Reel and Roll Handling
How do you choose a safe roll handling solution?
R
eel and roll handling is an integral part of the US$260Billion global fl exible packaging industry. Giant parent reels, such as those found in papermills and
the larger plastic fi lm extrusion plants, are initially handled straight after formation with overhead cranes and forklift trucks. Whilst this occurs, reels are rewound and cut down to enable them to feed printing, converting and packaging machines, therefore both the handling and operational safety requirements diversify greatly. A key decider in choosing the right roll handling equipment for a particular application might actually be how it can manoeuvre safely in the physically restricted and challenging environments often found in crowded production areas. Often, it is a ‘no-brainer’ for a manager to specify a fully powered lift and drive reel truck to move reels over one tonne, for example, to reduce the physical strain put on operators. However, what is so often not taken into consideration, is the dangers posed by having fully laden powered truck’s, weighing up to 750 kg themselves, manoeuvering into and around machinery in very close proximity to operators and other personnel. Witness the scuff and scar marks seen on not only the vehicles, but also the surrounding machinery and equipment in printing and converting plants.
Now consider the physical harm that these vehicles can infl ict on personnel. The German DGUV estimated that there were more than 3,000 accidents in 2022, involving industrial trucks with the operators themselves frequently being the victims and 45 percent of the accidents resulting in foot and ankle injuries.
So how do you choose a safe roll handling solution for your plant? First and foremost, there should be a comprehensive risk assessment, taking into account the working environment, including entry and exit paths for the rolls, the physical dimensions and weights of the rolls and the full range physical requirements put on the operators. The latter consideration is often controversial, particularly where the weights are relatively low in the sub 30 kg region, where healthy and active operators often prefer to physically manhandle rolls, rather than using intermediary equipment.
Where rolls are in the most common range that requires specialist roll handling trucks/trolleys, from roughly 150Kg to 600Kg, there are many
vehicles to choose from, including low-cost catalogue style trolleys and lifters. However, above the 600Kg mark, specialist heavy duty roll handling trucks come into their own with options at the lighter end for all manual push/manual hydraulic lift trucks, then through manual push trucks with battery powered lift. Generally, though, above 1000 kg capacity, the trucks all utilise battery powered drive and lift. It is typically these powered industrial trucks that can present an additional risk of physical harm to the operators from crush injuries, especially whilst manoeuvering in cramped areas. It was in order to combat these risks, that the add-on ACKBelt (Anti-Crush Kick-Belt), was developed.
The ACKBelt is a simple fl exible switch, made of impact absorbing rubber, which can be fi tted around the base, or any other point, of a powered handling truck and connected to the trucks own Anti-Crush Button. Now, if the part of a truck protected by the ACKBelt should hit an obstacle such as an operator’s ankle, machinery or goods, the truck’s own Anti-Crush Button is instantly activated.
Choosing the right kind of roll handling equipment for a particular application should involve not only the equipment itself, but also a study of how it will integrate with the environment, including how the operators will use it. Therefore, from the product coming in, to the product going out, and through all the production processes involved, the key to choosing the right roll handling equipment is risk assessment, risk assessment and risk assessment!
16
February 2025
www.convertermag.com
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