Project Scope:
The packaging industry consists of a variety of different materials. Paper to plastic films are commonly used to package snack foods or shavers. Some companies use these materials at sizes up to 60” wide x 32”od in order to convert them into packaging film. Some of these companies also need to store this material in special “conditioning rooms”. This “conditioning” of the film surface is necessary for further processing.
The rolls of packaging film are often moved and placed on wood pallets with foam wedge blocks, or on molded plastic cradle shaped pallets. Both the wood and plastic cradles are not stackable, which uses valuable floor space. These plastic cradles have design flaws that cause them to crack with rolls in the 800-lb range. Once the plastic cradle starts to crack the useful life is quickly reduced and the packaging film is prone to damage.
Design Expectations:
We were contacted by a large film converting operation hoping for the development of a better cradle base along with an integrated system for collapsible uprights to enable stacking. Our client had a keen need for stacking because they have a limited amount of floor space in the “cure room”. Consideration was given to installing rigid racks, but the permanent and limiting feature of those racks was not acceptable.
The flexible floor space would allow for both easy configuration and the ability to accommodate the various roll sizes.
The volume of rolls that needed to be processed demanded a design that could integrate with sitter and printing input positions.
The height and foot print of the designed solution must be comparable to the plastic cradle. The folding uprights need to allow for clear and easy access to the film rolls.
A medium density foam pad is placed on the plastic cradle to cushion the roll surface from the hard plastic, and this will be used in our design as well.
Final Product:
The final product has four formed cores, on two levels, with a center space that allows for the coiled cable to be placed three per side. Included removable covers with openings that will allow the operator on the line easy access for cutting the plastic ties. The release of the coiled cable is contained inside these covers. They also keep the cable from being tangled and provide for controlled unwinding of each cable coil. The two longer sides, (facing in view shown) have removable cross bars. These provide easy access to the covered coils.
The finished design will handle the 32”od of the converting roll. The width of the base is 36”; this is narrower than some of the film widths, which can be up to 55” wide. This allows the roll to be staged at the printer or slitter input location.
The collapsible uprights have a slip ring that completely locks the upright in their vertical position. To collapse the upright, the slip ring is easily raised above the interlocking section of the hinge allowing the upright to fold down.
Stacking four rolls is now easier than ever, and the floor space can be better utilized.
