Automatic Bearing Packing Line for EU Customer — SHOWCASE

How One EU Manufacturer Streamlined Their Bearing Packaging Process With Fhope's Automated Solution

Project Parameters at a Glance

Outer Diameter (OD): 400–600 mm
Inner Diameter (ID): 200–400 mm
Width: 100–250 mm
Product: Precision Industrial Bearings
Client Location: Central Europe
Industry: Bearing Manufacturing & Export

The Challenge: Manual Packaging Led to Delays, Damage, and Data Errors

Before adopting automation, the client's bearing packaging process relied heavily on manual labor. Operators wrapped each bearing by hand, scanned data from production reports, and manually matched them to printed labels. This caused three critical issues:

Time and Labor-Intensive Process:
Manual wrapping took 3–5 minutes per bearing, requiring multiple workers on each line. Labor costs were high, and throughput was unpredictable.
Frequent Shipping Damage:
Despite their robust quality control, bearings were often returned due to inadequate packaging protection during transport, especially for sea freight.
Data Mismatch Risk:
Matching printed labels to individual bearing IDs was entirely manual, leading to potential tracking errors, inventory mismatches, and even product recalls.

“Sometimes, even a single mislabeled bearing meant an entire batch needed to be recalled. It wasn’t just a logistics cost — it hurt our customer trust.”
— Plant Manager, EU Bearing Manufacturer

The Solution: Fhope’s Fully Automatic Bearing Packing Line

Our engineering team at Fhope developed and deployed a turnkey bearing packing solution, designed to automate every critical step — from protective wrapping to smart labeling.

Key Features of the Line:

Automated Infeed Alignment System:
Bearings are automatically aligned based on OD and ID for precise positioning, eliminating the need for manual handling.
Servo-Controlled Wrapping Station:
Ensures tight, uniform packaging using stretch film or VCI paper, based on customer preference. Adjustable for different widths from 100 mm to 250 mm.
Data Integration Module:
Real-time communication with the customer’s MES (Manufacturing Execution System) to fetch bearing ID, batch number, and QR code data.
Smart Label Printer with Vision Validation:
Each bearing is labeled with a unique code, and a camera system cross-verifies that the printed label matches the digital record from MES.
Edge Protection Applicator:
Automatically applies protective edge guards to prevent damage during shipment.
Palletizing Unit (Optional):
Automatically stacks wrapped and labeled bearings on pallets, based on OD grouping.

Technical Dive: Engineering Precision at Work

Here’s how the technical subsystems work together:

1. Sensing & Recognition

The machine uses laser displacement sensors to measure the OD and ID of each bearing before wrapping.
Readings are compared against a database to ensure the correct product is being packed.

2. Wrapping Module

Dual-axis servo motors adjust the wrapping tension based on the diameter and width of the bearing.
The film roll position is auto-adjusted using a proximity encoder for each product size.
Wrapping time: 20–25 seconds per unit, reducing total cycle time by 60% compared to manual operation.

3. Label Synchronization System

Once wrapping is complete, the system sends a query to the MES using an API-based interface.
The correct label data (bearing ID, production time, QR code) is retrieved and printed within 2 seconds.
A high-speed industrial camera reads the QR code and performs instant comparison with the digital label data.
Any mismatch triggers an automatic rejection chute.

4. Data Logging

Every packed bearing’s data — size, weight, label, operator ID (if manual override is used) — is logged into the system and stored for up to 5 years.
CSV or cloud export available for auditing and reporting.

Real-World Impact: What the Customer Said

“After integrating the Fhope system, our packaging became a non-issue. What used to take 4 workers now takes 1 supervisor monitoring the line.
But what surprised us most was the data accuracy — we went from 3–5 labeling issues per day to zero in the last 4 months.”
— Operations Director, EU Client

Measurable Outcomes:

Metric	Before Automation	After Fhope System
Wrapping Time	3–5 mins per unit	20–25 sec per unit
Labor Required	3–4 workers	1 operator
Labeling Errors	3–5/day	0/day
Return Rate due to Packaging	2.1%	<0.2%
Average Throughput	80 units/day	280+ units/day

Designed for EU Compliance and Beyond

CE Certified System
Supports multilingual HMI: English, German, French
Works with EU-standard label formats (GS1, QR, EAN)
Remote diagnostics and software updates available via secure VPN

Conclusion: Automation that Pays for Itself

This automatic bearing packing line didn’t just reduce costs — it transformed how the client thought about their end-of-line operations. By addressing manual pain points in wrapping, labeling, and data matching, the client saw improvements in productivity, accuracy, and customer satisfaction.

Whether you produce large industrial bearings or precision miniatures, Fhope's solutions are scalable, adaptable, and built to last.