Roll Handing - The Key to Balancing Productivity, Safety
Roll handling equipment helps maintain productivity and protect employees, but it can also make the process of
mounting hard-to-handle substrates a cinch.
TODAY'S POPULAR PACKAGING substrates aren't the easiest to handle. Materials like films and foils telescope and have more issues with core damage than hardier substrates like paper, which complicates the should-be-simple process of placing a roll on press.
There are roll handling remedies, however, that help make these types of materials easier to deal with, while helping companies keep their employees safe from work-related injuries. From simple machine add-ons to custom-made technology, roll handling equipment manufacturers have the solutions.
"The equipment can be adapted or tailored to particular applications," said Chris van Haasteren, president, Schlumpf, Inc. "Slippery films tend to telescope and, therefore, the unit needs to be equipped with an anti-telescoping clamp. Applications where core damage is a concern can be handled with modified gripping elements, etc."
Telescoping and damage to the edges and cores of film and foil rolls aren't the only complications converters and printers have to address with roll handling technology. Different advancements in flexible packaging substrates and design ornamentation materials have increased their popularity, but these materials are heavier than the substrates used in the past, said Jerry Morton, Tilt-Lock general manager. This is why, he added, "Good roll handling equipment is absolutely necessary to prevent back injuries."
On-the-jobs injuries stemming from operators lifting and moving heavy rolls around the facility are prevalent and very costly. The statistics are eye-opening. According to the Bureau of Labor Statistics, U.S. Department of Labor, 1.3 million injuries and illnesses in private industry required recuperation away from work in 2003. Among the top three occupations with the greatest number of such injuries and illnesses was material movers.
While preventing problems, such as damage to rolls, is a top priority for many converting and printing companies, it's important to find a balance between productivity and protecting operators, van Haasteren said. "The use of roll handling equipment is a balance between productivity and risk. In many cases, it's faster handling a roll by hand, but conversely nothing is potentially more dangerous and potentially more costly to the company if an operator is injured. So, we as a supplier, need to address both issues: the roll handling equipment should minimize or eliminate the risk of operator injury, but not significantly impede the productivity requirements," he said.
For a look at some new roll handling equipment available today, read on:
Two station rotating roll handling equipmentfor accurate positioning
Converter Accessory Corp. (CAC)
www.handleyourweb.com
CAC's new two station Rotating Roll Handling device, the Rol-handlR, is for rolls that weigh up to 2,000 lbs. The dual lift stations with two pivot points allow a roll to be readily maneuvered into true vertical and true horizontal positions, which help eliminate damage to roll edges and allow rolls to be securely and safely placed in the desired positions.
The CAC system consists of a unique "L"-shaped pivot arm and a tandem, 360° north-to-south rotating hoist assembly that mounts to and tracks along any standard I-beam. Additional features include a probe engineered with weight-activated teeth to remain safely engaged even during power outages, and an exceptionally ergonomic, user-friendly one-handed control unit.
Self-contained roll handling system for rolls up to 1,000 lbs.
Converter Accessory Corp. (CAC)
www.handleyourweb.com
CAC also offers Rol-handlR Model PH 1, a cost-effective exceptionally easy-to-operate solution for handling rolls up to 1,000 lbs., in a wide range of widths and diameters. Model PH 1 is an entirely self-contained and floor-based moveable system that complements I-beam-based Rol-handlR models for rolls to 2,000 lbs. Model PH 1 is available in mechanical or battery powered electrical configurations.
It's also an entirely self-contained unit that does not require overhead equipment, fork truck, or any other additional handling equipment. It is a rugged, compact system able to lift and turn rolls from horizontal to vertical, vertical to horizontal, and transport and place them on pallets, cantilevered unwind shafts, or other production, shipping, or storage areas.
The Rol-handlR Model PH1 mechanical version features simple hand-operated hoists while the electrically powered system features ergonomically designed remote pendant controls. Both versions are safe to operate, featuring locking casters, two-point flexible suspension, and mechanical core locking.
Roll handling with speed and safetyfor productivity
Schlumpf, Inc.
www.schlumpf-inc.com
The ERH-300-P portable electric roll-handling machine combines high quality, low cost, and ease of use to maximize productivity and safety. The ERH-300-P design features high-speed lifting and turning for safe and efficient palletizing, loading, and unloading of rolls to 300 lbs. Large casters, ergonomic handle bar, and hand-held control pendant make the ERH-300-P easy to maneuver and control. The unique fail-safe expanding mandrel grips rolls securely by the core and can be quickly changed for use in applications with multiple core sizes.
The machine is equipped with an on-board automatic battery charger for safe and simple charging of the maintenance-free sealed 24 V battery system. An on-board voltmeter shows operators battery status so they know when to recharge. The ERH-300-P gives users a competitive advantage through low initial cost, increased safety, decreased material damage, and less operator fatigue. Custom configurations are available.
Automatic leveling device to save time and material
Tilt-Lock
www.tiltlock.com
Tilt-Lock's Automatic Leveling Device is designed to be attached to the company's patented Tip Lift roll handling device. The leveling device assures that the frame of the tip lift is plumb at all times and that the roll is level when the roll is tipped to the horizontal position.
The leveling device offers stability when handling rolls of material up to 2,000 lbs., preventing damage to the roll, speeding up material handling time, and reducing injury risk.
The device features a ball screw and nut coupled to an inline reversing gear motor which is governed by level sensing switches. When the level switches sense that the roll is off balance, the gear motor is activated. When the correct suspension point has been achieved, the gear motor will automatically shut off, thus insuring a horizontal attitude.
This new mechanism provides a convenient method of handling rolls for loading and unloading of shafts. The leveling device may be operated in the automatic or manual mode.
by Kate Sharon
Associate Editor
