IP Library › Granted Patent US 12709428
Granted Patent B1
US 12709428 · App. 18/960,736 · Granted Aug 18, 2026

Pallet wrapping system with intelligent monitoring

Inventor: Darrel Bison (Phoenix, AZ)
Assignee: Allied Packaging Corporation
B65B57/00B65B11/025B65B41/16B65B2011/002
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Quick Facts
Patent No.
US 12709428
App. No.
18/960,736
Granted
Aug 18, 2026
Kind
B1
Abstract

A monitoring system for wrapping a pallet with a pallet wrapping system, at least two encoders, and a control box. The pallet wrapping system has a spool that dispenses stretch film and a pre-stretch machine operably coupled to the pallet wrapping system and configured to elongate the stretch film. The at least two encoders are affixed to the pre-stretch machine. A first of the at least two encoders is configured to measure a length of stretch film entering the pre-stretch machine and a second is configured to measure a length of stretch film exiting the pre-stretch machine. The control box is communicatively coupled to the at least two encoders and configured to collect data regarding the pallet wrapping system and transmit the data over a wireless connection to a central processor configured to gather the data.

Claims (40)

1 . A monitoring system for wrapping a plurality of pallets, comprising:

a pallet wrapping system configured to wrap stretch film around each pallet of the plurality of pallets, the pallet wrapping system having a pre-stretch machine configured to stretch the stretch film prior to wrapping the stretch film around each pallet; and

a control box configured to collect data regarding the pallet wrapping system and transmit the data to a central processor configured to gather the data, the data including characteristics of the pallet wrapping system's operation sufficient to calculate at least one of the following measurements:

a perimeter of each pallet;

a weight of stretch film wrapped around each pallet;

a number of times the stretch film is wrapped around each pallet;

a length of stretch film pulled into the pre-stretch machine for each pallet;

a length of stretch film applied to each pallet; and

an amount of time for the pallet wrapping system to wrap each pallet;

wherein the monitoring system is configured to determine a total applied stretch of the stretch film applied to each pallet; and

wherein the monitoring system has a corresponding range of acceptable values for each of the measurements and is configured to notify a user of the pallet wrapping system and a supervisor of the user when any one of the measurements leaves the corresponding range of acceptable values; and

wherein the monitoring system is configured to wait a predetermined amount of time before notifying the supervisor for a second time if any one of the measurements remains outside the corresponding range of acceptable values.

2 . The monitoring system of claim 1 , wherein the monitoring system is configured to monitor a plurality of pallet wrapping systems simultaneously.

3 . The monitoring system of claim 1 , wherein the monitoring system is configured to calculate the length of stretch film applied to each pallet by multiplying the perimeter of the pallet by the number of times that stretch film is wrapped around the pallet.

4 . The monitoring system of claim 3 , wherein the total applied stretch is the difference between the length of stretch film applied to each pallet and the length of stretch film pulled into the pre-stretch machine for each pallet.

5 . The monitoring system of claim 1 , wherein the total applied stretch is the sum of a length added to the stretch film through stretching within the pre-stretch machine and a length added to the stretch film through stretching as the stretch film is applied to the palletized load.

6 . The monitoring system of claim 1 , wherein the total applied stretch is the difference between a product of the perimeter of each pallet multiplied by the number of times the stretch film is wrapped around each pallet and the length of stretch film pulled into the pre-stretch machine for each pallet.

7 . A monitoring system for wrapping a plurality of pallets, comprising:

a pallet wrapping system configured to wrap stretch film around each pallet of the plurality of pallets, the pallet wrapping system having a pre-stretch machine configured to stretch the stretch film prior to wrapping the stretch film around each pallet; and

a control box configured to collect data regarding the pallet wrapping system and transmit the data to a central processor configured to gather the data;

wherein the monitoring system is configured to determine a total applied stretch of the stretch film applied to each pallet; and

wherein the data comprises a plurality of measurements and the monitoring system has a corresponding range of acceptable values for each of the measurements and is configured to notify a user of the pallet wrapping system and a supervisor of the user when any one of the measurements leaves the corresponding range of acceptable values; and

wherein the monitoring system is configured to wait a predetermined amount of time before notifying the supervisor for a second time if any one of the measurements remains outside the corresponding range of acceptable values.

8 . The monitoring system of claim 7 , wherein the monitoring system is configured to calculate a length of stretch film applied to each pallet by multiplying a perimeter of the pallet by a number of times that stretch film is wrapped around the pallet.

9 . The monitoring system of claim 7 , wherein the total applied stretch is the sum of a length added to the stretch film through stretching within the pre-stretch machine and a length added to the stretch film through stretching as the stretch film is applied to the palletized load.

10 . The monitoring system of claim 7 , wherein the total applied stretch is the difference between a product of a perimeter of each pallet multiplied by a number of times the stretch film is wrapped around each pallet and a length of stretch film pulled into the pre-stretch machine for each pallet.

11 . A monitoring system for wrapping a plurality of pallets, comprising:

a pallet wrapping system configured to wrap stretch film around each pallet of the plurality of pallets, the pallet wrapping system having a pre-stretch machine configured to stretch the stretch film prior to wrapping the stretch film around each pallet; and

a control box configured to collect data regarding the pallet wrapping system and transmit the data to a central processor configured to gather the data;

wherein the data comprises a plurality of measurements and the monitoring system has a corresponding range of acceptable values for each of the measurements and is configured to notify a supervisor of a user of the pallet wrapping system when any one of the measurements leaves the corresponding range of acceptable values; and

wherein the monitoring system is configured to wait a predetermined amount of time before notifying the supervisor for a second time if any one of the measurements remains outside the corresponding range of acceptable values.

12 . The monitoring system of claim 11 , wherein the monitoring system is configured to monitor a plurality of pallet wrapping systems simultaneously.

13 . The monitoring system of claim 11 , wherein the monitoring system is configured to calculate a length of stretch film applied to each pallet by multiplying a perimeter of the pallet by a number of times that stretch film is wrapped around the pallet.

14 . The monitoring system of claim 13 , wherein the monitoring system is configured to determine a total applied stretch of the stretch film applied to each pallet, wherein the total applied stretch is the difference between the length of stretch film applied to each pallet and the length of stretch film pulled into the pre-stretch machine for each pallet.

15 . The monitoring system of claim 11 , wherein the monitoring system is configured to determine a total applied stretch of the stretch film applied to each pallet, wherein the total applied stretch is the sum of a length added to the stretch film through stretching within the pre-stretch machine and a length added to the stretch film through stretching as the stretch film is applied to the palletized load.

16 . The monitoring system of claim 11 , wherein the monitoring system is configured to determine a total applied stretch of the stretch film applied to each pallet, wherein the total applied stretch is the difference between a product of a perimeter of each pallet multiplied by a number of times the stretch film is wrapped around each pallet and a length of stretch film pulled into the pre-stretch machine for each pallet.

17 . The monitoring system of claim 11 , wherein the data includes characteristics of the pallet wrapping system's operation sufficient to calculate an amount of stretch film remaining on a roll of stretch film when the roll of stretch film is replaced.

18 . The monitoring system of claim 11 , wherein the data includes characteristics of the pallet wrapping system's operation sufficient to calculate a number of web breaks in a specified time period.

19 . The monitoring system of claim 11 , further comprising a notice beacon or light visible at a workstation of the pallet wrapping system, the notice beacon or light configured to illuminate in conjunction with an alert being sent to the supervisor.

20 . The monitoring system of claim 11 , wherein the monitoring system is configured to alert additional third parties if any one of the measurements continues to remain outside the corresponding range of acceptable values.