Automated Stretch Wrapping for Solar Panels & Renewable Infrastructure
Secure delicate framed PV modules, individual solar panels, heavy aluminum racking, and torque tubes for utility-scale solar panels and arrays. Because there is no rotation of the load, you eradicate friction scratching and glass breakage. Our continuous-flow orbital packaging cells are engineered to handle everything from stacked panel bundles to complete shipping pallets for utility-scale solar arrays, applying gentle, controlled tension without stressing tempered glass. Featuring native ERP and WMS connectivity (via OPC UA, MQTT, and EtherNet/IP) for real-time predictive maintenance diagnostics, massive wide-ring capacities up to 2170mm (85.4"), and extreme weather protection for outdoor staging.
Explore the Core Technology: View our complete lineup of Horizontal & Orbital Stretch Wrapping Machines.
The Racking Bottleneck: Friction Scratching on Rails
Utility-scale solar farms require hundreds of thousands of feet of aluminum mounting rails, torque tubes, and support struts. When these massive extrusions are bundled loosely or secured only with steel banding, they slide internally during transport, scratching the anti-corrosive coatings before they even reach the job site.
The Solution: Perfect longitudinal unitization. The Dynawrap Pro 1100 and Pro 1400 are engineered specifically for these aluminum racking and heavy structural components. By passing the aluminum tracking straight through the orbital ring, the machine applies a high-tension, multi-layer stretch film web that locks every single rail together. This entirely eliminates internal friction and protects the structural coatings.
The Panel Bottleneck: Glass Breakage & Edge Crushing
Framed PV modules are heavy, exceptionally wide, and incredibly fragile. Traditional strapping methods crush the aluminum frames, while standard turntable pallet wrappers risk twisting or damaging the glass. Loose wrapping allows the heavy panels to shift on the skid, resulting in catastrophic breakage during transit. (For manufacturers handling unframed glass components, our tension-control technology is also deployed in our Architectural Glass & Raw Panel Wrappers.)
The Solution: Extreme volume capacity and delicate stabilization. Utilizing massive ring diameters (up to 2,170 mm), the Dynawrap Pro 2200 allows solar manufacturers to wrap multi-panel skids seamlessly. A heavy-duty roller or belt conveyor fully supports the skid to prevent point loads and flexing of the glass. Driven by flexible enterprise PLC architectures (Beijer, Siemens, Allen-Bradley, and Beckhoff), the wrapper connects via EtherNet/IP or native OPC UA servers to execute direct string-based data exchanges with your WMS, automatically processing production orders while MQTT telemetry streams real-time predictive maintenance diagnostics directly to your cloud. The powered pre-stretch carriage (yielding up to 70% stretch) applies low, adjustable film tension over foam corner protectors, securing the stack flawlessly without stressing the tempered glass.
The Logistics Bottleneck: Desert Weather Exposure
Solar arrays are constructed in harsh environments. Expensive components often sit staged in open desert fields or dusty lots for months, subjected to driving rain, sandstorms, and extreme UV exposure that can degrade wiring and damage glass surfaces.
The Solution: Total weatherproofing via fully automatic inline systems. Integrated across the Pro Series lineup, the W-Series Hybrid Welding Option offers true dual-material wrapping, combining stretch film with PE foam or bubble wrap for fragile surfaces. It automatically drapes and welds a thick, protective layer directly over the PV modules or racking bundles before the stretch film is applied. Operating at high volumes, this creates an impenetrable barrier against desert dust and moisture.
Enterprise Automation: Dynawrap LUMI™ 3D Algorithmic Vision
Achieve true recipe-free autonomy across your assembly line. Available as an option across the 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 mixed bundles of racking or varying panel stacks enter the zone, the system executes real-time 3D scanning to determine the exact geometry and dimensions.
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 glass breakage.
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 dark-warehouse 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.
Utility-Scale Consumables Ecosystem
Solar infrastructure demands specific film engineering. Our premium Cast Clear Machine Stretch Film is the industry standard for securing PV modules and racking. For extreme puncture resistance against the sharp sheared edges of aluminum mounting struts, we supply high-performance, up-gauged, and "blown-like" cast formulations to guarantee zero film failures.
Because solar components are universally staged outdoors prior to installation, deploying our UVI (Ultraviolet Inhibitor) Stretch Film is strictly required to prevent the plastic packaging from breaking down under severe sun exposure in open fields.
Technical FAQ: Solar Panel & Infrastructure Wrapping
How does the orbital wrapping process prevent tempered glass breakage when securing framed PV solar modules?
Unlike standard turntable wrappers that can twist heavy pallets, our orbital architecture keeps the solar modules completely horizontal and stationary on a fully supported belt or roller conveyor. This eliminates all flexing and point-loading. The orbital ring then utilizes a powered pre-stretch carriage to apply low, precisely controlled film tension over protective foam corner guards, ensuring the load is secured without ever stressing the tempered glass.
Can the packaging system accommodate the extreme widths required for utility-scale solar array skids?
Yes, utility-scale applications demand massive volumetric clearance. We deploy heavy-duty models like the Dynawrap Pro 2200, which features an enormous 85.4-inch (2170 mm) internal ring diameter. This allows the system to seamlessly pass fully stacked, double-wide shipping pallets of solar panels or wide-profile aluminum racking straight through the wrapping zone.
What automated weatherproofing options exist for solar racking and modules staged outdoors in harsh desert environments?
For outdoor job-site staging, the wrappers integrate our W-Series Hybrid Welding Option. Operating completely inline, this system automatically drapes and thermally welds a heavy-duty, impact-resistant PE bubble wrap over the components. Once the stretch film is applied over the bubble layer, it creates an impenetrable barrier against desert sandstorms, rain, and severe UV degradation.
How does the equipment interface with automated extrusion lines to secure heavy aluminum torque tubes without friction scratching?
Driven by enterprise PLCs (Siemens, Allen-Bradley, Beckhoff) connecting natively via EtherNet/IP or OPC UA, the wrapper integrates directly downstream from the extrusion line. It executes direct string-based WMS data exchanges to automatically adjust wrapping parameters. By replacing loose metal banding with a tight, multi-layer stretch film web, the machine unitizes the bundle perfectly, entirely eradicating the internal sliding that scratches aluminum anti-corrosive coatings.
Eliminate Scratched Racking & Broken Glass
From massive wide-ring capacities for PV modules to high-speed orbital wrapping for aluminum torque tubes, our automated cells are engineered for the sheer scale of the renewable energy sector. Tell us if you are wrapping delicate solar panels or heavy structural mounting rails, and whether your facility requires the W-Series hybrid PE bagging for outdoor moisture protection. Request a custom facility review today.