The Challenge:
Green Bay Packaging produces diverse paperboard packaging using 100% recycled materials. One stage of their operation involves slitting and sizing large paper rolls to meet customer demands. These finished rolls can weigh up to 600 pounds and measure up to 3' x 5'. Workers must move them into work cells and load them onto skids for final shipping.
Manual handling of these rolls created a severe occupational hazard. Back strains emerged as the leading cause of lost-time injuries. These injuries occurred frequently and sometimes reached a rate of once per week. Even when rolls were clearly too heavy to lift manually, operators still tried to move smaller, 60-pound rolls by hand to save time. This habit endangered operator safety. Management sought a robust solution to eliminate these injuries and prevent product damage during the stacking process.
The Solution:
Green Bay Packaging evaluated two options to address these concerns: an up-ender or a crane system equipped with a manipulator. The up-ender failed to meet their operational needs because it lacked the flexibility required to load skids efficiently. The company ultimately selected a 4,000-pound capacity Gorbel Free Standing Work Station Crane. This system utilized dual girder bridges to provide stability for a heavy-duty manipulator. To minimize physical strain on operators, the bridge crane featured motorized tractor drives. This addition allowed smooth, effortless movement along the runways.
The Execution:
The Gorbel Work Station Crane transformed the work cell into a controlled environment. First, the manipulator enters the hollow core of the paper roll. Once engaged, the device turns the roll to the exact orientation required for the skid.
Because the system utilizes a dual-girder bridge design, the load remains stable throughout the entire lift-and-transfer cycle. Stability holds even when the roll is not centered beneath the manipulator. Motorized tractor drives allow the operator to start and stop the movement of heavy loads along the X and Y axes with minimal force. This system removes the kinetic strain associated with starting or halting heavy paper rolls.
The Result:
The implementation was successful. Following the installation of the Gorbel system, Green Bay Packaging eliminated all injuries in the work area. By automating the heavy lifting and stacking process, the company protected its workforce. Operators report that handling the heaviest loads is now significantly easier. These reports confirm the system drives both safety and operational efficiency.