Roll Handling Slitting and Rewinding Fundamentals for Converters Ontario, CA November 15-16, 2005 Jeff Damour Converter Accessory Corporation 1-800-433-2413
Roll Handling What is roll handling? Why is roll handling important? How does various roll handling equipment work? What are the advantages and disadvantages of each type? What to consider when searching for roll handling equipment.
What is roll handling? Moving rolls From manufacturing or receiving to processing Between processing From processing to shipping or storage
What is roll handling? Turning rolls From perpendicular to horizontal Pallets to processing From horizontal to perpendicular Processing to pallets
Why is roll handling important? According to OSHA, back injuries are the nations #1 workplace safety problem Employee pain and suffering Costs industry BILLIONS Damage to rolls costs money in wasted material
Why is roll handling important? OSHA fact sheet #89-09 at: http://www.pp.okstate.edu/ehs/training/oshaback.htm No one specific weight limit for lifting Guidelines and formulas at: http://www.osha.gov/dts/osta/otm/otm_vii/otm_vii_1.html#app_vii:1_2
Why is roll handling important? How do you currently turn rolls? Employee safety! Roll damage!
Why is roll handling important? How do you currently move rolls? Employee safety! Roll damage!
How does roll handling work? Equipment that mounts on fork trucks Overhead devices Walk-behind units Tilt tables Robotic systems Picture is worth 1,000 words
Fork truck mounted equipment Clamp truck devices Common in applications with very heavy rolls up to 10,000 lbs. Grab rolls from outside Rugged designs for demanding applications Designed to mount to the mast of any fork truck Swivel to orient rolls horizontal to perpendicular and vice versa
Clamp truck devices
Clamp truck advantages Can handle large rolls up to 10,000 lbs. Move, turn, possibly load in one operation Rugged for very demanding applications Easy to use Can handle multiple rolls of same diameter Used in paper and paperboard applications Rigid roll handling no roll sway in the air
Clamp truck disadvantages Clamping outside of roll may damage layers Not well suited for foils and films Will not work for small rolls Hydraulics need maintenance Relatively expensive Limits use of existing fork truck Multiple rolls must be same diameter
Fork truck mounted equipment Core probe device Two types rigid core probe and flexible core probe Used mainly for smaller rolls up to 2,000 lbs. Grab rolls from core Designed to mount to the mast or forks of any fork truck Core probe pivots to orient rolls horizontal to perpendicular and vice versa
Core probe
Fork truck / rigid core probe Photos courtesy of Tilt-Lock Inc.
Fork truck / rigid core probe advantages Simple design, easy to use Will handle multiple rolls with one probe Remote or mounted controls Probe can be powered with electric, pneumatic or hydraulic actuators No outside roll damage Move, turn, load, unload all in one operation Rolls held rigidly in air no roll sway
Fork truck / rigid core probe disadvantages Roll weights up to 2000 lbs. Probe to core alignment critical may be difficult May have trouble gripping plastic or metal cores Probe teeth may damage cores Roll telescoping is a concern Additional vacuum plate may be needed to eliminate telescoping Roll weight is cantilevered could cause fork truck instability
Fork truck / flexible core probe
Fork truck / flexible core probe advantages Unit mounts on forks easy change Roll weight is centered under forks better fork truck stability Will handle multiple rolls with one probe No outside roll damage Move, turn, load, unload all in one operation Well suited for smaller rolls Flexible point suspension allows easy probe alignment with core
Fork truck / flexible core probe disadvantages Maximum roll weight is 1,000 lbs. Flexible probe suspension will allow roll sway May have trouble gripping plastic or metal cores Probe may damage cores Roll telescoping is a concern
Overhead devices Two types single hoist and dual hoist mounted Most handle roll weights up to 2,000 lbs. Use core probes to grip the roll Swivel to orient roll north to south Core probe pivots to orient rolls horizontal to perpendicular and vice versa
Overhead / dual hoist
Overhead / dual hoist Relatively simple, very easy to use Will orient rolls truly horizontal and perpendicular ensures zero roll damage Not as stable as single hoist units more roll sway Require two hoists Requires special swiveling tandem hoist assembly for north to south rotation
Overhead / single hoist Photos courtesy of Tilt-Lock Inc.
Overhead / single hoist Relatively simple, easy to use Need only one hoist north to south rotation with one hoist More stable than two hoist system less roll sway Can not achieve true horizontal roll orientation possible damage to corner of roll when rested on the floor Can be powered with electric, pneumatic or hydraulic actuator
Overhead (general) advantages Can handle multiple rolls with one probe Can have remote pendant or mounted controls Will handle rolls up to 2000 lbs. Will not damage outside of rolls Move, orient, load and unload rolls in one operation Very common, many designs and manufacturers to choose from
Overhead (general) disadvantages Generally cannot be used for roll weights over 2,000 lbs. May have trouble gripping plastic or metal cores Probe may damage cores Roll telescoping is a concern vacuum plate may be needed Roll positioning is limited to overhead placement
Overhead for moving only Photos courtesy of Tilt-Lock Inc.
Overhead for moving only Photos courtesy of Tilt-Lock Inc.
Walk-behind devices Common for light to medium duty applications most designed for up to 1000 lbs. Designs are available to handle rolls up to 2000 lbs. Designs use probes or roll clamps Self contained no overhead needed
Walk-behind devices Roll clamp type
Walk-behind devices Roll clamp type - advantages Can handle multiple rolls Manual or powered Can handle roll weights up to 1,000 lbs. Core material is not an issue Move, turn, load and unload in one operation
Walk-behind devices Roll clamp type - disadvantages Clamps may damage outside of some rolls Can t handle heavy rolls Powered units need battery, unit will be out of service periodically for recharge
Walk-behind devices Rigid core probe type
Walk-behind devices Flexible core probe type
Walk-behind devices Core probe type - advantages Can handle multiple rolls Manual or powered Can handle roll weights up to 1,000 lbs. No damage to outside of rolls, grips roll by the core Move, turn, load and unload in one operation
Walk-behind devices Core probe type - disadvantages Light to medium duty applications May have trouble gripping metal or plastic cores Probe teeth can damage cores Telescoping rolls are a concern Powered units need battery periodic recharge is necessary
Walk-behind devices Roll moving only
Tilt table devices Turn very heavy loads up to 10,000 lbs. 90 degrees Can be loaded with whole pallets to turn many rolls at one time Turn heavy rolls very gently with no damage to cores or roll outside layers
Photos courtesy of Tilt-Lock Inc. Tilt table devices
Tilt table devices advantages Turn multiple rolls, even whole pallets, 90 degrees at one time Avoid telescoping Can handle very heavy loads up to 10,000 lbs.
Tilt table devices disadvantages Tilt tables are stationary rolls must be brought to and from them Turning rolls and moving rolls are two separate operations
Robotic systems Automatic or semi-automatic Greatly limit or eliminate employee handling of rolls Ultimate in safety and efficiency
Robotic systems
Robotic systems
Robotic systems advantages Greatly reduce or eliminate people handling rolls Most efficient
Robotic systems disadvantages Very complex a lot of mechanical and electronic systems Changes in machine setups mean reprogramming Most expensive
Roll Handling Many types Each well suited for specific applications Each custom manufactured for specific applications
When considering equipment How heavy are your rolls? Do you need to move rolls, turn rolls or both? What is the width range of your rolls What range of roll diameters will you need to handle?
When considering equipment What core sizes do you need to handle? Are your core cardboard, metal or plastic? Will core damage effect other operations? Are the outside layers of your rolls delicate?
When considering equipment How fast do you need to move / turn / load and unload rolls? Do you need to add overhead or does it already exist?
When considering equipment Get everyone involved in the process! If equipment operators can t use the equipment because it is to slow, difficult or cumbersome they will not use it!
Roll Handling When roll handling equipment is designed and applied properly for your application it will improve your safety and bottom line. Less plant personnel injury, fatigue and less waste due to roll damage will improve your process and profits.
Roll Handling Thank you Slitting and Rewinding Fundamentals for Converters Ontario, CA November 15-16, 2005 Jeff Damour Converter Accessory Corporation 1-800-433-2413