Automated Stretch Wrapping for HVAC & Sheet Metal Ductwork
Secure long, lightweight, and hollow spiral pipe ductwork, fabricated ductwork, insulated rectangular ducts, and massive sheet metal components. Because the load is wrapped horizontally, our continuous-flow orbital packaging cells provide 360-degree containment to eliminate crushed seams, metal banding damage, and rolling loads. Engineered specifically for custom HVAC fabricators to eliminate the labor-intensive hand-wrapping of long runs, allowing you to wrap long loads in under a minute with one operator. Featuring native ERP and WMS connectivity (via OPC UA, MQTT, and EtherNet/IP) for direct string-based data exchange, robotic cell synchronization, and real-time predictive maintenance diagnostics.
Explore the Core Technology: View our complete lineup of Horizontal & Orbital Stretch Wrapping Machines.
The Rolling Bottleneck: Stabilizing Spiral Ducts
By nature, spiral pipe is cylindrical and wants to roll right off the pallet or conveyor before it can be packaged. Hand-wrapping these awkward, rolling metal assemblies is a slow and physically dangerous process for warehouse operators in small to medium HVAC fabrication shops.
The Solution: Absolute load control for long products fed horizontally through a stationary rotating ring. The Dynawrap Joy 1550 and Pro Series machines can be equipped with pneumatic top-pressers and adjustable side alignment rollers. As the spiral duct enters the machine, it is gently clamped from the top and cradled from the sides, keeping the cylindrical load perfectly stationary while the orbital ring secures it to the skid.
The Damage Bottleneck: Crushed Standing Seams
Sheet metal is rigid but hollow. When operators use ratcheted steel banding or heavy poly strapping to secure rectangular duct runs to a pallet, the localized pressure instantly crushes the standing seams and deforms the duct wall, leading to job-site rejection.
The Solution: Distributing the tension. The Dynawrap Pro 1700 solves this by replacing banding entirely. Utilizing precision tension control, the machine spreads the holding force across a wide, multi-layer web of stretch film. Unlike turntable wrappers, our systems can easily accommodate products well beyond pallet edges, fastening the ductwork securely without concentrating destructive force on fragile seams or corners.
The Size Bottleneck: Massive Industrial Ducting
Commercial HVAC fabricators don't just build small residential runs. While a 24x24" rectangular duct is standard, industrial exhaust systems and heavy commercial ductwork can easily exceed 48x48" cross-sections, making them impossible to pass through standard packaging equipment. (Note: Wrapping large residential HVAC cabinets or commercial condenser units? Our heavy-duty wrappers for Large Home Appliances & White Goods provide the massive ring clearance required for tall, bulky profiles.)
The Solution: Extreme ring clearance & Enterprise Integration. For these massive sheet metal components, the Pro 1900 and Dynawrap Pro 2200 provide the sheer volumetric capacity required. Featuring industry-leading orbital ring diameters, these machines easily swallow oversized duct runs, serving as fully automatic production-line systems for high-volume environments. Driven by flexible enterprise PLC architectures (Beijer, Siemens, Allen-Bradley, and Beckhoff), the system connects via EtherNet/IP or native OPC UA servers to execute direct string-based data exchanges with your ERP/WMS. This allows dynamic processing of custom duct production orders, while MQTT telemetry streams real-time predictive maintenance diagnostics directly to your cloud.
The Handling Bottleneck: Moving Awkward Assemblies
HVAC components are incredibly bulky and notoriously difficult to handle smoothly on a production line. Pushing lightweight but oversized sheet metal assemblies across gravity rollers often leads to snagging, tearing, and misalignment.
The Solution: Enterprise-grade material handling. We integrate our orbital wrappers with customized, heavy-duty motorized roller conveyors and high-friction PVC belt feeds. These continuous pass-through conveyor systems ensure that even the most awkwardly shaped ductwork is driven smoothly and consistently through the wrapping zone.
Enterprise Automation: Dynawrap LUMI™ 3D Algorithmic Vision
Achieve true recipe-free autonomy on your custom fabrication line. Available as an option across the Joy and Pro Series, the LUMI™ System utilizes an Intel® depth-sensing 3D camera and a dedicated embedded controller housed in a rugged industrial enclosure.
Volumetric Scanning
As irregularly shaped ducts and varying diameters enter the zone, the system executes real-time 3D scanning to determine the exact load geometry.
Automated PLC Handshake
Our proprietary algorithm automatically calculates and pushes the optimal wrapping parameters directly to the machine's PLC.
Zero-Touch Operation
Operators simply select 'Optimum' or 'Heavy' protection modes on the HMI, and the machine handles the rest - eliminating operator error and crushed seams.
Industry 4.0 Ready: Robotic Cell Integration
Engineered for absolute end-of-line autonomy. Our Pro Series wrappers serve as plug-and-play nodes for highly automated sheet metal fabrication environments, supporting direct handshakes with FANUC, ABB, KUKA, and Universal Robots.
Native SCADA Protocols
Seamless communication via EtherNet/IP, PROFINET, Modbus TCP, OPC UA, and MQTT for centralized ERP/WMS data exchange and telemetry logging.
Automated Handshakes
Standardized execution I/O (Ready, Start, Busy, Complete, Fault) allowing upstream robots to safely load and trigger wrapping cycles.
Predictive Maintenance
Stream real-time VFD faults, motor speeds, heater temperatures, and cycle counts directly to command centers to eliminate unplanned downtime.
EHS Perimeter Safety
CIP Safety and PROFIsafe network integration, paired with hardwired optical light curtains for zero-touch, fail-safe operational security.
HVAC Consumables Ecosystem
Sheet metal demands specialized packaging to maintain structural integrity and finish. Our premium Cast Clear Machine Stretch Film is the industry standard for securing ductwork, offering excellent load retention and high clarity without the noise of blown film.
For raw sheet metal and galvanized steel that is highly susceptible to oxidation during transit, we strongly recommend deploying our VCI (Volatile Corrosion Inhibitor) Stretch Film. This specialized film emits rust-inhibiting vapors directly into the packaged ductwork, completely eliminating moisture-related oxidation before installation.
Technical FAQ: HVAC & Sheet Metal Ductwork Wrapping
How does the orbital wrapper secure hollow rectangular sheet metal ductwork without crushing the standing seams?
The Dynawrap Pro series replaces heavy poly or steel strapping entirely. Instead of using concentrated point-loads that crush seams, the orbital ring applies a wide, overlapping web of stretch film with precision tension control. This distributes the containment force evenly across the duct walls, ensuring the sheet metal is firmly secured to the pallet without any structural deformation.
What mechanisms are used to stabilize long runs of commercial spiral ductwork that naturally want to roll off the packaging line?
To handle cylindrical payloads horizontally, the wrapping cell utilizes synchronized pneumatic top-pressers combined with adjustable side alignment rollers. As the spiral duct enters the machine, it is gently clamped from above and cradled from the sides, keeping the rolling load perfectly stationary while the rotating ring applies the stretch film.
Can the automated cell accommodate oversized industrial exhaust components that exceed standard pallet dimensions?
Yes. For massive HVAC fabrications, we deploy heavy-duty wrappers like the Dynawrap Pro 2200, which features an 85.4-inch (2170mm) internal ring clearance. This extreme volumetric capacity allows the system to easily swallow oversized 48x48-inch plus industrial exhaust ducting, utilizing heavy-duty motorized roller conveyors to manage the weight.
How does the equipment interface with our fabrication facility's ERP system and protect raw galvanized ducting from oxidation?
The cells operate on enterprise PLCs connecting via EtherNet/IP or OPC UA to execute direct WMS data exchanges. During the automated cycle, the machine seamlessly deploys VCI (Volatile Corrosion Inhibitor) stretch film. This specialized film emits rust-inhibiting vapors directly into the packaged ductwork, completely eliminating moisture-related oxidation before installation.
Eliminate Crushed Seams & Cut Labor Costs by >90%
From gentle pneumatic top-pressers and side alignment rollers to massive 85.4-inch ring capacities, our automated cells are built for the geometric realities of the HVAC industry. Tell us if you are wrapping standard commercial spiral ducts, insulated rectangular runs, or oversized industrial exhaust components, and whether you require VCI anti-rust film integration. Request a custom line review today.