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Handling rolls up to 1,000 kg: how to improve safety, ergonomics, and productivity

Handling large rolls is one of the most common and challenging operations in the packaging, paper, plastic, and converting industries.

When loads become heavier and bulkier, companies face a clear challenge: ensuring fast and safe handling operations without compromising operator ergonomics or production efficiency.

For this reason, an increasing number of manufacturers are adopting assisted handling systems that simplify reel handling while reducing the risks associated with manual load manipulation.

The main challenges of rolls handling

Rolls represent a particularly demanding type of load.

In addition to their significant weight, they often need to be:

Picked up from pallets or storage areas
Properly oriented before use
Transferred between workstations
Precisely positioned on production lines
Handled in areas with limited space

In many applications, operators must also access the reel handle from different positions, making flexibility of gripping a key requirement.

When reel weight reaches 1,000 kg, precision and safety become essential to prevent production delays, material damage, and workplace injuries.

How to handle heavy rolls safely

To ensure efficient reel handling, companies need equipment specifically designed for this type of application.

A pneumatic manipulator for reel handling compensates for the weight of the load and allows operators to guide movements naturally and effortlessly, significantly reducing physical strain.

The goal is not simply to lift the load, but to maintain full control throughout every step of the operation:

Gripping
Lifting
Positioning
Releasing

The ATIS Solution for Handling Rolls up to 1,000 kg

To meet the needs of the packaging industry, ATIS has developed a dedicated solution for handling reels weighing up to 1,000 kg.

The manipulator is equipped with a customized gripping system that enables operators to work safely and accurately, even in demanding applications.

Lateral Handle Gripping

One of the key advantages of this solution is the ability to grip the rolls handle from the side.

This feature increases operational flexibility and makes the manipulator ideal for applications where front access to the reel is limited or impractical.

90° Forward Tilt

The gripping tool allows the reel to be tilted forward up to 90°, making orientation and positioning operations quicker and more efficient.

This controlled movement allows the load to be aligned precisely with production requirements while maintaining maximum control.

Smooth and Precise Movements

Thanks to pneumatic weight compensation, operators can move heavy reels smoothly and accurately, reducing the risk of impacts and product damage.

Fast and Controlled Release

Once the rolls reaches its destination, the system ensures safe, fast, and controlled release, supporting workflow continuity and operational efficiency.

The Benefits of a Pneumatic Rolls Handling Manipulator

Implementing a dedicated reel handling manipulator provides several advantages:

Improved workplace safety
Reduced operator fatigue
Enhanced workstation ergonomics
Increased productivity
Greater positioning accuracy
Shorter cycle times
Reduced risk of material damage
Improved process quality

Industries and Applications

This solution can be used across a wide range of industrial environments.

Packaging Industry

Handling reels used in automated packaging lines.

Plastics Industry

Managing plastic film reels and flexible materials.

Paper and Cardboard Industry

Moving and positioning paper rolls used in converting and printing processes.

Printing and Graphics Industry

Lifting and positioning rolls used in printing and graphic production processes.

Why Choose a Customized Solution?

Every roll has unique characteristics in terms of weight, dimensions, gripping points, and handling requirements.

For this reason, a customized pneumatic manipulator can deliver the highest levels of safety and productivity by adapting the gripping system to the specific application.

The combination of dedicated gripping tools, lateral gripping capability, and a 90° forward tilt makes this manipulator an extremely versatile solution for companies looking to optimize the handling of heavy reels.

Watch a real application: