ERGONOMIC LIFTING GUIDE

FOR THE

PACKAGING, FOOD PROCESSING,

AND PHARMACEUTICAL

INDUSTRIES

Visit our websites at: www.alum-a-pack.com

& www.alum-a-lift.com

Since 1990, it has been a privilege to construct and furnish ergonomic lifting devices for many companies in the packaging, food processing, and pharmaceutical industries. There is, in fact, a good chance that either the reader or a colleague will have had first-hand experience in specifying an ALUM-A-LIFT. Experience has revealed commonality among ergonomic lifting problems within the pharmaceutical industry. In a number of instances, what was thought to be a unique requirement resurfaced, often related to the use of similar functions, equipment, processes and containers. Operating environments may also be similar. The requirement for cleanliness is usual: In some instances, in Class 100 Cleanrooms. A number of clients are large, multinational companies with manufacturing facilities diversely located throughout the world. Some of them are “sisters”. Lifting problems may be commonly experienced. It has been found that projects directed to solve these problems may be conducted independently by engineers and consultants with neither confluence nor sharing of knowledge. Accordingly, with a body of knowledge accumulated over the years, the primary purpose of this booklet is to share this knowledge with those who are charged with the solution of ergonomic lifting problems. It is well known that the cost of human back injury is large. Prevention is worthwhile. This booklet is organized by lifting categories, ranked according to frequency of encounter. Each category is accompanied by one or more examples of problem solutions. By no means are they exhaustive. New perceptions and challenges continue to arise. Some of these may find their ways into www.alum-a-lift.com.

ROLL HANDLING: A frequently experienced application There are many methods for handling rolls. Selection of a specific method

depends upon such variables as:

Roll properties:

• Weight • Dimensions: OD, web or length and core diameter • Material: paper, plastic, metal (foil), fragility, tendency to telescope

Source and conditions at source:

• Pallet, floor, rack, other • Stacked (how many tiers) • Bare or wrapped • Orientation (core up or horizontal)

Target conditions and elevation (relative to the floor):

• Rack (style of rack, storage orientation) • Using machine (type) • Mandrel(s) and pay-off or take-up from top or bottom • Through shaft (on pay-off or take-up stand) • Rollers

Accessibility to target and obstacles:

• Machine supports, aprons, controls, stairs • Columns • Overhead: ductwork, lighting • Floor conditions: smooth, irregular, level, cracks, elevator

Frequency of occurrence (how often used per hour or shift):

Goals:

• Ergonomics, human and product safety • Increase roll size to reduce scrap, downtime and labor costs

L

D

W #

W

L

H2

H1

Source, Floor or Pallet, Core Horizontal: Target Horizontal Machine Mandrel Any diameter core. EE = Mandrel. Diameter and length of EE are dimensioned to fit to roll dimensions and to reach core (if on pallet, for example). Lift EE usually has a bullet nose to ease alignment to roll core. If roll is light (to approximately 100 lbs, and to about 24” long, the EE is usually tubular aluminum. Stainless is often used for heavier and longer rolls. The lift‘s footprint is dimensioned to straddle the roll, if it is on the floor, while assuring stability.

For roll weights over 100 lbs and to about 250 lbs, small rollers are imbedded into EE to ease the transfer from the lift to the target mandrel.

For rolls weighing more than 250 lbs, and if the target is either high (over shoulder height) or low (below knee height), a powered pusher is employed to apply the force required to transfer the roll from the lift to the target.

Source, Floor or Pallet, Core Up: Target Horizontal Machine Mandrel 3” or 6” Core EE = Expanding Mandrel, Powered with standard safety features: Light signals that mandrel is expanded and safe to lift; dual button control to contract mandrel, thus requiring conscious decision of user.

If the material is fragile, EE is usually an expanding mandrel. If both 3” & 6” cores are used, a quick exchange mandrel end is available.

A good idea is to use standoffs under pallets to provide crawl space for the lift’s forward projecting legs. Doing so may reduce the reach required for the EE, thus also reducing the forward tipping moment. Try to locate pallets such that access is provided for the lift at all four sides or corners

. Method: Align EE with core, lower EE into core, expand EE mandrel, lift from source, move to target area, rotate roll 90o (powered), align with machine mandrel, thrust forward, contract EE If the roll material is slippery, use telescoping stop mechanism andrel, lift aside, manually push roll home.

IF MATERIAL IS SLIPPERY, SPECIFY ANTI-TELESCOPING

GRIPPERS

Source, Floor or Pallet, Core Horizontal: Target Horizontal Machine Mandrel HEAVY ROLLS (Continued):

ROLL TRANSFER

HEIGHTS EXCEED ERGONOMIC

LEVELS. POWERED PUSHER

REQUIRED

TO ASSIST IN ALIGNING THE EE AND THE TARGET MACHINE MANDREL; AND TO COMPENSATE FOR DEVLECTION; A SPECIAL DOCKING DEVICE MAY BE EMPLOYED. Method: Align EE with core, insert, lift to bear load, move to target area, keeping roll at low, safe height, align in x direction, elevate or lower to required height, gain final alignment between mandrels, set lift’s wheel brakes, and either manually push roll onto machine mandrel (lighter rolls), or push button on powered pusher pendant control. Note: Powered pusher can operate in reverse as a powered puller.

FE\MALE END

MALE END

Source Floor, Pallet or Rack: Target, Machine Pay-off Stand Alternative: (Reverse) Source, Take-up Stand: Target, Pallet, Floor, Rack or Cart

NOTCHED FORK SET LIFT AND FORK WIDTHS DIMENSIONED TO STRADDLE ROLL. Method: Lift aligned to straddle roll and inserted until notched forks are aligned with shaft, earlier assembled to roll’s core, roll lifted by through shaft, moved to pay-off stand, aligned and lowered until load transferred from lift to pay-off stand. At take-up side of machine, process is reversed.

ADJUSTABLE WIDTH

FORK SET

DUAL-PRONG END EFFECTER. WITH FIXED OR VARIABLE WIDTH PRONGS TO STRADDLE ROLLS PRONGS CAN BE SHAPED AND PADDED IF ROLL MATERIAL IS FRAGILE, SUCH AS FOIL

Source, Floor, Pallet or Pin Rack: Target, Machine Mandrel (When Roll Core Must be kept Open)

ACCESS TO MANDREL MUST BE MADE AVAILABLE

Method: 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 on machine mandrel. If source is a pin cart, after aligning prongs to the roll, lift slightly to transfer 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 projecting legs. Solution is to use laterally mounted trough to support roll.

LONG REACH REQUIRED FOR

ACCESS TO MACHINE PAY-OFF. MANUALLY OPERATED ROLL RELEASE. LIFT MODEL A250 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). Access to mandrel may also be head-on; or obstacles can require lateral discharge of roll to machine mandrel. Solution is to use a front-to-back trough or a rotating trough. Rotating troughs generally have detents at 90o.

FRONT TO BACK, STATIC TROUGH

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

CLAMPS HAVE POWERED ROTATION FRONT & BACK FOR ROLL PAY-OFF

FROM EITHER TOP OR BOTTOM

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

SINGLE AXIS ROTATION

TWO AXIS ROTATION

SOME SPECIAL HANDLING CONDITIONS REQUIRE GETTING A ROLL FROM A CART, ASSEMBLING A THROUGH SHAFT, LIFTING BY MEANS OF THE SHAFT, THEN ROTATING THE ROLL TO ALIGN IT WITH A PAY-OFF STAND. WHEN FORK TRUCKS ARE UNWELCOME, ALUM-A-LIFT IS USED BY ANYONE TO LIFT AND LOCATE PALLETS, SAVING TIME AND ELIMINATING WAITING.

POWERED CLAMP AND

ROTATION FOR HEAVY ROLLS

HEAVY ROLLS MAY REQUIRE LATERAL

SHUTTLING MOTION FOR ALIGNMENT TO MANDREL

PLACE THE PALLET ON THE DOLLY INSTEAD OF ON THE FLOOR. DOING SO WILL:

PROVIDE CRAWL SPACE FOR LIFT’S FORWARD PROJECTING LEGS

REDUCE REACH DISTANCE FOR END EFFECTER

ELIMINATE OR MINIMIZE COUNTER WEIGHTS

ALLOW FOR A LIGHTER, MORE USER FRIENDLY LIFT

LOCATE PALLET WHERE MOST CONVENIENT

SAVE FLOOR SPACE ELIMINATE WAITING TIME FOR FORK

LIFT & LICENSED DRIVER

7909 Bankhead Hwy Winston, GA 30187

Tel 770 489 0328 Fax 770 489 7247

www.alum-a-lift.com stanb@alum-a-lift.com

FLUIDS AND POWDERS

As with all applications, basic information includes object descriptions, weights, heights, sources, destinations and functions to be performed. Handling certain fluids and powders may be done in special environments such as in class 100 cleanrooms. When volatile fluids or fine powders are handled, it is likely necessary that the lift be intrinsically safe.

As seen in Roll Handling applications, the lift to be specified depends upon the weight to be handled and the maximum height to be reached. The challenge is to either configure or design an end effecter to adapt the lift to perform its intended 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 of various capacities. Functional requirements include:

• Get, lift, move and place associated with relocation • Elevate and dispense contents into a receiving vessel (forwards or to one

side)

Containers: Glass carboys, around 40 liters (with and without ears). Plastic carboys, usually larger, in the 100 liter range Drums, metal, typically 55 gal Drums, plastic Drums, fiber

Sources: Pallets Racks or shelves Floor Cabinets

Destinations (Targets) Containers Mixers Washers

End Effecters (EE) Belly Band (With and without Rotation) Clamp (No rotation, side rotation, forward rotation) Platform Roller Deck Parrot Beak

Application examples are shown on the following pages in this section.

CARBOYS:

MOVE TO & FROM SHELVING

20 LITERS MANUAL CLAMP AND POUR TO SIDE

40 L, COUNTERBALANCED LIFT, CLAMP & MANUALLY ROTATE FORWARD TO DISPENSE INTO HOPPER

Carboys: (Continued)

CARBOYS: (Continued)

Fluids & Powders (Continued) End Effecters: Dual Purpose

LIFTING CARBOY BY EARS WITH DUAL PRONGS

LIFTING CARBOY BY ITS BOTTOM WITH A PLATFORM

POWERED ROTATION FLAPS REMAIN CLOSED TO PREVENT

DISPENSING UNTIL DRUM IS OVER RECEIVING CONTAINER

MAST LENGTHS CAN BE DEFINED TO PASS UNDER OBSTACLES SUCH AS DOORWAYS. HIGH REACH

ELIMINATES THE NEED FOR STAIRWAYS. DISPENSING RATE MAY BE CONTROLLED.

TOP DISPENSING

EITHER FORWARD

OR TO SIDE

LEFT DISPENSE TO EITHER SIDE

RIGHT

DISPENSE TO EITHER SIDE,

POWERED, CONTAINER

TRAPPED, CONTROLLED

RATE

Raw materials arrive in various kinds and sizes of containers, many of which are drums. Such containers are often received on pallets. Pallets, initially handled by forklift trucks, are typically taken to a storage area. When a material is required, its destination and disposition are variable. Handling strategies depend on a myriad of variables such as container material, shape, weight and functions to be performed. The first such function is often to remove the container from a pallet. Most often, pallets are 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 the lift’s access to the container. A basic requirement is that the pallet must be isolated such that access is provided for the lift to any of the four sides or four corners. If practical, placing the pallet on stand-offs instead of on the floor, may provide crawl space for the lift’s forward projecting legs. With the availability 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 reach required by the end effecter to place the containers onto the pallet is seen to be 31”. Even with 50 lbs to handle, considerable countermass is required in order to satisfy the stability criterion.

DRUMS & VARIOUS CONTAINERS: Affect of Pallets

DRUMS & VARIOUS CONTAINERS: Affect of Pallets (Continued)

Lifting and relocating 200 lb fiber drums make use of a combination parrot beak and a cradle end effecter. A counterbalanced lift was selected because there is no space for forward projecting legs. The large tilting moment produced by the load requires a large amount of ballast, adding to the weight to be pushed by the user.

By placing the pallet on stand-offs, space is provided for a lift with forward projecting legs. The affect is to reduce the reach to the target. Leg lengths may be determined to attain stability with minimum or without countermass. Weight and cost savings are significant.

Various Containers

TOTES ARE FREQUENTLY USED AS

CONTAINERS. THEIR CONTENTS MAY

BE DISPENSED BY A SET OF ROTATING

FORKS WHICH SECURELY TRAP IT

DURING MANUAL OR POWERED ROTATION

ALTERNATE

ADUSTABLE WIDTH FORK SET FOR DIFFERENT WIDTH TOTES

ROTATING CLAMP FOR FORWARD DISPENSING. MAY BE POWERED

Various Containers (Continued)

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

Various Containers (Continued-2) Funnel shaped platform to dispense contents of bags containing powders or granules.

Shape at end traps bag. Dumping to side may be done manually or under power. Bag is slit after placed on platform. May alternatively be

oriented for front dump action.

Special loose funnel shaped

hopper fits lift’s forks for lifting

Sliding Valve

A Handling System

Powered, variable Width clamp with controlled force.

Manual side dump to either side.

Powered Clamp, With Manual Front Dump Action For Granules

Various Containers (Continued-3)

FORWARD FACING FUNNEL SHAPED PLATFORM FOR FORWARD DISPENSING OF GRANULAR MATERIALS INTO HOPPER OR CONTAINER

FORWARD DUMPING OF DRUMS FOR TABLET PROCESSING

STANDARD EURO DRUMS: STEPS LEADING TO DISPENSING CONTENTS INTO TALL RECEIVER

NOTE: AFTER TARING UNLOADED LIFT, IT MAY BE DRIVEN ONTO FLOOR LEVEL PLATFORM

SCALE TO WEIGH NET CONTENTS

Various Containers (Continued-4)

COUNTERBALANCED LIFT: NO FORWARD PROJECTING LEGS

CLAMP TRAPS VESSEL’S HANDLES

POWERED ROTATION

Carts The introduction of forklifts and pallets into a clean work area is often prohibited. In such instances, special carts may be employed as devices for transporting rolls and for their temporary storage. A number of designs, configurations and sizes have been provided for companies in the pharmaceutical industry. Ideally, the lifts and carts are configured within the same project in order to assure their compatibility and smooth interfacing. Pincarts

Specifications 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 large as can be practically used. Braking casters are usually provided at rear (operator) locations. Total load should not exceed that which produces push/pull forces not in excess of those used in ergonomic guidelines. Docking devices may be employed to locate the lift relative to the rolls.

Carts (Continued-1)

DUAL PRONG CARTS : These carts are often used for transport and storage. The prongs fold up and out of the way when the cart is not in use. They are available for use in Class 100 Cleanrooms. Mandrel dockers are also available for alignment with the lift’s mandrel.

Interaction between a cart and an ALUM-A-LIFT. Illustrated is a cart with an articulating platform. It has its own power source and operating controls.

SS Processing may be done in areas requiring special equipment attributes such as in cleanrooms or 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 these lifts are certified. Special, intrinsically safe lifts are also available, however, after conducting a fee based engineering project. Intrinsically safe lifts are air-powered and require connections to shop air. Some application examples follow.

SPECIAL ENVIRONMENTAL CONDITIONS

SEALED DRIVE TRAIN & MOTOR COMPARTMENT

MEETS CLASS 10,000 CR REQUIREMENTS

SPECIAL ENVIRONMENTAL CONDITIONS (Continued)

FOR CLASS 100 CLEANROOMS

INTRINSICALLY SAFE CONSTRUCTION

POWERED ROTATION

POWERED DUMPER

Packages and Packaging Starting with receipt and ending with shipment, there inevitably exists the need to handle various packages; often in the form of cartons. When their weights exceed the 35 lb guideline limit, a lifting device becomes a requirement. There are various methods of introducing such packages to the lift at the source and discharging them at the destination.

Platforms General purpose lifts with simple platforms are often used in receiving and shipping areas to handle a wide variety of cartons, weighing up to 150 lbs. The lifts weigh but 120 lbs and are user-friendly.

Simple platform lift for loads to 200 lbs, with front ramp to get down to floor level.

Platform lift with front stop and powered tilt

Lift with tilt-up platform with ledge, take package from one side and rotate 90o to retain on ledge for discharge

When packages have flat bottoms and can roll, it may be advantageous to use roller decks or ball transfer sections to ease their displacements. These end effecters may be either manually operated or powered by the lift’s internal battery. Roller Decks & Ball Transfers

Packages & Packaging (Continued-2)

Lift-Smart, 100 lb capacity with lateral roller deck. Lift is parallel parked for receiving & discharging load.

Model A250, with manual front to back roller deck. Brakes lock up rollers.

Balls raised for omni-directional transfer

Balls lowered to keep load in place during movement of lift. Can use high-fricton surface.

Model L150 with dual race roller deck

Packages & Packing (Continued-3)

Placing objects into cartons or removing them with powered tongs.

Light-weight lift with dual purpose platform; handling cartons and rolls. Roll adapter is removable.

Lift for handling and stacking pallets to 2000 lbs. Goes where fork lifts are not welcome. Can be used by anyone without a special license. Saves time awaiting material handlers. Can be made with short mast to get under pallet racks.

Stacking or unstacking cartons. Can be used to pre-load pallets for later placement into trailers. Powered clamps have force regulation to prevent crushing of containers.

Since 1990, ALUM-A-LIFT engineers have designed and configured ergonomic lifting devices for literally thousands of applications. The foregoing are intended to comprise a representative sample. Hardly a day goes by without being challenged by yet a new or different problem to which a solution is sought. Visiting www.alum-a-lift.com affords an opportunity to view additional uses for these products. Available is access to libraries of application drawings and digital images. The libraries are organized by several keywords including the object handled, how it is handled and functions to be performed. Digital images are usually sent by e-mail. As in most organizations, ergonomic problems may be perceived in, as examples, laboratories and office environments. Heavy instruments, files, cabinets, office machinery, servers, monitors and the like are often handled. Sharing, installing, relocating and servicing are activities resulting in exposure to potential back injury.

Additional Applications

Model L150 with A 72” mast and platform for lifting a variety of office equipment. Large wheels are used for running on carpeted areas.

Model L100 as a height adjustable, mobile workstation

On-Board vacuum system for handling large monitors and TV’s

Alum-A-Lift, Inc. is privileged to provide product to the

following pharmaceutical and related companies:

3M Abbott Labs

Advance Tissue Alcon Labs

Alkab Altron

Ami Gibson Armour Pharmaceuticals

Astra USA Ballard Medical Products

Baxter Healthcare Bayer Corporation Becton Dickinson

Bioject Bio-Lab

Bio-Medicus Boston Scientific

Ciba Vision Cobe Labs

Commonwealth Scientific Convatec Diasonics

Dura Pharmaceuticals Ethicon

Fluke Corporation GE Medical Systems

Gendex GenenTech

HC Stark Jansenn

Johnson & Johnson Life Technologies

Lilly Del Caribe Ludens Medrad

Medtronics Merck

Neutrogena Novartis

Nutrasweet Ortho-McNeil

Pfizer Animal Health Pharmacia

Point Biomedical PPG

Proctor & Gamble Rhone Diagnostics

Roche Medical Systems Sanofi Diagnostics

Searle Spectra Physics

Squibb Stryker

Warner Lambert West Pharmaceuticals

Ziatech