goods, the algorithm automatically increases the number of top wraps and reduces the stretch ratio. For goods with an offset center of gravity, the wrapping order is adjusted to enhance stability.1

After introducing this AI production line, a home appliance company reduced packaging parameter debugging time from the traditional two hours to 10 minutes, and the breakage rate of packaged goods during transportation testing dropped significantly by 85%.

The automation sector is also experiencing significant success. On August 4th, AIMAY Automation Technology (Nanjing) Co., Ltd. was granted a patent for an "Automatic Pallet Stacking Device" (Grant No. CN223175276U). This device uses a gripping mechanism to grip pallets from the roller conveyor and uses a lifting cylinder to assist in stacking. This allows pallets to be separated from the roller conveyor during stacking without affecting subsequent pallet transportation, significantly improving efficiency.2

On August 6th, Haotian Automation Equipment Co., Ltd. also received a patent (CN223187734U) for a "Fully Automatic Stretch Film Wrapping Machine." This innovative design features automatic cutting and suction of film joints. A pneumatic cylinder drives a lifting frame to press the film against the surface of the object to be packaged. After the cutter completes the cut, a suction strip immediately absorbs the film joint to prevent it from loosening, effectively reducing manual intervention.

Market Demand: The Selection Dilemma Behind an Average Annual Growth of 12%

According to a 2024 survey by the China Federation of Logistics and Purchasing, market demand for wrapping machines is growing at an average annual rate of 12%. With the advancement of warehouse automation in enterprises, fully automatic wrapping packaging machines are expanding from single-model models to multi-purpose and customized models to accommodate the packaging needs of goods of varying sizes, weights, and shapes.

Behind this booming market lies a widespread selection dilemma:

38% of manufacturing companies experience packaging cost overruns of more than 15% due to improper wrapping machine selection.

27% of logistics companies have experienced production line downtime exceeding four hours due to equipment failure.

Companies' requirements for wrapping machines have evolved from simple functional requirements to comprehensive considerations of intelligence, customization, and cost-effectiveness. These requirements require machines that can adapt to the specialized packaging needs of diverse industries, such as automotive parts, food and beverages, and building materials, while also utilizing advanced technology to reduce film consumption and providing fast, localized service.

In terms of technical requirements, CNOOC's recent procurement announcement for wrapping film balers specifies: a packaging height of at least 2.3 meters, a turntable diameter of at least 180 cm, and a turntable load capacity of at least 2,000 kg.

These specifications represent the current market demand for heavy-duty, high-efficiency wrapping equipment.

Industry Benchmark: Five Innovative Solutions Leading Market Change
1. Multifunctional Integrated Model: KABWEI SA-LS-600 Vertical Wrapping Packer
This machine integrates wrapping, weighing, and labeling functions. It simultaneously detects weight with ±5g accuracy and prints information labels during the wrapping process. Labels contain weight, production date, batch number, and other data, enabling integrated packaging and traceability.

The wrapping parameter library can store 50 recipes, and the response time for product switching is less than 3 seconds. For custom-shaped vertical products (such as barrels with handles and irregular bottles), this machine is equipped with flexible pressure rollers that adapt to the product's contours.

In the food processing industry, a seasoning company used this machine to reduce the packaging, weighing, and labeling processes from three operators to one person, increasing single-shift production by 40% and reducing the mis-shipping rate to zero.

2. Film Management Expert: KABWEI Film Management System
Film costs account for a significant portion of packaging operating costs. The film management system developed by KABWEI uses sensors to monitor film remaining volume, tension, and stretch ratio in real time. It automatically issues an alert when film is nearing depletion and immediately adjusts motor speed to compensate if abnormal tension is detected.

The system automatically identifies the thickness and material of different film batches and matches the corresponding stretch parameters. After using this system, a daily necessities company reduced film waste from 8% to 2%, saving 35,000 yuan in annual material costs. Furthermore, due to the stable tension, packaged goods are stacked more neatly, increasing warehouse utilization by 10%.

3. King of Energy Efficiency: KABWEI TP Series Pallet Wrapping Machine

Shandong KABWEI's TP Series utilizes a PLC programmable control system and variable frequency speed regulation technology. The turntable speed is infinitely adjustable from 0 to 12 rpm, and a slow-start and slow-stop design ensures a smooth packaging process. Its pre-stretched film rack structure increases the film stretch ratio to 300%, reducing film consumption by 18%-22% compared to traditional equipment.

Based on an average daily packaging capacity of 200 pallets, this can save over 30,000 yuan in film costs annually. The equipment boasts an adjustable lifting speed of 0-15m/min and a packaging height range of 500-2400mm, meeting the packaging needs of goods of varying specifications, such as automotive parts, glassware, and food and beverages.

4. Palletless Solution: KBOW Online Top-Down Wrapping Machine
For loose materials, KBOW Equipment's patented "Online Top-Down Wrapping Machine" (CN222373160U), acquired in January this year, utilizes a combination of a lifting cylinder and linear guide rails to automatically compress the goods during wrapping, improving packaging stability.

The added clamping mechanism and thermal insulation rods on the swing arm automatically break the film, reducing operating costs. It excels in handling loose materials, meeting the higher demands placed on packaging equipment in modern production.

5. Safety Benchmark: KBOW's Safety Protection System
Safety is always a top priority for industrial equipment. The safety protection system of Keepway  wrapping packaging line meets the highest industry standards. Infrared safety light curtains and protective fencing surround the production line, triggering an emergency stop if personnel enter a hazardous area. Key rotating components are equipped with protective covers and interlocks. The electrical system features a double-insulated design and is CE certified.

The system also features self-diagnostic fault detection, automatically shutting down the machine and displaying the fault location and troubleshooting instructions when it detects motor overload or sensor anomalies. After implementing this line, an automotive parts manufacturer achieved a zero-safety incident record in its packaging workshop.

Future Trend: The "Nerve Endings" of Smart Factories
With the deep integration of the Industrial Internet and artificial intelligence technologies, the next generation of wrapping packaging machines is evolving from standalone equipment to the "nerve endings" of smart factories. KABWEI's remote monitoring and management system now collects real-time equipment operating data (such as packaging quantity, film consumption, and equipment status) and uploads it to a cloud-based management platform.

Managers can remotely monitor equipment status via a mobile app or computer. When equipment fault warnings occur, the system automatically sends push notifications to relevant personnel. A group enterprise uses this feature to centrally manage wrapping machines across multiple sites, increasing equipment utilization by 15%.5

In the future, fully automatic wrapping machines will develop towards a highly intelligent, flexible, and environmentally friendly approach. These machines will possess enhanced data exchange capabilities, supporting advanced features such as remote operation and maintenance, self-learning control, and automatic optimization of packaging parameters, enabling truly intelligent packaging management.8

With the widespread adoption of intelligent logistics processes like AGV handling and automated palletizing, fully automatic wrapping machines will be further integrated into the overall intelligent logistics system, becoming a key component in enterprises' full-process automation upgrades.58

In an increasingly competitive market, these technological innovations not only represent a leap forward in packaging efficiency but also symbolize the remarkable transformation of China's manufacturing industry from "manufacturing" to "intelligent manufacturing." Embracing intelligent packaging solutions will give companies a head start in improving quality and efficiency.