Packaging Food Processing & Pharmaceutical ... - Alum-A-Lift

Source, Floor or Pallet, Core Horizontal:Target Horizontal Machine MandrelHEAVY ROLLS (Continued):ROLL TRANSFERHEIGHTS EXCEEDERGONOMICLEVELS.POWERED PUSHERREQUIREDTO ASSIST IN ALIGNING THE EEAND THE TARGET MACHINEMANDREL; AND TO COMPENSATEFOR DEVLECTION; A SPECIALDOCKING DEVICE MAY BEEMPLOYED.Method: Align EE with core, insert, liftto bear load, move to target area,keeping roll at low, safe height, align inx direction, elevate or lower to requiredheight, gain final alignment betweenmandrels, set lift’s wheel brakes, andeither manually push roll onto machinemandrel (lighter rolls), or push button onpowered pusher pendant control.Note: Powered pusher can operate inreverse as a powered puller.MALEENDFE\MALEEND

Source Floor, Pallet or Rack: Target, Machine Pay-off StandAlternative: (Reverse)Source, Take-up Stand: Target, Pallet, Floor, Rack or CartADJUSTABLEWIDTHFORK SETNOTCHED FORK SETLIFT AND FORK WIDTHS DIMENSIONED TO STRADDLE ROLL.Method: Lift aligned to straddle roll and inserted until notched forks are alignedwith shaft, earlier assembled to roll’s core, roll lifted by through shaft, moved topay-off stand, aligned and lowered until load transferred from lift to pay-off stand.At take-up side of machine, process is reversed.

Source, Floor, Pallet or Pin Rack: Target, Machine Mandrel(When Roll Core Must be kept Open)DUAL-PRONG END EFFECTER.WITH FIXED OR VARIABLE WIDTHPRONGS TO STRADDLE ROLLSACCESS TO MANDREL MUSTBE MADE AVAILABLEPRONGS CAN BE SHAPED ANDPADDED IF ROLL MATERIAL ISFRAGILE, SUCH AS FOILMethod: If source is floor, prongs aligned to and straddle roll where roll is tangent to floor.Lift, move to and align with machine mandrel, move lift forward, lower lift to place weight onmachine mandrel. If source is a pin cart, after aligning prongs to the roll, lift slightly totransfer load from pin on cart to lift’s prongs.

Source, Pin Cart: Target Machine Mandrel(Requirement, Roll Core Be Kept Open)Access to machine mandrel limited; little or no crawl space available for lift’s forward projectinglegs. Solution is to use laterally mounted trough to support roll.LONG REACH REQUIRED FORACCESS TO MACHINE PAY-OFF.MANUALLY OPERATED ROLLRELEASE. LIFT MODELA250 WITH 72” MAST

Source, Pin Cart: Target Machine Mandrel(Requirement, Roll Core Be Kept Open)Access to rolls on pin cart is longitudinal (head-on). Accessto mandrel may also be head-on; or obstacles can requirelateral discharge of roll to machine mandrel. Solution is touse a front-to-back trough or a rotating trough. Rotatingtroughs generally have detents at 90 o .FRONT TO BACK, STATIC TROUGH

Source, Floor or Pallet, Core Up (“Eye-to-the-Sky”): Target Machine MandrelSINGLE AXISROTATIONTWO AXISROTATION

PLACE THE PALLET ON THE DOLLYINSTEAD OF ON THE FLOOR.DOING SO WILL:PROVIDE CRAWL SPACE FOR LIFT’SFORWARD PROJECTING LEGSREDUCE REACH DISTANCE FOR ENDEFFECTERELIMINATE OR MINIMIZE COUNTERWEIGHTSALLOW FOR A LIGHTER, MOREUSER FRIENDLY LIFTLOCATE PALLET WHERE MOSTCONVENIENTSAVE FLOOR SPACEELIMINATE WAITING TIME FOR FORKLIFT & LICENSED DRIVER

7909 Bankhead HwyWinston, GA 30187Tel 770 489 0328Fax 770 489 7247www.alum-a-lift.comstanb@alum-a-lift.com

FLUIDS AND POWDERSAs with all applications, basic information includes object descriptions, weights,heights, sources, destinations and functions to be performed. Handling certainfluids and powders may be done in special environments such as in class 100cleanrooms. When volatile fluids or fine powders are handled, it is likelynecessary that the lift be intrinsically safe.As seen in Roll Handling applications, the lift to be specified depends upon theweight to be handled and the maximum height to be reached. The challenge isto either configure or design an end effecter to adapt the lift to perform itsintended tasks.Fluids are usually are contained in such vessels as carboys (glass or plastic),drums and tanks. Powders are often received and stored in fiber drums ofvarious capacities. Functional requirements include:• Get, lift, move and place associated with relocation• Elevate and dispense contents into a receiving vessel (forwards or to oneside)Containers:Glass carboys, around 40 liters (with and without ears).Plastic carboys, usually larger, in the 100 liter rangeDrums, metal, typically 55 galDrums, plasticDrums, fiberSources:PalletsRacks or shelvesFloorCabinetsDestinations (Targets)ContainersMixersWashersEnd Effecters (EE)Belly Band (With and without Rotation)Clamp (No rotation, side rotation, forward rotation)PlatformRoller DeckParrot BeakApplication examples are shown on the following pages in this section.

CARBOYS:20 LITERSMANUAL CLAMP AND POUR TO SIDEMOVE TO &FROMSHELVING40 L, COUNTERBALANCED LIFT,CLAMP & MANUALLY ROTATEFORWARD TO DISPENSE INTOHOPPER

Carboys: (Continued)

CARBOYS: (Continued)

Fluids & Powders (Continued)EndEffecters: Dual PurposeLIFTING CARBOY BY EARS WITHDUAL PRONGSLIFTING CARBOY BY ITS BOTTOMWITH A PLATFORM

POWERED ROTATIONFLAPS REMAIN CLOSED TO PREVENTDISPENSING UNTIL DRUM ISOVER RECEIVING CONTAINERMAST LENGTHS CAN BE DEFINED TO PASS UNDEROBSTACLES SUCH AS DOORWAYS. HIGH REACHELIMINATES THE NEED FOR STAIRWAYS.DISPENSING RATE MAY BE CONTROLLED.

TOPDISPENSINGEITHERFORWARDOR TO SIDELEFTDISPENSE TOEITHER SIDERIGHTDISPENSE TOEITHER SIDE,POWERED,CONTAINERTRAPPED,CONTROLLEDRATE

DRUMS & VARIOUS CONTAINERS: Affect of PalletsRaw materials arrive in various kinds and sizes of containers, many of which are drums. Suchcontainers are often received on pallets. Pallets, initially handled by forklift trucks, are typically taken toa storage area. When a material is required, its destination and disposition are variable. Handlingstrategies depend on a myriad of variables such as container material, shape, weight and functions tobe performed. The first such function is often to remove the container from a pallet. Most often, palletsare placed on the floor by the forklift operator.The first challenge is to capture the container and remove it from a pallet. The pallet edges limit thelift’s access to the container. A basic requirement is that the pallet must be isolated such that access isprovided for the lift to any of the four sides or four corners. If practical, placing the pallet on stand-offsinstead of on the floor, may provide crawl space for the lift’s forward projecting legs. With theavailability of such crawl space, two things are apt to result: Shorter reach distance to the container;and, avoidance of counterbalanced lifts or countermass (for stability).By placing the pallet on the floor, the lift cannot be configured with forward projecting legs. The reachrequired by the end effecter to place the containers onto the pallet is seen to be 31”. Even with 50 lbsto handle, considerable countermass is required in order to satisfy the stability criterion.

DRUMS & VARIOUS CONTAINERS: Affect of Pallets (Continued)Lifting and relocating 200 lbfiber drums make use of acombination parrot beak and acradle end effecter.A counterbalanced lift wasselected because there is nospace for forward projectinglegs.The large tilting momentproduced by the load requiresa large amount of ballast,adding to the weight to bepushed by the user.By placing the pallet onstand-offs, space is providedfor a lift with forwardprojecting legs.The affect is to reduce thereach to the target.Leg lengths may bedetermined to attain stabilitywith minimum or withoutcountermass.Weight and cost savings aresignificant.

Various ContainersALTERNATETOTES AREFREQUENTLY USED ASCONTAINERS.THEIR CONTENTS MAYBE DISPENSED BY ASET OF ROTATINGFORKS WHICHSECURELY TRAP ITDURING MANUAL ORPOWERED ROTATIONADUSTABLE WIDTH FORK SET FORDIFFERENT WIDTH TOTESROTATING CLAMP FOR FORWARDDISPENSING. MAY BE POWERED

Various Containers (Continued)Tall lifts usually require powered end effecters since heights may exceed those whichmay be reached by humans for manual operation. Such end effecters are powered bythe lift’s battery, have their own pendant controls and appropriate safety devices.

Various Containers (Continued-2)Special loosefunnel shapedhopper fits lift’sforks for liftingFunnel shaped platform to dispense contentsof bags containing powders or granules.Shape at end traps bag. Dumping to side maybe done manually or under power. Bag is slitafter placed on platform. May alternatively beoriented for front dump action.SlidingValveA HandlingSystemPowered, variableWidth clamp withcontrolled force.Manual side dumpto either side.PoweredClamp, WithManual FrontDump ActionFor Granules

Various Containers (Continued-3)FORWARD FACING FUNNELSHAPED PLATFORM FORFORWARD DISPENSING OFGRANULAR MATERIALS INTOHOPPER OR CONTAINERNOTE: AFTER TARING UNLOADED LIFT, IT MAYBE DRIVEN ONTO FLOOR LEVEL PLATFORMSCALE TO WEIGH NET CONTENTSFORWARD DUMPING OF DRUMS FOR TABLETPROCESSINGSTANDARD EURO DRUMS: STEPS LEADING TO DISPENSING CONTENTS INTO TALL RECEIVER

Various Containers (Continued-4)COUNTERBALANCEDLIFT: NO FORWARDPROJECTING LEGSCLAMP TRAPSVESSEL’SHANDLESPOWEREDROTATION

CartsThe introduction of forklifts and pallets into a clean work area is often prohibited. In suchinstances, special carts may be employed as devices for transporting rolls and for theirtemporary storage. A number of designs, configurations and sizes have been provided forcompanies in the pharmaceutical industry. Ideally, the lifts and carts are configured within thesame project in order to assure their compatibility and smooth interfacing.PincartsSpecifications Include• Number, sizes and roll weights• Desired array, x and y• Constraints (aisles, doors, etc)• Desired access• Environment (eg cleanroom)Wheel diameters should be as largeas can be practically used. Brakingcasters are usually provided at rear(operator) locations.Total load should not exceed thatwhich produces push/pull forces notin excess of those used in ergonomicguidelines.Docking devices may be employed tolocate the lift relative to the rolls.

Carts (Continued-1)Interaction between a cart and an ALUM-A-LIFT. Illustrated is a cart with anarticulating platform. It has its own power source and operating controls.DUAL PRONG CARTS : These carts are oftenused for transport and storage. The prongs foldup and out of the way when the cart is not in use.They are available for use in Class 100Cleanrooms. Mandrel dockers are also availablefor alignment with the lift’s mandrel.

SS SPECIAL ENVIRONMENTAL CONDITIONSProcessing may be done in areas requiring special equipment attributes such as in cleanroomsor areas in which there may be powders or volatile materials.ALUM-A-LIFT, without any modification, will satisfy class 10,000 cleanroom particulation limits.Any model ALUM-A-LIFT may be specified for use in class 100 cleanrooms, for which theselifts are certified. Special, intrinsically safe lifts are also available, however, after conducting afee based engineering project. Intrinsically safe lifts are air-powered and require connectionsto shop air. Some application examples follow.SEALED DRIVETRAIN & MOTORCOMPARTMENTMEETS CLASS10,000 CRREQUIREMENTS

SPECIAL ENVIRONMENTAL CONDITIONS (Continued)FOR CLASS 100 CLEANROOMSPOWEREDDUMPERINTRINSICALLY SAFE CONSTRUCTIONPOWEREDROTATION

Packages and PackagingStarting with receipt and ending with shipment, there inevitably exists the need to handlevarious packages; often in the form of cartons. When their weights exceed the 35 lb guidelinelimit, a lifting device becomes a requirement. There are various methods of introducing suchpackages to the lift at the source and discharging them at the destination.PlatformsGeneral purpose lifts withsimple platforms are oftenused in receiving and shippingareas to handle a wide varietyof cartons, weighing up to 150lbs. The lifts weigh but 120lbs and are user-friendly.Simple platform lift for loads to 200 lbs, withfront ramp to get down to floor level.Platform lift with front stop and powered tiltLift with tilt-up platform with ledge, take package fromone side and rotate 90 o to retain on ledge for discharge

Packages & Packaging (Continued-2)When packages have flat bottoms and can roll, it may be advantageous to use rollerdecks or ball transfer sections to ease their displacements. These end effecters maybe either manually operated or powered by the lift’s internal battery.Roller Decks & Ball TransfersModel A250,with manualfront to backroller deck.Brakes lockup rollers.Lift-Smart, 100lb capacity withlateral rollerdeck. Lift isparallel parkedfor receiving &dischargingload.Balls raised foromni-directionaltransferModel L150 withdual race roller deckBalls lowered tokeep load inplace duringmovement oflift. Can usehigh-frictonsurface.

Packages & Packing (Continued-3)Placing objects into cartons orremoving them with poweredtongs.Light-weight lift with dual purposeplatform; handling cartons and rolls.Roll adapter is removable.Lift for handling and stacking palletsto 2000 lbs. Goes where fork liftsare not welcome. Can be used byanyone without a special license.Saves time awaiting materialhandlers. Can be made with shortmast to get under pallet racks.Stacking or unstacking cartons. Can be used topre-load pallets for later placement into trailers.Powered clamps have force regulation toprevent crushing of containers.

Additional ApplicationsSince 1990, ALUM-A-LIFT engineers have designed and configured ergonomic lifting devices forliterally thousands of applications. The foregoing are intended to comprise a representativesample. Hardly a day goes by without being challenged by yet a new or different problem to whicha solution is sought. Visiting www.alum-a-lift.com affords an opportunity to view additional uses forthese products. Available is access to libraries of application drawings and digital images. Thelibraries are organized by several keywords including the object handled, how it is handled andfunctions to be performed. Digital images are usually sent by e-mail.As in most organizations, ergonomic problems may be perceived in, as examples, laboratories andoffice environments. Heavy instruments, files, cabinets, office machinery, servers, monitors and thelike are often handled. Sharing, installing, relocating and servicing are activities resulting inexposure to potential back injury.Model L150with A 72” mastand platform forlifting a varietyof officeequipment.Large wheelsare used forrunning oncarpeted areas.Model L100 as a heightadjustable, mobile workstationOn-Board vacuum system for handling largemonitors and TV’s

Alum-A-Lift, Inc. is privileged to provide product to thefollowing pharmaceutical and related companies:3MAbbott LabsAdvance TissueAlcon LabsAlkabAltronAmi GibsonArmour PharmaceuticalsAstra USABallard Medical ProductsBaxter HealthcareBayer CorporationBecton DickinsonBiojectBio-LabBio-MedicusBoston ScientificCiba VisionCobe LabsCommonwealth ScientificConvatecDiasonicsDura PharmaceuticalsEthiconFluke CorporationGE Medical SystemsGendexGenenTechHC StarkJansennJohnson & JohnsonLife TechnologiesLilly Del CaribeLudensMedradMedtronicsMerckNeutrogenaNovartisNutrasweetOrtho-McNeilPfizer Animal HealthPharmaciaPoint BiomedicalPPGProctor & GambleRhone DiagnosticsRoche Medical SystemsSanofi DiagnosticsSearleSpectra PhysicsSquibbStrykerWarner LambertWest PharmaceuticalsZiatech