Latvia E-Bike Battery Packer Cuts Manual Shrink Wrapping with Three ACEY-HSM5035 Shrink Tunnels

An e-bike battery manufacturer based in Latvia replaced manual heat shrink film wrapping on its battery PACK line with three ACEY-HSM5035 Heat Shrink Tunnel Wrapping Machine. The project moved from purchase order in early March to a fully packed and shipped shipment by mid-March. Within the first production cycle the customer recorded roughly 40% shorter packaging time per battery pack, about 70% higher throughput per hour, and a 67% reduction in manual labor allocated to the wrapping step.

The customer operates in the European e-bike supply chain, assembling lithium battery packs from individual cells into finished, road-ready power units. E-bike battery packs are dimensionally varied, electrically sensitive, and shipped under strict handling requirements, so the outer shrink film is not cosmetic packaging — it is the first barrier against moisture, dust, and abrasion during transport.

Before the project, operators wrapped each assembled battery pack by hand using a heat gun and loose shrink film. That approach created three problems:

• Inconsistent finish — film tightness, wrinkle level, and edge coverage depended entirely on operator technique, so film fit and conformity varied from pack to pack.
• Labor-heavy and slow — every unit absorbed hands-on time, and the step became a bottleneck as production volumes grew.
• Fragile process control — uneven heating risked loose film on one unit and over-shrunk film on the next, with no repeatable parameter to return to.

As order volumes increased, the customer wanted to move from an operator-dependent craft step to a controllable, repeatable machine process that could absorb growth without proportionally adding headcount.

ACEY supplied three ACEY-HSM5035 Automatic Heat Shrink Tunnel Wrapping Machine, sized to run in parallel so the line keeps moving even when one tunnel is being reloaded. The machine heats shrink film so it conforms tightly to the outer profile of each battery pack as the pack travels through the heated chamber.

Key design points that mattered for this application:

• Adjustable heating temperature and conveyor speed — operators dial in the parameter set that suits each film type and pack size, so different battery pack formats all reach a proper, uniform shrink result.
• Mesh belt conveyor — packs pass through the heating chamber smoothly and continuously, which removed most of the manual handling previously needed around the hot zone.
• Double-layer insulation structure — reduces heat loss and keeps the working environment around the tunnel more manageable.
• Electrical fault alarms — phase loss, phase sequence error, and short circuit alarms flag problems immediately, so an operator can react before a batch is affected.

Because temperature and conveyor speed can be tuned to the film and the pack size, the shrink result no longer depends on who is standing at the station. Film fit and packaging consistency improved, and the wrapping step became a documented, repeatable process rather than a matter of operator feel.

The order was placed in early March and the machines were packed and shipped by mid-March — a compressed cycle that let the customer stand up three parallel tunnels within a single production planning window.

"We use the ACEY-HSM5035 Automatic Heat Shrink Tunnel Wrapping Machine to replace manual shrink wrapping of our e-bike battery packs. The adjustable parameters give us a stable, even packaging result. While improving packaging quality, the machines also reduced our labor requirement, and the equipment runs reliably. We are satisfied with the service ACEY provided."

In battery PACK production, the packaging step sits at the end of a high-value assembly chain — a bottleneck here delays every pack behind it, and an inconsistent wrapper creates rework at the worst possible moment. Moving to a shrink tunnel with adjustable temperature and conveyor speed converts that step into a controlled process: predictable cycle time, uniform film conformity, fewer hands on the product, and alarms that surface electrical faults before they turn into scrap. For manufacturers scaling e-bike battery output, that combination is what makes packaging capacity keep up with assembly capacity.

If you are evaluating heat shrink packaging for battery packs, modules, or other dimensionally varied assemblies, ACEY can help size the tunnel, film, and conveyor parameters to your actual pack range.