Case Study: Improving Bag Handling Safety in a Dust-Rated Processing Environment

Lindsay Rutherford
6 min read

Industry:    Consumer Goods / Oral Care Manufacturing 
Solution Provided By: RonI | Lift-O-Flex

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Customer Challenge

A new consumer goods processing facility required an ergonomic material-handling solution for routine bag handling operations involving packaged materials weighing up to 50 lbs. The application demanded a system that could support frequent lifting, positioning, and placement while meeting strict environmental and safety requirements.

Key challenges included:

  • Repetitive manual handling of bags weighing up to 50 lbs
  • Operator fatigue and increased injury risk from frequent lifting
  • Need for precise, controlled bag positioning during processing
  • Compliance with Class 1, Division 1, flammable gases, vapers and liquids. 
  • Wash-down and sanitation considerations requiring stainless-steel construction
  • Limited floor space requiring overhead reach and articulation

The customer sought a solution that would improve operator ergonomics and safety without compromising process efficiency or facility compliance.

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Our Solution

RonI engineered a dust-rated ergonomic lifting solution tailored to the facility’s environmental and operational constraints. Based on application requirements, RonI proposed a Vacuhand vacuum tube lifting system integrated with a fixed stainless-steel crane and articulating MOBI-Arm.

The system was designed to allow a single operator to lift, maneuver, and place bags smoothly using minimal physical effort, while maintaining full compliance with hazardous-area standards.

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Proposed Equipment Configuration

Vacuhand Vacuum Tube Lifter – Stainless-Steel Version

  • 6.30" diameter vacuum lift tube
  • 8.20 ft. tube length for vertical reach
  • Vacuum pump
  • In-line filter unit mounted at the vacuum pump
  • Ergonomic Vacuhand operator control handle
  • Noise level <70 dB(A) with integrated sound muffler
  • 2” vacuum supply hose with hose support straps
  • Oval suction foot designed specifically for bag handling
  • Electrical: 460V, 3-Phase, 60 Hz

Fixed Crane with Articulating MOBI-Arm

  • Stainless-steel construction for hygiene and corrosion resistance
  • 10 ft. articulated arm length for extended horizontal reach
  • Fixed-height column design
  • Arm locking catch for controlled positioning
  • Vacuum lift tube hanging device for improved balance and operator control
  • Rated lifting capacity up to 75 lbs

This configuration allowed operators to lift bags directly from pallets or staging areas and move them smoothly through the required working space with minimal effort.

Outcome

The proposed Vacuhand crane system provided a clear ergonomic improvement path for the facility, addressing both safety and operational needs in a dust-rated environment.

Key benefits included:

  • Significant reduction in manual lifting strain for operators
  • One-operator bag handling, improving labor efficiency
  • Smooth, controlled handling of bags up to 50 lbs
  • Improved consistency in bag placement and positioning
  • Stainless-steel construction suitable for hygienic processing environments
  • Flexible crane articulation allowing coverage of multiple workstations

By integrating vacuum lifting technology with an articulating crane system, RonI delivered a solution designed to support long-term safety, productivity, and regulatory compliance.