Case Study: Improving Efficiency with a Custom Roll Handling Solution

Industry: Manufacturing
Solution Provided By: RonI | Lift-O-Flex

Customer Challenge

A long-standing leader in custom textile technologies approached us with a complex roll-handling need. Their production process required operators to lift and manipulate multiple narrow-width rolls simultaneously—each roll measuring 40"–50" in diameter, 4.25" wide, and weighing a combined total of 450 lbs. The rolls were wound on a 6.75” ID core, and three rolls needed to be lifted in a single motion to maintain production efficiency.

Operators previously relied on manual handling or improvised tools, leading to concerns around operator safety, inconsistent loading precision, and slow changeover times. In particular, the rolls needed to be lifted vertically from a pallet and then rotated 90 degrees to allow for horizontal insertion into a machine, with tight space constraints for both lifting and maneuvering.

Our Solution

To address this, RonI designed and delivered a customized LIFT-O-FLEX® 19700 Series Ergonomic Lifter equipped with a custom Expand-O-Turn® end-effector.

Key Customizations:

• A 13” long core expander capable of engaging all three rolls at once via their shared core.
• Integrated rollers on the top of the core expander to streamline roll transfer.
• A tool lock, keeping the roll fixed during transport.
• A tapped hole in the end of the expander for potential attachments.
• A max vertical reach of 69” to lift rolls from pallets and align with the machine spindle.
• Powder-coated and anodized aluminum construction for clean operation and industrial compatibility.

This configuration allowed the operator to:

1. Securely grip the triple-roll stack from a pallet.
2. Rotate the rolls into the horizontal orientation required for machine loading.
3. Transport and align the rolls precisely with the machine spindle.
4. Easily release the rolls into position using simple manual controls.

Results & Benefits

• Time savings: Reduced roll loading and changeover time by over 40%.
• Ergonomic improvement: Eliminated the need for manual lifting of heavy rolls.
• Safety compliance: Improved operator safety and reduced strain injuries.
• Operational consistency: Enabled predictable roll alignment and machine uptime.

Why It Worked

Our ability to custom-design tooling to fit the customer’s unique application, combined with our reliable ergonomic lifter, provided a robust, long-term solution. The tailored Expand-O-Turn expander was key to enabling multi-roll handling without compromising precision or operator control.