Optimise Packaging with Roll Material Handling Equipment

Handling raw materials in packaging production 

The packaging production process involves several stages that require handling various raw materials. Effective handling is essential because of the size, weight, and sensitivity of these materials. Their heavy and bulky nature makes safe and efficient movement a challenge at every step of the process.

Workers often handle packaging rolls multiple times during production. Packaging rolls are unwound, cut, slit, folded, or fed into packaging machines. Without the right equipment, each step carries a risk of injury and a risk of damage to both staff and materials.

What is roll material handling equipment? 

Roll material handling equipment safely lifts, moves, tilts, and positions heavy rolls. Manufacturers can make these rolls from materials such as paper, film, or corrugated board for use in packaging. This type of equipment includes roll and reel moving equipment, ranging from vacuum lifters to reel lifting trolleys, for efficient and ergonomic handling.

Reel Lifting Trolleys

Reel lifting trolleys play a key role in minimising downtime by:

• Enabling operators to lift, tilt, and load rolls into packaging machines without assistance.  
• Improves overall workflow efficiency and speeds up changeovers.
• Preventing accidents and reducing the risk of roll damage.

Vacuum Lifters for Various Packaging Materials

Vacuum lifters for rolls and various packaging materials provide a versatile solution for handling boxes, rolls, and other packaging materials by:

• Allowing operators to lift, stack, and palletise multiple items safely and efficiently.
• Increasing lifting capacity.
• Transforming a two-person task into a one-person job.
• Reducing the risk of workplace injuries.

By combining precision, safety, and efficiency, roll material handling equipment enhances consistency, ensures reliable production, and helps maintain high product quality.

What are the risks of manual roll handling?

Manual roll handling is risky because it causes injuries, damages rolls, and slows production. Packaging rolls are heavy, bulky, and difficult to manoeuvre. Operators often need to lift, twist, or push rolls in confined spaces, sometimes above shoulder height. This repetitive manual handling leads to serveral potential problems:

• Injury risks: Manual roll handling increases the risk of strains, crush injuries, and long-term musculoskeletal disorders.
• Non-compliance: Many safety guidelines recommend limiting manual lifting to 55 lbs, which is far below the weight of typical reels.
• Product damage: Manual handling can cause deformation, edge dents, scratches, or contamination that compromise downstream processes.
• Production delays: Damaged rolls can disrupt slitting, sealing, or palletising, which leads to costly downtime.

Manual handling slows down production. It can also lower profits by increasing scrap rates and by increasing lost work hours.

According to the European Agency for Safety and Health at Work, manual handling of rolls exceeding 25kg typically violates ergonomic safety guidelines. Industry reports consistently cite musculoskeletal disorders as one of the most common workplace injuries in packaging facilities.

How does roll material handling equipment improve packaging production?

Ergonomic roll handling equipment improves production by reducing injuries, protecting materials, and increasing efficiency. By automating the heavy lifting, ergonomic solutions transform productivity in packaging operations. Key benefits include:

• Faster roll changes: Operators can lift, tilt, and load reels into machines quickly and consistently.
• Fewer errors and less waste: Handling rolls with precision reduces damage and scrap.
• Reduced downtime: Safer handling prevents workplace accidents and equipment stoppages.
• Improved employee well-being: Reducing physical strain creates a healthier and more motivated workforce.

Ultimately, using reel moving equipment helps packaging facilities run more reliably and achieve higher throughput with less effort. These benefits prove themselves in real packaging environments, not just in theory. 

Case Studies

SCA – Smoother production flow with reel lifting trolleys

At SCA, one of Europe’s leading hygiene and paper product manufacturers, heavy reels were a daily challenge. Operators used to handle large and heavy reels by hand every day. This manual task slowed down the workflow and increased the risk of injuries to backs, shoulders, and knees.

To solve this, the company invested in six TAWI Reel Lifting Trolleys. These trolleys help staff lift, tilt, and position heavy reels safely and efficiently. Staff can now mount the reels directly onto the machine shaft without heavy lifting. The result has been a clear boost in both ergonomics and efficiency, minimising health risks while streamlining production.

Read the full SCA case here 

Clarebout – Enhancing food packaging operations with roll material handling equipment

Clarebout, a Belgian frozen food producer, faced a similar challenge with 80 kg rolls of packaging film. Workers lifted rolls vertically from pallets, tilted them into a horizontal position, and then moved them into packaging machines. These tasks were both time-consuming and physically demanding, which increased the risk of injuries and slowed the workflow.

To fix this, Clarebout installed TAWI lifting systems. The solution included a hoist to lift and tilt the rolls, plus a reel lifting trolley to transport and mount them. A single worker can now lift the rolls from pallets, tilt them into place, and load them into machines easily. This change not only reduces injury risks but also speeds up changeovers and improves overall productivity.

Discover the full Clarebout case here  

These cases highlight how roll material handling equipment directly impacts employee safety, reduces waste, and supports more reliable packaging operations.

What makes TAWI roll handling equipment unique?

TAWI offers a wide selection of ergonomic equipment specifically designed for packaging environments. With decades of experience in solving manual handling challenges, our solutions combine safety, flexibility, and efficiency in a single roll handling system.

Key solutions for roll material handling:

• Electric lifting trolleys: Versatile reel lifting trolleys that can lift, rotate, and transport rolls with ease.
• Vacuum lifters: Ideal for quick and precise handling of reels, paper, and film in both production and packaging lines.
• Modular designs: Modular designs allow customised equipment with a wide range of tools to fit specific materials and workflows.
• Specialised options: Stainless steel solutions are easy to clean and suitable for hygiene-sensitive environments.

See more:
Reel handling solutions
Classic lifting trolleys
Packaging industry solutions

Main features of our reel lifting trolleys:

• Flexible movement: Lift, tilt, rotate, and transport rolls effortlessly.
• QuickLoad technology: Provides precise stops at the correct height for stacking or mounting.
• Adjustable legs: Allow easy access to pallets and smooth manoeuvring in tight spaces.
• Effortless movement: Robust wheels ensure effortless movement across the facility.
• Built-in safety functions: Automatic stop activates if the lifter encounters obstacles, protecting both the operator and the load.

Learn more about TAW’s lifting trolleys here 

Learn more about TAWI’s vacuum lifters here 

Ergonomic roll material handling equipment is no longer a “nice to have”. It is now a critical investment for safe, sustainable, and productive operations.