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Operator Training Paper Roll Handling General
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Operator Training Paper Roll Handling General

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Operator Training Paper Roll Handling General Operator Training Paper Roll Handling General Presentation Transcript

  • Operator Training Paper roll handling BOLZONI-AURAMO HOMEWOOD, ILL 1-800-358-5438
  • Table of contents: Section 1: Paper handling in general. Section 2: Damage prevention Click on your choice Forest products, pulp bales and paper rolls in particular, are one of the most demanding cargo commodities requiring specialized lift truck attachments and skilled drivers. Our education will help paper producers in the aim to deliver their products without damages.
  • Table of contents Paper handling in general Paper handling in general Daily inspection Safety rules and capacity Contact pad guide Choosing lift truck and clamps Select the correct clamping force Click on your choice
  • Table of contents Damage prevention Damage prevention in general End damage Edge damage Belly damage Out-of-roundness damage Click on your choice
  • The paper rolls may be handled up to 15 times before delivery to the customer ! The transport chain of forest products is often very long. A paper roll may require as many as 15 handling stages on its way from paper machine to the printing machine. This makes it essential to use well-chosen, well-maintained equipment dedicated to forest products handling. Paper handling in general
  • Reducing damage is our mission and the customer’s vision Paper handling in general Delivery from paper mill to customer
  • Newsprint
    • Small paper rolls
    • • Typical weight 500 - 1600 kg (1,100 - 3,300 lbs)
    • • Typical roll width/height 800/1200/1600 mm (31.5”/47”/63”), lots of variations
    • • Typical diameter below 1300 mm (51”) Future 1500 mm!!!!
    • Relatively soft paper
    • • Prone to out-of-roundness damage
    • • Does not require very much clamping force
    • • Does not tolerate excessive clamping force
    • • Often high recycled fibre content
    • • Typical grammage 35 - 55 g/m2
    Paper handling in general
  • Magazine paper
    • Bigger paper rolls
    • • Typical weight up to 7000 kg (13,000 lbs)
    • • Typical roll width/height up to 4600 mm (140”), lots of variations
    • • Typical diameter below 1300 mm (51”)
    • Medium hard paper
    • • Tolerates clamping quite well
    • • Requires high clamping force
    • • Typical grammage 50 - 100 g/m2
    Paper handling in general
  • Tissue paper
    • Large diameter rolls
    • • Typical weight up to 5000 kg (11,000 lbs)
    • • Typical roll width/height up to 2000 mm (78”), lots of variations
    • • Typical diameter up to 2500 mm (98”),
    • lots of variations
    • Soft paper
    • • Soft, sometimes very soft paper
    • • Requires minimum clamping force
    • • Deforms easily under clamp pads
    • • Low grammage
    Paper handling in general
    • Bigger paper rolls
    • • Typical weight up to 6000 kg (13,000 lbs)
    • • Typical roll width/height up to 3600 mm (140”), lots of variations
    • • Typical diameter below 2000 mm (78”)
    • Relatively hard paper
    • • Tolerates clamping quite well
    • • Requires high clamping force
    • • Typical grammage up to 160 g/m2
    Paperboard Paper handling in general
  • Safety rules and capacity
    • • Working safety
    • • Lift truck stability
    • • Correct handling and driving procedures
    • • Daily checks
    Safety rules and capacity
    • No overloading
    Safety rules and capacity
  • Do not stand under the load Safety rules and capacity
    • Do not stand on top of the load
    Safety rules and capacity
    • Do not stand in front of the load
    Safety rules and capacity
    • Do not stand on the side of the load
    Safety rules and capacity
    • Do not stand between
    • the clamping arms
    Safety rules and capacity
    • No loose rolls
    Safety rules and capacity
    • Do not lift unsuitable loads
    Safety rules and capacity
    • Do not rotate
    • when the roll is off centre
    Safety rules and capacity
    • Do not drive with horizontal roll
    Safety rules and capacity
    • Do not clamp too deep
    Safety rules and capacity
    • No tip clamping
    Safety rules and capacity
    • Do not open clamp while driving
    Safety rules and capacity
    • Do not drive
    • with load lifted high
    Safety rules and capacity
    • Keep mast vertical
    • when clamping vertical rolls
    Safety rules and capacity
    • Multiple rolls with
    • split arm clamp only
    Safety rules and capacity
    • Do not use damaged
    • or defective clamp
    Safety rules and capacity
    • Do not lift or carry load with red light
    Intelligent clamps DON’T FORGET TO FOLLOW LOCAL SAFETY REGULATIONS! Safety rules and capacity
  • Lift truck’s center of gravity
    • • The main target is to maintain a stable handling situation, with a defined safety margin
    Safety rules and capacity • An unloaded lift truck has a fixed center of gravity • Lift truck, attachment and load have a combined center of gravity point. It moves forward the heavier the load is and the more forward the load is situated. Never exceed the rated capacity of the attachment & lift truck combination !
  • Net capacity rating
    • Why a 3000 kg (7000 lbs) lift truck can’t
    • safely lift a 3000 kg (7000 lbs) paper roll?
    • The standard lifting capacity rating for lift trucks is based on the use of forks
    • The weight of the clamp reduces the lifting capacity of the truck – a clamp suitable to lift 3000 kg (7,000 lbs) rolls can have a weight of 900 kg (2,000 lbs) or more
    • The thickness of the attachment pushes the load forward and reduces the lift truck capacity
    • Depending on the roll diameter the center of the load can be further forward than the lift truck’s rated load center
    Safety rules and capacity
  • The effect of loading 1
    • When the load’s center of gravity moves forward, the lift truck’s lifting ability decreases
    • Example: 5000 kg (11,000 lbs) at 600 mm (24”) load center is the same as 2500 kg (5,500 lbs) at 1200 mm (47”) load center
    • This means that a 5000 kg (11,000 lbs) at 600 mm (24”) specified lift truck cannot lift a 5000 kg (11,000 lbs) at 1200 mm (47”) load !
    • Check where the real load center of gravity is, and what is its effect on the lift truck’s lifting capacity !
    Safety rules and capacity 5000 kg / 600 mm (11,000 lbs / 24”) 5000 kg / 1200 mm (11,000 lbs / 47”)
  • The effect of loading 2
    • Lifting capacity reduces when the load center moves forward
    • Example: loading with a load extender
    Safety rules and capacity
  • The effect of loading 3
    • Load center moves upwards when the lift mast is raised, reducing the lift truck’s stability
    • Lift truck’s specifications define the maximum loads to different loading heights
    • Notice also the possible danger with the lift truck’s stability when tilting, sideshifting, accelerating, braking and cornering
    Safety rules and capacity
  • Lifting a paper roll on a horizontal position
    • Do not drive with horizontal roll !
      • high safety risk in case the paper roll gets loose
      • higher stress directed to clamp arms
      • higher stress directed to rotation system
      • higher stress directed to the lift mast and carriage
    • Rotate the roll to vertical position as soon as possible
    Safety rules and capacity
  • Choosing truck and clamps
  • Check list for the right clamp: • Weight of the paper roll • Max- and min diameter • Roll width • Paper quality/rec clamping force • Type of wrapping • Storage and stowage pattern • Number of rolls per handling • Rotation Check list for the right lift truck: • Type of clamp • Secured lifting capacity • Height of stowage • Hydraulic functions, pressure and flows • Tilting functions • Clamp mounting Choosing truck and clamps
    • Single and multiple vertical rolls
    • • Non-rotating, pivot-arm or sliding-arm clamps
    • • Multiple arm pairs if roll or roll stack height so requires
    • • Non-split or split arm
    Choosing truck and clamps
    • • Rotating, pivot-arm or sliding-arm clamps
    • • Multiple arm pairs if roll or roll stack height
    • so requires
    • • Tippling
    • • Non-split or split arm
    Single and multiple vertical and horizontal rolls Choosing truck and clamps
  • Non-split or split arm ? Choosing truck and clamps
  • Always use the correct clamp Choosing truck and clamps
  • Non-split or split arm
    • Paper rolls handling more than one roll at a time should always have a split clamping arm design
    • A split arm enables safe and damage free handling of two paper rolls of unequal diameters
    • It reduces roll edge damage and the risk to drop the rolls
    • Split-arm models can also handle single paper rolls
    • Most Bolzoni Auramo roll clamps are available as non-split and split arm versions
    Choosing truck and clamps
    • Optimized clamping on each roll
    • Secure handling
    • 2-4 split arms enables safe and damage free handling of paper rolls of unequal diameters
    • For reducing roll edge damage and the risk to drop the rolls due to incorrect clamping
    • Clamping force is divided between all rolls
    Why 2, 3 or 4 arms? Choosing truck and clamps
    • The target is that each roll is carried by its own clamping force and clamped in the optimal position
    Why 2, 3 or 4 arms? Choosing truck and clamps 1250 kp 1250 kp 1250 kp 1250 kp 1250 kp 1250 kp 3750 kp
    • • 50 % force / arm
    • For example, if 9,OOO lbf is needed,
    • there is 4,500 lbf/arm
    Choosing truck and clamps Avoid edge damage ! 4,500LBF 4,500LBF
  • 20 + 20 = 40 kN 20 + 0 = 20 kN When handling a single roll, special attention must be paid to the total clamping pressure 20 = 20 kN Why 2, 3 or 4 arms? Choosing truck and clamps 20kn=4,480lbf 4,480+4,480=8,960lbf 4,480+0=4,480 4,480+4,480=8960lbf
  • Target is to give each roll their own clamping force Normal handling Big risk for accidents and out of roundness damge due to high clamping force on lowe rolls.
  • Oveloading / Wrong loading
    • An example on what happens to the need of clamping force with different ways to handle the rolls
    • The more rolls – the heavier the load – the more clamping force is required.
    • Extra free-riding rolls lead into increased clamping force need. This will cause out-of-roundness on the lowermost rolls.
    • Exampel with clamping factor 1.5 and roll weight 2,200lb
    3,360lbf 10,080lbf 6,600lbf 13,440lbf
  • Handling of jumbo rolls - Why 2, 3 or 4 arms? Choosing truck and clamps F c F n F n F c ROLL A ROLL B F c /3 F c /3 F c /3 F c /3 F c /3 F c /3 F n /3 F n /3 F m F m F m F m F m F m F m F m F n /3 F n /3 Micro and macro friction F n /3 F n /3
  • Short arm should be against the floor while lifting a roll from the ground Short arm makes handling in tight spaces easier and minimizes the risk of roll damage Short and long arm Choosing truck and clamps Short arm inside Long arm outside
  • Daily inspection
    • Check the clamping force
    • Check the condition of the equipment:
      • clamping arms
      • contact pads and pad surfaces
      • frame
      • Hydraulics and hoses
      • mounting
    • Check that the arms, pads and frame are clean and there are no sharp edges to damage the paper rolls
    Never use a defective or damaged equipment ! Daily inspection
  • Contact Pads - Friction surface service
    • Clean the friction surface regularly
    • Re-surface or replace pads whenever the friction surfaces are too worn out
    • Remember that a clamp with worn out friction surfaces can require up to 3 - 5 times more clamping force than a clamp with good pads. This difference has a significant negative effect on the paper roll out-of-roundness values.
    Daily inspection 
  • Contact Pads - Sharp edge removal
    • If contact pads have sharp edges, they easily cut the wrapper of the roll
    • Remove all sharp edges from the pads with a suitable tool such as a file or an angle grinder
    • Ensure that the pad protector loops on the arms have enough material left to protect the pads from wearing out
    • Ensure that the wear plates on the short arm pads are not too worn out
    Daily inspection 
  • Contribute to everyone’s safety: If you find anything wrong with the lift truck or the attachment, the service staff should be notified at once ! Daily inspection Don´t drive like this ! This is perfect !
  • Contact pads guide
  • Paper roll clamp contact pads
    • Contact pads are the most important part of the clamp
    • In most handling situations, the pads are the only part of the clamp in contact with the paper roll
    • Bolzoni Auramo pays special attention to designing and manufacturing contact pads, to ensure a safe and non-damaging roll handling
    Contact pads guide
  • Contact Pad features
    • All Bolzoni Auramo contact pads have the following properties in common:
      • Thin pad design. The minimized pad thickness ensures good knifing properties when handling tightly stacked rolls.
      • Pad radius suitable for the roll diameter
      • Well-rounded, smooth pad profile and safe finish. The pads have no protruding parts or edges to damage the adjacent paper rolls.
    Contact pads guide
      • Contact pad friction surfaces to suit the loads
    Contact pads guide
  • Contact Pad Friction Properties Friction Coefficient μ Contact pads guide
    • Rubber edges are well protected with a protective steel lips. This prevents the rubber from peeling off the pad.
    Contact pads guide
  • With worn out pads, the required clamping force can be up to three times higher ! Worn out pad Good pad Contact pads guide Rubber-faced Cross grooved Cast pad Worn out pad Theoretical clamping force with 1000 kg (2,200 lbs) paper roll Clamping force kp Steel sprayed
  • Selecting the correct clamping force
    • Too high clamping pressure
    • • Rolls may deform
    • • Roll cores may deform
    • • Out-of-roundness
    • Too low clamping pressure
    • • Rolls may drop
    • • Rolls may slide
    • • Rolls may telescope
    • Important procedures
    • • Select the correct clamping pressure to suit the properties of the rolls
    • Test the clamping pressure regularly
    • When checking the clamping force, also check that the pressure is constant for approx 10 minutes
    Selecting the correct clamping force
    • Clamping force is usually given in lbf (pound force)
    • If stated in kN convert to lbf. Multiply each KN by 224 to establish lbf. ex (20KN X 224)=4,480lbf
    • 4,480lbf clamping force corresponds to a weight of 4,480 lbs applied to the paper roll.
    Selecting the correct clamping force 4,480lb
  • Max clamping force according to weight of the roll: Paper quality Clamping factor Newsprint 1.0-1.4 Kraftliner 1.5-1.8 SC Printing paper 1.6-1.8 LWC print.paper/KCB Kemiart 1.7-2.0 Roll Tissue/Fluff Paper 1.1-1.3 For example: Total paper weight 6,000lb x factor 1.3 = total pressure = 7,800lbf What is correct clamping force ? Measuring and control of clamping force Selecting the correct clamping force
  • Always follow the paper mill’s instructions! Selecting the correct clamping force
  • Measuring and controlling the clamping force Exampel from newprint, SC and LWC producers Selecting the correct clamping force
  • Equipment for adjusting the clamping force Completely automatically with the CTX-series intelligent paper roll clamp Manually with the four stage pressure relief valve Selecting the correct clamping force
  • Damage prevention
    • Various handling related problems cause a significant part of the paper roll damage, all too common in today’s paper transport
    Damage prevention
    • Roll damage in paper
    • handling can be reduced
    • by concentrating special
    • efforts into:
    • • Correct handling practises
    • • Continuous personnel training
    • • Right choice of equipment
    • • Correct condition of the equipment
    • • Protection of the loads
    Damage prevention 100% QUALITY RELIABILITY DAMAGE REDUCTION EFFICIENCY OPERATION UPTIME TARGETS
  • Waste percentage in a damaged reel of 100 cm (40”) diameter Damage prevention 100mm=3.9” 70mm =2.8” 40mm =1.6” 20mm =.8”
  • Damage prevention Training • Bolzoni Auramo has excellent knowledge about handling paper. We can offer complete training programs.
  • Clamping force measurements
    • • There are several Bolzoni Auramo test devices available for quality control
    • Modern clamping force testing tools enable easy and safe measuring operations
    Damage prevention
  • Out-of-roundness measurements
    • Out-of-roundness measuring device can be used as a quality control tool to determine how well the paper handling chain takes damage control into consideration. The device is mainly used for:
      • troubleshooting
      • handling surveys
      • regular quality control
    Damage prevention
  • Out-of-roundness measurements
    • Paper roll out-of-roundness measuring device, The Spider, measures variations in the radius of paper rolls to determine the degree of out-of-roundness
    • It utilizes state-of-the-art microprcessing and ultrasonic technology to quickly and accurately measure the roundness of a paper roll
    • Test results can be viewed on an internal LCD display or directed to an external computer for further analysis
    Damage prevention
  • Out-of-roundness measurements
    • A dedicated analysis program shows the out-of-roundness values measured from the paper roll
    • The device indicates the location and degree of any possible problems
    Damage prevention
  • Accelerations measurements
    • An acceleration measuring device collects and analyzes paper roll movement information throughout the transportation chain
    • It indicates if the paper roll has been subjected to excessive shocks during the transport, due to accidents or incorrect handling practises
    Damage prevention
  • Load protection
    • Paper rolls and pallets located on aisle corners and other high-traffic areas in the warehouse require special protection
    Damage prevention
  • Edge damage Damage prevention
  • Stacking with too low lift height Damage prevention Edge damage Wrong tilt angle Wrong clamping Oblique stacking
    • Chain slack prevention valve reduces the risk for edge damage
    • When the roll is released after clamping and the chains slack, there is a risk of damage to roll edges
    • Our special valve prevents edge damage effectively
    Damage prevention Edge damage
  • Stacking ”off-line” High risk for edge damage when lifting the paper roll Correct stacking Damage prevention Edge damage
    • Lowering the roll’s position during lifting increases the risk for edge damage
    • Rolls should always be clamped in the center, allowing the weight distribute evenly
    Damage prevention Edge damage
  • Incorrect clamping can cause edge damage Damage prevention Edge damage
    • Paper roll clamps handling both vertical and horizontal rolls need a rotation device
    • Rotate the clamp to so that the end of roll is parallel with floor's surface.
    • Lift the roll high enough before rotating
    • Bolzoni Auramo roll clamps are equipped with 180-degree rotators. They have the following advantages over 360-degree models:
      • fast, safe handling
      • fixed vertical end positions
      • hydraulic cushioning in the vertical end positions
    Damage prevention Edge damage
  • End damage Damage prevention
  • NAIL Damage prevention End damage CLEAN STORAGE AND TRAILER FLOORS BEFORE LOADING ROLL ONTO THEM. REMOVE ALL PROTRUDING OBJECTS, NAILS, ETC. FROM THE LOADING AREA. DO NOT PUSH THE ROLL ON THE FLOOR.
  • Use hydraulic extension ! Damage prevention End damage Do not push the roll!
  • Belly damage Damage prevention
  • Use the correct clamp size according to roll dimensions ! The clamp is designed for a larger roll. The clamp is correct for the roll diameter. Open the clamping arms sufficiently when clamping a roll. Damage prevention Belly damage
  • Clamping too deep • Clamp pad corners press the roll • Clamping arms press the roll • Pad corners and arm frame cause local deformations on the roll surface • Risk for dropping the roll due to incorrect clamping Tip clamping • Rolls may drop or “spit” out when braking Pivot arm clamps • Rolls with diameters varying from 90% to maximum should be clamped against the clamp frame. Clamp smaller rolls with contact pads only – no contact against the frame. Sliding arm clamps • Clamp rolls against the push plates. Damage prevention Belly damage
  • Wrong tilt angle
    • If the lift mast is tilted too much during clamping, result can be:
      • the lift mast tilts forward
      • local deformations on the roll surface under the pad corners
      • risk for dropping the roll due to incorrect clamping
    Damage prevention Belly damage – Lift mast position during clamping
  • Damage prevention Belly damage – Not lifting high enough
  • Incorrect clamping distributes the weight unevenly ! Damage prevention Belly damage • Clamping the rolls at the bottom exposes the roll wrapper to stress
  • Do not use the clamp to push the rolls ! Damage prevention Belly damage
  • Incorrect Correct - the long arm is positioned on the outside of stack Short arm inside ! Damage prevention Belly damage
    • Control tilting angle by clamping
    • Use the correct clamp for every handling
    • Control the condition of clamp pads
    Damage prevention Belly damage Do not drive like this... … but like this! … and not like this
    • Drive and stack correctly
    • Clamp correctly
    • Leave enough space between the roll stacks
    • Choose the right contact pad friction surface
    • Keep the contact pads in good condition
    • Use roll guards
    Damage prevention Belly damage – How to prevent it?
  • Out-of-roundness
  • What does out-of-roundess mean to end customer ?
    • The printing presses run faster and faster and maximum out-of-roundness tolerance is 2 mm (0,08”)
    • Exceeded out-of-roundness can cause:
      • break of paper web during printing
      • problems during automatic roll change
      • bad printing quality
      • reduced printing speed
      • late distribution of daily newspaper
      • increased production costs
    Damage prevention Out-of-roundness
  • Correct handling
    • Too high clamping force
      • roll may deform
      • roll cores may deform
      • out-of-roundness
    • Too low clamping force
      • roll might drop
      • roll might slide
      • roll might telescope
    • Select the correct clamping force according to the roll properties
    • Test the clamping force regularly
    • Check the condition of contact pads regularly
    • Select the correct clamp for the load
    Out of roundness diagram Damage prevention Out-of-roundness
  • • Out-of-roundness is measured by the difference of radius • Measured in millimeters (mm) • Depending of the amount of handling times it gives different shape of damage Damage prevention Out-of-roundness
  • Most common incorrect handling: clamping over paper roll edge Damage prevention Out-of-roundness
  • Damage prevention Out-of-roundness – Wrapping as a load carrier F t F t F n F n F r F r Wrapper F c F c Wrapper carries approx 30 % of roll weight
  • Damage prevention Out-of-roundness
    • An example on what happens to the need of clamping force with different ways to handle the rolls
    • The more rolls – the heavier the load – the more clamping force is required.
    • Extra free-riding rolls lead into increased clamping force need. This will cause out-of-roundness on the lowerest rolls.
    • Exampel with clamping factor 1.5 and roll weight 2,200lbf
    3,360lbf 10,080lbf 6,600lbf 13,440lbf Out-of-roundness – Overloading / Wrong loading
  • Damage prevention Out-of-roundness – Overloading / Wrong loading STOP
  • Incorrect clamp placement Correct clamp placement Overclamping can cause out of roundness ! Damage prevention Out-of-roundness
  • OUR GOAL IS TO DELIVER HAPPY PAPER ROLLS ! I need a new wrapping! I am useless! I am perfect!