Standard forks are the lift-truck OEM’s traditionally supplied

attachment, but the trend towards depalletising, repalletising

and palletless handling calls for other solutions

load sense

ENGINEERING & TECHNOLOGYuwE kILLmaNN

When goods have to be handled along the internal and external logistic supply chain, from incoming raw

materials through their manufacturing process and up to their delivery to the end user, pallets are practically indispensable. Therefore, the forks that pick up pallets are the typical standard attachments preselected by forklift truck OEMs.

But what are the alternatives when:• Expensive production pallets (such as those made from stainless steel or plastic for hygiene reasons in the food or pharmaceutical industries) must be returned;• Wooden pallets have to be exchanged (because a growing number of countries no longer allow the import of unfumigated wooden packing materials); • A cheaper, one-way pallet is used to reduce packing costs, resulting in a more

attractive price for customers;• Transport volume in containers, trailers and railway wagons is to be optimised;• Load carriers have to be eliminated because the recipient of the goods will not accept the related cost.

German forklift truck attachment manufacturer Kaup – in the business for over 40 years – provides a wide variety of handling solutions to solve all required tasks. So here are some details of the relevant attachment systems, with descriptions of their design, operation, benefits and restrictions.

Palletless transportation of certain loads can be achieved with standard fork clamps with relevant slip-on arms that embrace the load, usually with dedicated attachments such as block and brick clamps, bale clamps, drum clamps and roll clamps. Their names speak for themselves.

Pallet turnover clamp with pusher

Push-pull attachment for use with slip-sheets

large- surface clampThe ideal attachment for palletless handling of carton-boxed goods are large-surface clamps – their large rubber-coated arms grab cubed loads from the side. These goods can be lifted up without a load carrier (e.g. pallet) from roller belts, or from pallets – whichever way they come. In addition, some of the boxes can be taken from the top of the cube. The forklift truck will then carry the loads, place them in containers, on trailers or place them onto other forms of load carriers.

To avoid squeezing or other damage to the load, pressure regulation valves form an integral part of the hydraulic system and enable minimum pressure to be applied between the arms. The system can be upgraded to allow the driver to choose from a selection of preset pressures for different loads, or upgraded to a sensor system that automatically selects the correct pressure according to the load’s volume or weight.

Kaup recently redesigned its large-surface clamp range to provide optimal grip of the load and improved user- and service friendliness. Arm and clamp design have been optimised to prevent damage to loads, while the lifetime of the rubber pads was doubled, allowing them to be turned and swapped easily.

The proven Load Sensor Force Control System (LSFCS) can be added to the structure without modification, as it forms an integral part of the modular build system in this attachment family.Palletless transportation with large-surface clamps also means that load size can be

93iVT InternatIonal 2006

ENGINEERING & TECHNOLOGY

coffee, sugar or plastic chips, for example. These can be depalleted by means of a pusher, which consists of the carrying part – usually a plate – and a hydraulically operated pushing grate that moves the load to the front.

There are different choices for carrying parts. If standard features are selected, the pallet is held in position by a little gripper clamp holding its centre block between the forks so that it cannot shift while the load is being pushed off. With this system, the load can be transferred to another pallet or placed on top of another stack, although pushing the load to the floor might be problematic because of the pallet height of about 150mm. This can be overcome for carton-boxed loads by placing the load against a container wall or another stack and reversing the truck at the same speed as the pusher moves the load to the front. The load stack remains in the air until the pallet is fully retracted from below and then slides down as a complete entity.

Another configuration is usually selected for bagged goods. The carrying part in this case consists of five to six multitines and the loads are provided on comb pallets. The pusher with multitine arrangement is introduced (as counter comb) into the centre spaces formed by square length members (comb) on which the load rests until it is taken up. By lifting the load it rests on the tines and can be pushed off these afterwards.

But sometimes goods are not provided directly on comb pallets. In this case, a stationary pallet turnover clamp can be used, where one side provides a plate onto which the production pallet is placed and the other side of the clamping arm is of a comb shape design. By clamping the load together and turning it through 180°, it

then rests on the comb arm and can be moved with the multitine pusher in the same way as described above.

A third way, and the thinnest variation of carrying parts, is a plate. Here, the difficulty lies in transferring the goods from pallets on to the plate. This can be achieved with a transfer station that incorporates a stationary pusher – once the load is placed onto the carrying plate of the attachment, it can be pushed off.

Pallet turnover clampsOne method of repalletising is the pallet turnover clamp. This attachment features a rotating clamp with fork pairs on both arms. An empty one-way shipping pallet is loaded onto the first (upper) fork pair, and after being rotated 180°, the clamp opens so that the lower fork pair can insert the production pallet under the stack. After closing the clamp and rotating back 180°, the load is then placed on the shipping pallet. By opening the clamp, the production pallet stays on the upper forks and can then be placed on the floor to be returned into the work cycle.

A complete mobile depalletisation system can be created by upgrading this clamp with a pusher mechanism between the two arms and refitting one side of the clamp arms as a carrying plate. Through turning the plate 180°, the load will rest on the carrying plate and can be pushed off the same. Turning back 180°, the empty pallet is then placed on the ground.

Push-pull handlingIn cases where goods are likely to be shipped without pallets, or where comparatively expensive pallets are to be replaced with a cheaper variety, slip sheets can be taken into consideration.

Large-surface clamp for handling carton-boxed goods

independent from the typical pallet/load carrier sizes, which are usually in the range of a 1,200x1,200mm surface. Applications for these clamps include handling of white and brown goods. Handling cubes of eight units (two wide by two deep by two high) has now become a standard configuration in manufacturers’ and logistic service providers’ warehouses.

However, by creating innovative telescopic profiles for its clamps, Kaup has met the industry’s efficiency demand of handling even bigger cubes. Now, using the same clamp attachment, it is possible to handle either one household appliance at a time or up to 16 units (four wide by two deep by two high) in one go. The ability to load a full container or trailer width (2,400-2,500mm) at a time increases the efficiency of handling such cargo tremendously.

The arms of the new clamp design are so slim that, in most cases, the remaining space between the container/trailer wall and the goods is sufficient for opening and retracting them. The only condition for applying such handling equipment is that the recipient of the cargo also requires a large surface clamp for unloading, but due to the system’s efficiency and attractive price, the amortisation period is quite short.

Using a pusherSome goods cannot be grabbed from the sides, such as bagged goods containing

94 iVT InternatIonal 2006

Pallet turnover clamp features a rotating clamp with fork pairs on each arm

These are usually made of cardboard or plastic, about 2-3mm thick and can be obtained in all shapes and sizes depending on load pattern and stack surface. Their low height in comparison with pallets also allows more layers of the relevant goods to be stacked into a container or into a warehouse where height is an important consideration. This applies mainly to lightweight/high-volume goods. As they provide no room for inserting forks, the process of working with slip sheets is very different from conventional pallet handling. Slip sheets feature a flap of about 10cm long on one side which is preformed with an angle of around 30°.

A push-pull is similar to the pusher system described above but features a hydraulically operated gripper bar at the bottom of the pushing grate, which grabs the flap of the slip sheet. The slip sheet

cCONTaCTwww.kaup.de kaup@kaup.de

and load are pulled onto the wide carrying plate and moved to the warehouse or loaded directly into a container or trailer, where the goods, including slip sheet, are pushed off.

However, the goods can only be unloaded if the recipient also has push-pull on site. Otherwise, they have to be manually removed, one by one – a system not accepted in developed countries due to the high labour costs and regulations from the health and safety boards regarding prolonged exposure of backs and knees to stress.

In cases where loads are repalletised, such as after space-saving/optimised transport in a container, there is the possibility to retain the slip sheet with a sheet saver. Opening the gripper bar in retracted position releases the sheet flap. An additional lifting component – incorporating a sheet saver bar – allows

the lifting of the complete pushing mechanism. While lifting, the protruding flap of the slip sheet falls under the clamping bar of the slip sheet saver and, during lowering, will be firmly pressed down by the same. When pushing off the load, the slip sheet rests on the carrying plate and can be manually removed from there for re-use.

Whichever system of handling is preferred, Kaup – with its specialist experience – can provide all the required configurations. Its worldwide dealer network is happy to assist in the selection of optimal materials handling solutions. iVT. Uwe Killmann is Kaup’s export marketing and sales manager and has been with the company for 13 years

Kaup GmbH & Co. KGBraunstrasse 17 · D-63741 AschaffenburgFon + 49 (0) 60 21/8 65- 0Fax + 49 (0) 60 21/8 65- 213E-Mail kaup@kaup.de · www.kaup.de

No matter which loads you have to transport withyour forklift truck you can do this best with Kaup attachments. These attachments turn your forklifttruck into a multi-talented and versatile tool.

With our comprehensive product range for each kindof application we have acquired an outstanding reputation in the past 40 years ... world-wide.

The technical press describes Kaup as the leading manufacturer of forklift truck attachments in Europe.

In addition to attachments Kaup produces Con-tainer - Spreaders and Stationary Handling Equipmentwhich provide smooth material handling in proven Kaup quality.

Kaup know-how is in world-wide demand...

Kaup (Xiamen) Forklift Truck Attachments Co. Ltd Yiai RoadLongshan Industrial ZonePRC - 361009 XiamenFon + 86 (0) 592 5516 220Fax + 86 (0) 592 5513 249E-Mail philip.lin@kaup.com.cn

Helping hands for

your forklift truck