Roll Handling Equipment Doubling Production with Roll Handling Carts
Client:
A global leader in plastics and bulk rolled materials, with applications in industries such as automotive, electronics, and packaging.
Challenge:
The customer secured a major contract that required them to quickly scale production of a UV-filtering film used in car windshields. However, their current process of manually moving a cart loaded with 6,000lb of film that was 40 inches in diameter and spanned 80 inches in length was physically demanding and time-consuming, requiring a lot of manpower to move the cart into different processing stations.
The solution was roll handling equipment that could improve load handling and maneuvering while streamlining the overall production process, accommodating the functions of different reshaping, splitting, or resizing machines based on the film’s final output.
Solution: Rail-Guided Roll Material Handling Carts by Conceptual Innovations
After thoroughly assessing the customer’s production needs, the engineers at Conceptual Innovations worked closely with the customer’s engineers to design 3 Rail-Guided Roll Handling Carts. These carts have a unique function that allows them to deploy a set of regular casters to easily move them between production line rail systems.
A unique “float” mechanism was also incorporated to ensure proper clearance and engagement with the selected processing machine, resolving prior issues with inconsistent roll handling disengagement.
Due to the care taken by Conceptual Innovations engineers to fully understand all the facets of the system, they were able to design and deliver a material handling carts solution that required half the commissioning time. In total, Conceptual Innovations designed and delivered 3 custom Rail Guided Transfer Carts for what the competition quoted for 1.
Key Improvements:
- Improved Efficiency: The Rail Guided Roll handling carts reduced the manpower needed to move and position the cart to accommodate the requirements of various machines, allowing operators to significantly reduce processing time.
- Enhanced Safety: Handling heavier loads became safer for workers, eliminating the strain and risk of manually maneuvering the film rolls.
- Precision Engineering: Conceptual Innovations’ unique “float” mechanism accommodated the complex processing stages. This feature ensured proper clearance and engagement with the machine to prevent inconsistent roll handling disengagement.
Measurable Results
Conceptual Innovations develops innovative, cost-effective roll material handling carts equipment that is easy to integrate and adaptable to all materials and environments. By streamlining workflow and enhancing operational efficiency, the customer saw a number of benefits, including:
- 50% Faster Commissioning: The system was so well-designed and integrated that it took only half the expected time to become fully operational.
- Operational Excellence: With the new cart and process improvements, the customer saw a 100% increase in production.
- Cost-Effectiveness: The seamless integration of the cart minimized downtime and worker injury, providing a safe and cost-effective solution to handle the expanded workload.
For more information on how motorized material handling carts can benefit your business, visit Conceptual Innovations or call 269-248-7932.