Industry: Food & Beverage Manufacturing
Solution Provided By: RonI | Lift-O-Flex
Customer Challenge
A leading refrigerated foods manufacturer needed a safer, more ergonomic, and washdown-compatible way to handle heavy roll stock used throughout its production process. Operators were handling polyester/polyethylene film rolls weighing up to 350–400 lbs, with roll diameters ranging from 10”–28” and roll widths from 22”–33”.
The existing process required operators to move rolls from a staging queue or pallet area to the production machine, position the roll, insert a shaft through the core, and raise the roll into place on the machine’s bearing blocks. With roll weights reaching up to 400 lbs, the application created concerns around operator safety, manual effort, positioning accuracy, and repeated handling in a food production environment.
Because the equipment would be used in a food manufacturing facility, cleanability and corrosion resistance were also important considerations. This customer needed a lifting solution that could support heavy-duty roll handling while also fitting into a washdown production environment.
The customer’s goals were to:
- Reduce manual handling of heavy roll stock
- Improve operator safety and ergonomics
- Provide a washdown-compatible lifting solution for a food production environment
- Safely transport rolls throughout the manufacturing process
- Assist with loading rolls onto the machine at multiple drop-off heights
- Support repeated use over a two-shift operation
Our Solution
RonI provided a LIFT-O-FLEX® 19500 Series Washdown Lifter with a custom Squeeze-O-turn roll-handling attachment.
With this solution, the operator can move the lifter to the roll staging area, position the Squeeze-O-Turn arms next to the roll located on the pallet, grip the roll into the Squeeze-O-Turn arms, rotate the roll from core vertical to core horizontal, and transport it to the machine. Once at the machine, the operator inserts the shaft through the roll core, raises the roll to the proper height, and places the roll and shaft into the bearing blocks.
The washdown lifter design makes the unit well-suited for food manufacturing environments where equipment cleanability, corrosion resistance, and sanitary handling are important. The custom Squeeze-O-Turn attachment helps cradle the roll during transport and positioning, giving the operator a more controlled way to handle heavy roll stock.
The system was designed to support roll drop-off centerline heights of approximately 10” and 60” from the floor. The unit would be used approximately 6–10 cycles per hour across a two-shift operation.
An aluminum pallet stand was also recommended as an option to improve roll access from the pallet and support smoother operation during loading.
Key Features of the Solution
- Washdown-compatible design for food manufacturing environments
- Roll handling capacity for rolls weighing up to 350–400 lbs
- Roll size range of 10”–28” in diameter and 22”–33” wide
- Material handled: polyester/polyethylene film roll stock
- Core size: 6” ID core
- Custom roll attachment with Squeeze-O-Turn arms
- Effective lift height: 69.5”
- Lift speed: 3” per second
- Manual brake: foot-activated, 3-position brake
- Operator controls: stepless remote hand control
- Adjustable handlebar: approximately 38.5” from the floor
- Battery powered: 24V DC battery system with 110/240V charger
- Low noise level: less than 70 dB(A)
- Approximate unit weight: 170 lbs. without end-effector
Results & Benefits
The LIFT-O-FLEX® 19500 Series Washdown Lifter provided the leading refrigerated foods manufacturer with a safer and more controlled way to handle heavy roll stock in a food production environment.
By using the Squeeze-O-Turn attachment, operators can move rolls from staging to the machine without manually lifting the full weight of the roll. The powered lift function helps raise rolls into the correct loading position, while the mobile design allows the lifter to support the roll handling process throughout the manufacturing area.
Key benefits included:
- Improved operator safety by reducing manual handling of 350–400 lb rolls
- Better ergonomics during roll transport, positioning, and machine loading
- Controlled roll placement at multiple machine loading heights
- Washdown-compatible construction for food manufacturing environments
- Improved process consistency for repeated roll changes over multiple shifts
- Custom roll support through the Squeeze-O-Turn attachment
- Reduced physical strain during frequent roll handling cycles
Why It Worked
The LIFT-O-FLEX® 19500 Series Washdown Lifter addressed the customers' key handling challenges by combining powered lift assistance, a mobile lifter platform, and a custom Squeeze-O-Turn attachment designed specifically for roll handling.
Instead of relying on manual effort to move and position heavy roll stock, operators gained a safer and more ergonomic way to retrieve rolls from staging, transport them through the production area, and load them onto the machine.
The washdown design also made the lifter a strong fit for a food manufacturing environment where cleanability and corrosion resistance matter. By tailoring the solution to the customer’s roll size, roll weight, core size, machine loading heights, and production cycle requirements, RonI delivered a practical ergonomic lifting solution for demanding roll handling applications.