How REEMAN Smart Pallet Wrapping & Handling Workstation Connects an Autonomous Forklift with a Stretch Wrapper
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REEMAN Smart Pallet Wrapping & Handling Workstation integrates a 1.5-ton Ironhide Autonomous Forklift with a turntable stretch wrapper through an external wireless communication module.
Depending on the equipment controller and project architecture, the module can interface through I/O, RS485, Ethernet or CAN, while LoRa or Wi-Fi can be used for wireless machine-to-machine communication.
In this demonstrated application, pallet pickup alignment deviation is controlled within 2 cm, pallet placement deviation within 5 cm, stretch wrapping and film separation are automatic, and the complete pallet-handling and packaging workflow takes approximately 6 minutes.
Case Overview
The REEMAN Smart Pallet Wrapping & Handling Workstation connects two machines that would otherwise operate independently: the REEMAN Ironhide Autonomous Forklift and a turntable stretch wrapper.
Ironhide handles pallet pickup, autonomous transport, precise positioning, wrapped-pallet pickup and downstream delivery. The stretch wrapper handles turntable rotation, stretch-film application and automatic film separation.
The external wireless communication system allows the two machines to exchange task commands and operating states, connecting pallet transport and packaging into one continuous workflow.
Key Technical Parameters
| Category | Parameter | Case Data | Engineering Relevance |
|---|---|---|---|
| Autonomous Forklift | Model | REEMAN Ironhide | Autonomous pallet handling |
| Load Capacity | Rated Payload | 1.5 tons | Forklift rated capacity |
| Pickup Positioning | Alignment Deviation | ≤2 cm | Supports reliable fork entry |
| Pallet Placement | Placement Deviation | ≤5 cm | Keeps pallet within required turntable area |
| Packaging Equipment | Wrapper Type | Turntable stretch wrapper | Automatic pallet wrapping |
| Equipment Interface | Local Connection | I/O / RS485 / Ethernet / CAN | Interface options depend on equipment controller and project |
| Wireless Communication | Data Link | LoRa or Wi-Fi | Transfers commands and machine status wirelessly |
| Integration | Retrofit Method | External wireless communication module | Avoids major mechanical redesign |
| Wrapping | Process | Automatic | No manual wrapper start during configured sequence |
| Film Finishing | End of Cycle | Automatic film separation | Pallet can proceed directly to autonomous pickup |
| Complete Cycle | Demonstrated Workflow | Approx. 6 minutes | Includes transport, wrapping and delivery |
| Video | Playback Speed | Approx. 5× | Video accelerated for viewing |
Important: 1.5 tons is the rated payload of the Ironhide configuration shown, not the measured pallet weight in the video.
The approximately 6-minute value represents the complete demonstrated workflow, not the wrapping time alone and not a guaranteed hourly throughput.
The Challenge: An Automatic Wrapper Does Not Automatically Create an Automated Pallet Flow
A turntable stretch wrapper can automate the wrapping process itself, but pallet movement before and after wrapping may still require manual coordination.
The video shows pallet pickup, autonomous transport, precise turntable positioning, wireless machine communication, automatic stretch wrapping, automatic film separation, wrapped-pallet pickup and downstream delivery.
Autonomous Pallet Pickup and Turntable Positioning
Ironhide adjusts its position relative to the pallet openings before fork entry.
The pallet is positioned within the required working area of the turntable.
The workflow begins with Ironhide approaching the loaded pallet. Once pickup alignment is complete, the forks enter the pallet, lift the load and begin autonomous transport toward the stretch-wrapper station.
After positioning, Ironhide lowers the pallet, withdraws its forks and moves outside the rotating work area.
Wireless Machine-to-Machine Communication
The key integration component is the external wireless communication module. It allows the moving autonomous forklift and the stationary stretch wrapper to exchange task information without requiring a physical communication cable between the two machines.
Equipment-Side Interface
Depending on the controller and project architecture, the communication module can interface through:
- I/O
- RS485
- Ethernet
- CAN
Wireless Data Link
Depending on communication distance, site layout and project requirements, the wireless link can use:
- LoRa
- Wi-Fi
↓
I/O / RS485 / Ethernet / CAN
↓
External Wireless Communication Module
↓
LoRa / Wi-Fi
↓
Wrapper-Side Communication Module
↓
Stretch Wrapper Controller
Start wrapping.
Pallet ready for pickup.
The communication module acts as the communication bridge. It does not replace the stretch wrapper’s original controller.
Turntable rotation, stretch-film application, wrapping sequences and automatic film separation remain controlled by the stretch wrapper itself.
Automatic Stretch Wrapping and Automatic Film Separation
After receiving the start command, the turntable stretch wrapper begins its programmed cycle.
The pallet rotates while stretch film is applied around the load. Ironhide remains outside the rotating area.
After the programmed wrapping cycle is complete, the wrapper automatically performs the final film separation step.
Once wrapping, film separation and turntable stopping are complete, the wrapper sends the task-complete state back to Ironhide.
Automatic Re-Pickup, Delivery and Unloading
After receiving the completion signal, Ironhide returns to the wrapping station, performs another alignment operation and aligns its forks with the pallet openings.
The wrapped pallet is lifted and transported to the designated downstream logistics area.
At the destination, Ironhide adjusts its position, lowers the pallet and withdraws its forks.
Can the Existing Stretch Wrapper Be Retrofitted?
In this implementation, the stretch wrapper does not require major changes to its original mechanical structure or core control logic.
Integration is mainly achieved by adding an external wireless communication module and connecting it to the wrapper’s existing control interface.
Keep Existing Equipment
An existing stretch wrapper may remain in service if its controller, interfaces and safety requirements are suitable for integration.
Add Machine Communication
External communication hardware transfers task commands and operating states between the autonomous forklift and packaging equipment.
Automate the Handoff
Pallet transport and stretch wrapping become one coordinated material-handling workflow.
What Does the Approximately 6-Minute Cycle Include?
The demonstrated complete workflow takes approximately 6 minutes.
This includes pallet pickup, autonomous transport, turntable positioning, fork withdrawal, wireless task handoff, automatic stretch wrapping, automatic film separation, completion feedback, forklift return, re-alignment, wrapped-pallet pickup, downstream transport and unloading.
The approximately 6-minute value does not mean the wrapping machine itself operates for six minutes.
Actual cycle time can vary with transport distance, forklift speed, wrapping program, film layers, pallet dimensions, load geometry, site traffic, waiting conditions and equipment utilization.
Labor-Saving Potential and Estimated ROI
The economic value comes from reducing manual involvement across connected tasks such as:
forklift transport + wrapper loading + start coordination + waiting + wrapped-pallet pickup + downstream delivery
Traditional Process vs. REEMAN Automated Workflow
| Process Stage | Traditional Workflow | REEMAN Automated Workflow |
|---|---|---|
| Pallet Pickup | Manual forklift / operator coordination | Ironhide automatic pickup |
| Transport | Driver-operated forklift | Autonomous transport |
| Wrapper Loading | Operator / forklift positioning | ≤5 cm automated placement |
| Wrapper Start | Manual coordination | Wireless start signal |
| Wrapping | Automatic or semi-automatic | Automatic |
| Film Separation | May require operator depending on equipment | Automatic in this application |
| Completion Notification | Manual observation / coordination | Wireless completion signal |
| Wrapped-Pallet Pickup | Forklift called again | Ironhide automatic return |
| Downstream Delivery | Driver-operated transport | Autonomous delivery |
Where Can This Workstation Be Used?
- End-of-line pallet packaging
- Finished-goods wrapping
- Automated packaging cells
- Warehouse staging areas
- Pallet consolidation areas
- Outbound logistics
- Factory material handling
- Smart factory logistics
This type of integration is particularly relevant for factories that already operate a turntable stretch wrapper and want to automate pallet loading and post-wrapping transport.
Frequently Asked Questions
Below are common technical and integration questions about connecting the REEMAN Ironhide Autonomous Forklift with an existing turntable stretch wrapper.
A: Ironhide communicates with the stretch wrapper through an external wireless communication module. Depending on the equipment controller, the module can interface through I/O, RS485, Ethernet or CAN, while LoRa or Wi-Fi can be used for wireless communication between the two machines.
A: The Ironhide configuration shown in this application has a rated payload capacity of 1.5 tons. This is the forklift’s rated capacity, not the measured pallet weight shown in the video.
A: No major modification to the wrapper’s original mechanical structure or core control logic is required in this implementation. Integration is mainly achieved by adding an external wireless communication module and connecting it to the wrapper’s existing control interface.
A: Depending on the equipment controller, the communication module can interface through I/O, RS485, Ethernet or CAN. For the wireless link between the forklift and wrapper, LoRa or Wi-Fi can be used depending on the project.
A: Not necessarily. The wireless communication system can use LoRa or Wi-Fi, depending on communication distance, site layout, interference conditions and project requirements.
A: Potentially, yes. The key requirement is whether the existing wrapper provides suitable control signals or communication interfaces. The wrapper model, controller, available interfaces and safety requirements should be evaluated before integration.
A: No. The wireless communication module mainly transfers task commands and machine-status signals. Turntable rotation, stretch-film application, wrapping sequences and automatic film separation remain controlled by the stretch wrapper itself.
A: After the wrapping program and automatic film separation are complete and the turntable has stopped, the wrapper sends a task-complete signal back to Ironhide through the wireless communication system.
A: Yes. In this demonstrated application, the stretch wrapper automatically completes the final film-separation step before the pallet is released for autonomous pickup.
A: In this application, pallet pickup alignment deviation is controlled within 2 cm.
A: In this application, pallet placement deviation is controlled within 5 cm. The acceptable placement tolerance can vary according to pallet dimensions, turntable size, load geometry and workstation layout.
A: No. Ironhide places the pallet on the turntable, withdraws its forks and leaves the rotating area before wrapping begins.
A: The complete demonstrated workflow takes approximately 6 minutes, including pallet pickup, transport, turntable positioning, wrapping, automatic film separation, re-pickup, downstream delivery and unloading.
A: Not necessarily. Actual throughput depends on transport distance, wrapping program, pallet availability, site traffic, waiting conditions and equipment utilization. The 6-minute figure refers to the demonstrated complete workflow, not a guaranteed hourly production rate.
A: Potentially, yes. The available interfaces, start signals, completion feedback, equipment status, fault handling and safety requirements need to be evaluated for the specific controller.
A: REEMAN typically needs the wrapper model, controller information, available I/O / RS485 / Ethernet / CAN interfaces, pallet dimensions, pallet fork openings, loaded pallet weight, load dimensions, turntable dimensions, wrapping requirements, transport route, loading and unloading positions, and safety requirements.
A: The main benefit is reducing manual coordination between pallet transport and packaging. The two machines can exchange task states and complete pallet pickup, positioning, wrapping, automatic film separation, re-pickup and downstream delivery as one connected workflow.
Final Technical Summary
The core engineering value is not simply the autonomous forklift or the stretch wrapper individually.
It is the ability to make two independent machines communicate, coordinate and complete one continuous workflow .
Planning a Similar Automated Pallet Wrapping Project?
If your factory already uses a turntable stretch wrapper and wants to automate pallet loading, wrapping coordination, finished-pallet pickup and downstream delivery, send REEMAN the key project information below.
REEMAN can evaluate the communication architecture, mechanical compatibility, autonomous forklift configuration and estimated ROI for your application.