The Challenge: Challenges in paperboard manufacturing
Green Bay Packaging manufactures pulp and paper products using 100% recycled materials. The company slits and sizes large bulk rolls to meet customer demand. Workers move these stacks to a work cell where they load them onto skids or into a machine for rewinding. These rolls vary in size. Some reach $3^{\prime}\times5^{\prime}$ and weights up to 600 pounds.
Manual handling was a major safety concern. Back strains caused the most lost time and happened as often as once per week. While the largest rolls require mechanical help, operators often moved smaller rolls by hand to save time. The work cell also had space restrictions. These constraints made it impossible for a standard overhead crane to cover the entire work area.
The Solution: Selecting the lifting solution
The company needed a way to stop injuries and prevent product damage. They looked at up-enders and cranes with manipulators. John Frederick of Green Bay Packaging noted that up-enders did not allow the control needed to stack rolls on skids. A manipulator was necessary for stacking.
The facility chose a 600 pound capacity Cleveland Tramrail crane. This system uses dual monorails and a platform to support the manipulator. The dual monorail design provides the strength to support the weight of a large manipulator even when it reaches outside the support structure to pick up 600 pound rolls.
The Execution: Implementing the manipulator system
The manipulator inserts a probe into the center hole of the paper rolls. It then turns the roll to the right position for the machine. Operators manage the linear movement through drive controls located on the handle. The dual tracks keep the platform stable while the operator guides the roll.
The Result: Safety and efficiency
The new process was effective immediately. Workers found that moving even the heaviest loads became easier. Safety was the primary goal for this installation. Frederick stated that there has been a huge reduction in injuries. Since the crane was installed, zero injuries have occurred in that area.