Posted 14 Sun By Shaun Bryce

Fixing a Pallet Wrapper: Common Problems and How to Solve Them

Pallet wrappers are essential for securing loads safely and efficiently. But like any piece of machinery, they can occasionally run into issues. At MPS Packaging Australia, we often hear from customers about common problems that interrupt wrapping operations. Here are three frequent issues with pallet wrappers—and what you can do to fix them.

My Pallet Wrapper Just Keeps Spinning

If your turntable continues to spin without stopping, it’s usually a sign that the sensor isn’t detecting the end of the wrapping cycle. This could be due to:

A dirty or misaligned sensor not picking up the film or load.
A wiring issue or faulty connection.
An incorrect cycle setting.

Fix: Check and clean the sensor, ensure it’s correctly aligned, and review your machine settings. If the problem persists, you may need a technician to inspect the wiring or replace the sensor.

My Pallet Wrapper Won’t Go Up

When the carriage refuses to move upward, it usually points to an issue with the lift system. Common causes include:

A loose or broken chain/belt that drives the carriage.
A faulty motor or motor drive.
Obstructions or damage to the mast track.

Fix: Start by inspecting the chain or belt for tension and wear. If they’re intact, listen for the motor running—if it’s silent, it may need repair or replacement. Always ensure the mast is free from debris or damage before restarting.

My Pallet Wrapper Keeps Going Up

If the carriage won’t stop rising, the issue often lies with the limit switch or height sensor. This sensor tells the machine when to stop at the top of the load. If it’s misaligned, dirty, or broken, the carriage will continue moving upward.

Fix: Locate and clean the top limit switch or photo-eye sensor. Make sure it’s positioned correctly to detect the pallet height. If cleaning doesn’t solve the problem, replacement may be necessary.

Preventative Maintenance Matters

Most pallet wrapper issues can be prevented with regular cleaning, sensor checks, and lubrication. Keeping the machine in good condition not only reduces downtime but also extends the life of your equipment.

Pallet wrapper fixes Summery.

Common Problems, Causes & Fixes

Problem	What It Means / What’s Happening	Common Causes	How to Fix It
“My pallet wrapper just keeps spinning”	Turntable (or wrapping platform) won’t stop; wrapper stays in motion beyond where the cycle should end.	• The turntable sensor (or limit switch) is dirty, misaligned, or not detecting the end-of-cycle signal. • Fault in the control panel or wiring, so the stop signal isn’t reaching the motor controller. • HMI panel or programming settings might have been changed (cycle timing, sensor thresholds).	1. Inspect the turntable’s stop (end‐of‐cycle) sensor. Clean it—remove dust, debris, or stretch wrap residue. 2. Check alignment: ensure the sensor is correctly positioned and aimed so it can “see” the pallet or the film at the correct spot. 3. Inspect wiring from sensor to controller: loose connections, breaks, or corroded contacts. 4. Test with the operator panel (HMI) to ensure settings haven’t been altered. Reset cycle settings if needed. If none of this helps, contact a technician to check internal control components.
“My pallet wrapper won’t go up”	The wrap carriage, which holds the film, is stuck at the bottom; the wrapper does not raise to wrap the load.	• Lift mechanism (chain, cable, belt) may be broken, detached, or lose tension. • Motor or drive component (gearbox, motor driver) for lifting is faulty. • Mast/tracks may be jammed, misaligned, or obstructed. • Safety interlock / limit switch might be preventing upward motion.	1. Inspect the lift chain/cable/belt. If slack, broken, or disconnected—repair or replace it. 2. Check mast or track: look for debris or damage; ensure carriage can move freely. 3. Listen to motor when you try to raise: is it running? If not, check motor power, fuses, wiring. 4. Inspect safety switches / limit switches: these can cut power or prevent movement if they sense wrong position or danger. 5. Try manual override (if available) to check function of mechanical parts. If mechanical or electrical failure, schedule maintenance.
“My pallet wrapper keeps going up”	Carriage keeps rising past expected height; doesn’t stop at the top.	• Top limit switch or height sensor is failing, misaligned, blocked, or dirty. • The sensor signal isn’t reaching the controller (wiring or connection issues). • Controller/HMI settings may have drifted or been misconfigured (upper travel limit set too high or disabled).	1. Locate the top limit switch / height sensor. Clean it—remove any plastic dust, film, grime. 2. Check alignment: make sure it is positioned to trigger at correct height. 3. Inspect wiring / signal path from sensor to controller: ensure secure connections. 4. Review HMI / control settings for maximum carriage up‐limit. Restore or reconfigure if incorrectly set. 5. If sensor is faulty (i.e. fails to trigger even when carriage is at top), replace it.

Problem

What It Means / What’s Happening

Common Causes

How to Fix It

“My pallet wrapper just keeps spinning”

Turntable (or wrapping platform) won’t stop; wrapper stays in motion beyond where the cycle should end.

• The turntable sensor (or limit switch) is dirty, misaligned, or not detecting the end-of-cycle signal.
• Fault in the control panel or wiring, so the stop signal isn’t reaching the motor controller.
• HMI panel or programming settings might have been changed (cycle timing, sensor thresholds).

1. Inspect the turntable’s stop (end‐of‐cycle) sensor. Clean it—remove dust, debris, or stretch wrap residue.
2. Check alignment: ensure the sensor is correctly positioned and aimed so it can “see” the pallet or the film at the correct spot.
3. Inspect wiring from sensor to controller: loose connections, breaks, or corroded contacts.
4. Test with the operator panel (HMI) to ensure settings haven’t been altered. Reset cycle settings if needed. If none of this helps, contact a technician to check internal control components.

“My pallet wrapper won’t go up”

The wrap carriage, which holds the film, is stuck at the bottom; the wrapper does not raise to wrap the load.

• Lift mechanism (chain, cable, belt) may be broken, detached, or lose tension.
• Motor or drive component (gearbox, motor driver) for lifting is faulty.
• Mast/tracks may be jammed, misaligned, or obstructed.
• Safety interlock / limit switch might be preventing upward motion.

1. Inspect the lift chain/cable/belt. If slack, broken, or disconnected—repair or replace it.
2. Check mast or track: look for debris or damage; ensure carriage can move freely.
3. Listen to motor when you try to raise: is it running? If not, check motor power, fuses, wiring.
4. Inspect safety switches / limit switches: these can cut power or prevent movement if they sense wrong position or danger.
5. Try manual override (if available) to check function of mechanical parts. If mechanical or electrical failure, schedule maintenance.

“My pallet wrapper keeps going up”

Carriage keeps rising past expected height; doesn’t stop at the top.

• Top limit switch or height sensor is failing, misaligned, blocked, or dirty.
• The sensor signal isn’t reaching the controller (wiring or connection issues).
• Controller/HMI settings may have drifted or been misconfigured (upper travel limit set too high or disabled).

1. Locate the top limit switch / height sensor. Clean it—remove any plastic dust, film, grime.
2. Check alignment: make sure it is positioned to trigger at correct height.
3. Inspect wiring / signal path from sensor to controller: ensure secure connections.
4. Review HMI / control settings for maximum carriage up‐limit. Restore or reconfigure if incorrectly set.
5. If sensor is faulty (i.e. fails to trigger even when carriage is at top), replace it.

Drawing on MPS’s Training Materials

We’ve built a suite of quick reference guides, HMI panel guides, and Safe Operating Procedures (SOPs) to help operators and maintenance staff diagnose faults like these quickly. MPS Packaging Australia
If you haven’t already, it’s a good idea to:

Keep the “pallet wrapper Quick reference guides” near the wrapper machine so operators can refer to them whenever a problem arises.
Use the “pallet wrapper HMI Panel Guide” to understand how control settings govern motion, sensor behaviour, and limit switches.
Follow the pallet wrapper SOP (Safe Operating Procedure) for regularly checking sensors, switches, carriage alignment, and safety devices. Regular preventive checks reduce breakdowns substantially.

Need Expert Help?

While some minor adjustments and cleaning can be done in-house, more serious faults—especially with wiring or motors—should always be handled by a trained technician. At MPS Packaging Australia, we supply and support pallet wrapping machines, ensuring your business stays productive and your loads stay secure.