Reel & Roll Handling
Adapting reel handling to modern production environments
I
n fast-paced manufacturing such as printing, film and foil, textiles and cable production, the way reels and rolls are handled can make or break operational performance. These cylindrical loads challenge both productivity and safety: they’re heavy, unstable in orientation and prone to damage if mishandled. As production lines demand cleaner, quieter and more efficient material flow, companies must rethink reel handling using smarter, flexible solutions.
THE CORE CHALLENGE
Reels and rolls differ fundamentally from boxed or palletised loads. Their round profiles, variable diameters, and cores make gripping, lifting and positioning difficult. A reel dropped, dented, twisted, or misaligned on a mandrel can cause downstream rejects or machine faults. Operators handling reels manually are exposed to risks: back strain, repetitive motion injuries, slips or missteps when controlling a swinging load, or even crushing injuries in tight spaces.
When lines must turn reels quickly (for example, mounting a fresh roll on a converter or feeder), delays or mistakes directly hit throughput. Moreover, in environments such as food, pharmaceuticals, or cleanrooms, handling equipment must avoid oil leakage, excessive noise, or dust generation.
INNOVATIONS THAT HELP Compact, electric stackers are proving especially valuable in reel handling
applications. Freedom Stackers, for example, combine a small footprint with ergonomic, battery-powered lifting. This makes them ideal for working in production aisles or tighter areas where forklifts are impractical. The smooth electric drive also reduces the jolts associated with manual handling, which lowers the risk of reels slipping or being damaged in transit.
For more specialised reel and drum tasks, the Pronomic lifting trolley range offers lightweight, highly configurable solutions. Their modular design means operators can choose attachments tailored to the application: an Expand & Turn tool grips reels securely through the core and rotates them into position, while the Squeeze & Turn clamps drums or barrels for controlled movement. Because the trolleys are available in cleanroom-friendly formats, they can be deployed even in sensitive production environments.
Together, these types of equipment illustrate how reel-specific handling solutions deliver real operational value: improving workplace safety, protecting materials from damage, and reducing the time needed to set up or change over lines. Their modularity also means one platform can adapt to multiple reel sizes or weights simply by switching attachments, offering flexibility as production requirements evolve multiple reel sizes or weights by simply swapping attachments.
BEST PRACTICES FOR INTEGRATION • Match equipment to reel specs: Always evaluate weight, diameter, core dimensions and centre of gravity
• Start with modular attachments: Use interchangeable grippers, mandrels, or rotators so that one handling unit adapts to varying reels over time
• Minimise manual touches: Wherever possible, use core lifting and direct mounting methods (e.g. via the Pronomic Expand & Turn) to avoid intermediate transfers
• Consider the footprint: Compact stackers must navigate narrow aisles or doorways. The Freedom stackers are designed to fit through standard doors
• Maintain clean and quiet operation: Regular maintenance to avoid hydraulic leaks, and use low-noise drive systems to meet modern floor standards
THE PAYOFF
By combining ergonomic stackers with versatile lifting trolleys and reel-specific attachments, businesses can dramatically reduce downtime, scrap and injury risk. Setup times shrink, reel misalignments or drops decline, and operator fatigue becomes less of a bottleneck.
In environments pushing for low-noise, clean and flexible workflows such as pharma, packaging, food, or high-tech manufacturing, the right reel handling tools become a strategic advantage, not an optional upgrade. For businesses looking to modernise reel handling, the key is choosing equipment that balances safety, efficiency and adaptability. Speaking with a specialist supplier can help identify the right solution for your operation.
Visit
www.advancedhandling.co.uk for more information.
18 October 2025
www.convertermag.com
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