Eyes on Ergonomics
The technology behind cores, shafts, and chucks appears basic, but further inspection reveals a world of science aimed at efficiency, safety, and ease of operation.
ERGONOMICS HAS BECOME an increasingly important focus for package printing and converting companies. Also called human engineering, ergonomics is the science of "designing jobs and workplaces to match human capabilities and limitations," according to Sean Craig, product manager for Tidland. "Interest in this science has grown steadily, along with the rising number of workers' compensation claims for work-related, non-traumatic injuries or disorders involving soft-tissues (nerves, tendons, muscles, and supporting structures), known as work-related musculoskeletal disorders (WMSDs or MSDs)."
According to the U.S. Department of Labor's Occupational Safety and Health Administration (OSHA), MSDs account for 34 percent of all lost-workday injuries and illnesses reported to the Bureau of Labor Statistics. In addition, MSDs account for $1 of every $3 spent for workers' compensation—it's estimated that employers spend about $20 billion per year on direct costs for MSD-related workers' compensation.
Hence, ergonomics is important in reducing the number of on-the-job injuries related to tasks like lifting heavy objects—such as a shaft used in package printing.
"We have seen a large number of companies adopting ergonomics lifting limits that depend on a variety of factors such as the frequency, duration, and type of lifting, as well as individual variables such as age, sex, body type, size, etc.," said Courtney Donaldson, Goldenrod Corp. director of marketing. "The most common guideline we hear is that one operator should not be lifting more than 50 lbs., but this seems to be an informal limit. Some customers just want the shaft to be a certain percentage lighter than what they presently use and are trying to meet a certain level in order to justify the cost of a new lightweight shaft (i.e. if it's only 10 percent lighter, is it worth the expense?)."
The interest in lighter and easier-to-handle cores, shafts, and chucks is evident by the latest offerings. For more on ergonomics products for package printing, as well as some of today's newest releases, packagePRINTING recently contacted some of the industry's leading manufacturers of cores, shafts, and chucks.
Round/square geometry for safety chucks
Boschert LLC
www.boschertllc.com
Boschert offers a new round/square seat geometry for its safety chucks, called the VT-7 style. The seat geometry is a square, triangle, or other geometry. This new seat geometry separates the load of the roll from the torque of the roll, offering the customer longer life for the roll shaft journal and for the seat of the safety chuck. Because the load of the roll is on the round portion of the seat, the bar rides in the bottom of the seat during operation. This means a smoother vibration-free run every time. The VT-7 is easily retrofitted by simply removing the existing Boschert VT insert and installing the VT-7 style. Turnaround time for this change is five minutes or less.
Boschert also has introduced its fourth generation of positive locks for Boschert Safety Chucks. This new lock style, the Type IV (patent pending) is internal and accessed from the side by means of a tool. It is safer, and operators are less likely to pinch their fingers manipulating the lock. The Type IV is also more robust than any of the other Boschert locks.
Inflation toggle valve cuts changeover time
Converter Accessory Corp. (CAC)
www.handleyourweb.com
CAC introduces a patented new inflation toggle valve COR-LOK® airshaft option, TVCLAS, that helps reduce roll changeover times. TVCLAS employs a standard rotary union for pneumatic hook-up and is specifically engineered for use in cantilevered applications. It is available in COR-LOK airshafts in 2˝-18˝ diameters. The main advantage of the TVCLAS is that it facilitates rapid roll changeovers. Since the easily reached toggle valve is built into the end of the airshaft, an operator does not have to leave the station to access a remote inflation control or retrieve any tools.
Easy-to-operate sliding safety chucks
Double E Co.
www.doubleeusa.com
Double E's sliding safety chucks for use in shafted applications are safer, easier to operate, and more rugged than tilting designs. These chucks slide open with a patented pushbutton mechanism. They only open in the upright position, so roll security is guaranteed. Chucks can be flange- or foot-mounted, fixed or with sidelay adjustment. Sidelay adjustment models, with a horizontal range up to 2˝ or 4˝, allow accurate roll positioning with easy handwheel operation. A fixed drive shaft option is also available. A special swivel base or rotary table is available for use with Double E safety chucks, allowing operators to pivot the chucks to compensate for baggy edges in the web material.
Light-weight 3˝ leaf shaft
Goldenrod Corp.
www.goldenrodusa.com
Goldenrod Corp. has introduced its new 1260-LF Ultralight Aluminum Multiple Bladder 3˝ Leaf Shaft (patent pending). The model was developed under critical ergonomic guidelines, and weighs less than 0.25 lbs. per inch of assembled body. The air bladders are easily accessible and can be replaced in 10-15 minutes. The 1260-LF shaft has custom-designed journal ends and is aimed at light-duty single- or multiple-roll applications.
Durable plastic cores for packaging
Sandell® Plastics
www.sandellplastics.com
Sandell®'s Plastic, a division of Sandell® Manufacturing Co., offers a wide variety of durable plastic cores for all industries. Sandell's plastic cores reduce dust, contamination, and unnecessary debris collection. They have the ability to hold an exorbitant amount of weight in comparison to cardboard cores, and will not breakdown or decompose over time. Common consideration when choosing a plastic core over standard cardboard cores are durability, longevity, and recycling qualities of the material. Sandell's plastic cores are an economical solution for any application in that they have the ability to be reused time and again. Extruded or injection molded, Sandell's plastic cores can be customized to accommodate any project or purpose.
Professional-grade chucks and adapters
Convertech Inc.
www.convertech.com
Convertech has introduced a full line of professional grade chucks and adapters. The system's approach incorporates advanced technological capabilities for faster and less-expensive solutions. Matching chucks with adapters equals savings. The chucks, available in mechanical or pneumatic designs, come in diameters up to 16˝, with face lengths up to 150˝. There are adapters for all brands of shafts.
Air powered lug chuck for high-speed jobs
Tidland
www.tidland.com
Tidland recently launched a new line of shaftless core chucks, called The Raptor Series. The new 3˝ Air Powered Lug Chuck is the first in the series and is designed for high-speed printing, laminating, and sheeting applications on unwind flying or zero speed splicers, and other shaftless unwind/rewind applications. The chuck reduces downtime and the risk of injury, while increasing productivity.
In addition, converters can dramatically improve splice reliability, increase operating speeds, and save time and money with repeated use of cores, without damage to core ends. Wide footprint lugs provide a consistent grip on the core, without damaging the inside. The Air Powered Lug Chuck enables on-machine maintenance and toolless adapter changes from 3˝-6˝ cores in less than five seconds. Unique ergonomic benefits are provided to operators, who no longer have to remove the entire chuck from the machine for routine maintenance or core size changes.
by Kate Sharon
Associate Editor
