Understanding Materials Handling Applications, Solutions for the Paper Industry

Transcription

1 Solutions for the Paper Industry This white paper explores some of the environmental impacts and operating conditions typically found in the paper products industry. Also included is an overview of some of the types of materials handling equipment, attachments and options available to enhance productivity in all phases of the paper industry.

2 Solutions for the Paper Industry Page 2 Introduction The paper industry is an intense, fast-moving environment with little tolerance for downtime in operations running 24 hours a day, 7 days a week, 365 days a year. Paper is produced in several manufacturing steps (pulping, manufacturing, converting), then distributed and may finally be recycled. Each step of the process involves materials handling activities, where raw materials, paper, other paper products and waste paper have to be moved, stored, loaded or unloaded. A paper roll, for example, can be loaded, transported and unloaded 14 times or more. Lift trucks are versatile and flexible material handling tools, making it the most common means of paper product handling. Paper manufacturing stages include pulping, paper manufacturing, and converting. Ranking these different paper environments on a scale of one to 10 for their impact on materials handling equipment, with one being a low difficulty, easy environment and 10 being the most harsh and abusive environment, the following is observed: Pulp and paper mills that convert wood byproducts and pulp into paper and cardboard products rank about an eight or nine, largely because of the chemicals used throughout the manufacturing process. Ranking a two or three are the converting facilities, which convert paper products from purchased materials. These facilities require equipment to operate in largely indoor and clean conditions. And at the extreme end of the scale - at a 10 - is the recycling operation for converting waste materials into the pulp that can be used again for paper manufacturing. Applications found in the paper products industry are pulp and paper mills, converting facilities, and recycling plants.

3 Solutions for the Paper Industry Page 3 Determining the equipment needs of paper converting facilities is easier because they generally don t require specialized equipment for these operating conditions. This allows a more focused review of the industry on the equipment needs of the more difficult applications: pulp mills, paper mills and recycling facilities. Which truck for which operation? Lift truck equipment for the paper industry can be broadly categorized as either sit-down counterbalanced lift trucks or warehouse equipment, such as reach trucks, motorized walkies and end riders. Sit-down counterbalanced equipment is available with internal combustion engines (ICE) as well as electric powered. Traditionally, the paper products industry has been dominated by ICE lift trucks, because they have generally been more suited for the more rugged environments found in Paper applications are dominated by Class IV and V trucks due to often harsh applications - rough, dirty, highhour usage.

4 pulp and paper mills. However, improved performance has opened the doors for electric lift trucks, especially in the indoor, cleaner environment of converting facilities. Warehouse materials handling equipment is found in the paper products industry s distribution functions, where end products are typically palletized to be moved. Understanding Materials Handling Applications, Solutions for the Paper Industry Page 4 In mill operations, where roll handling is a major part of the production process, the diameter, height and weight of the roll dictates the type of lift truck and attachment needed to handle the rolls. Paper rolls can weigh from 1,000 to 18,000 pounds and special attachments can handle up to four rolls at a time. To determine the needed capacity of a lift truck, the maximum, as well as the average, load weight should be established. It is important to note that a lift truck s capacity rating noted on the capacity plate installed by the OEM is usually based on the truck being equipped only with forks. A roll clamp will move the center of load gravity outward, The right combination of lift truck and attachment is essential for damage free roll handling.

5 which in addition to the attachment s own weight, will reduce the effective capacity rating of the lift truck. A lift truck s capacity therefore must be re-rated if equipped with a roll clamp or other attachments. Understanding Materials Handling Applications, Solutions for the Paper Industry Page 5 Paper rolls typically will come off the line in a horizontal, also called bilge, position. Rotating clamps are often needed to lift a roll from the bilge position and turn it vertically for stacking and storage. Once the roll is in a vertical position, nonrotating clamps can be used to pick-up, transport and load into truck trailers. The right combination of lift truck and attachment is essential to damage-free roll handling. Depending on the attachment, the lift truck must have at minimum two, but often three, four or even more hydraulic functions (valves) to enable several different directional movements of the mast and the attachment. Some roll attachments require sufficient mast forward tilt, and the mast s lifting height must allow for required stacking needs. An optimal hydraulic pressure and oil flow from the truck to the clamp is important and allows for maximum performance and the right amount of grip, while the front-end shock accumulators cushion the load to prevent a roll from slipping or dropping. In some applications, the hydraulic system performs so much work that additional oil coolers are required. The load weight of palletized paper products found in converting operations can typically be handled by 5,000 8,000lbs counterbalanced lift trucks. In converting facilities, which are mostly indoors, rolls are received and loaded into the converting process by rollclamp equipped trucks. However, the finished converted product, such as pizza boxes or tissue paper, mostly is palletized for transport and storage. The load now weighs significantly less than paper rolls, and can typically be

6 Solutions for the Paper Industry Page 6 handled by 5,000- to 8,000-pound counterbalanced lift trucks with forks, electric or ICE. This reduces the complexity of equipment s specifications significantly, but parameters such as distance traveled, possible rack heights, aisle widths and loading docks must be understood to ensure the right truck specifications for the right job. The warehouse operations, in which palletized paper products are stored, are similar to other typical warehouse operations. Space is a factor that directly affects cost, and therefore significant attention is applied to using warehouse space as effectively and efficiently as possible. Racking height and aisle spacing become important factors for picking the right materials handling equipment. To choose the right lift truck solution, it is best to thoroughly understand the operations current layout and needs by consulting with a lift truck dealer (or manufacturer, or both) to conduct an application survey. Lift Truck Options Class I Warehouse and Converting Applications With Class I lift trucks used primarily in warehouse or converting facilities, the focus of the following options is on increasing operator comfort and reducing product damage. Through these two factors, operations can utilize materials handling equipment to boost their overall productivity and bottom line. Hydraulic accumulator to help minimize product damage, especially when lift trucks are traveling over unimproved surfaces or carrying large, bulky loads For many warehouse operations it is best to conduct an application survey to understand the operation s needs and determine the best lift truck solution.

7 Solutions for the Paper Industry Page 7 Three- or four-function hydraulic valve with mechanical or mini-levers to help maximize productivity and reduce operator fatigue during actuating the controls Full-suspension, cloth seat to help maximize operator comfort Rear drive handle with horn button for when the operator is driving in reverse Telescopic steer column with tilt memory for operator comfort and to help entering and exiting, especially with drivers who are frequently on and off the truck Dual rear view, overhead, guard-mounted mirrors as additional options for viewing along the side to observe the tail swing area Class IV Paper Roll Handling Paper rolls come in many sizes and weights, so the preferred method for handling these is with a paper roll clamp attachment. Clamps are heavy attachments, so operations need to consider a lift truck that can accommodate not only the weight of the load, but also the weight of the attachment. 4,000 to 7,000 pound capacity trucks A radiator lint screen provides an easy clean out alternative for the radiator core. The paper application kit (described further below) helps to reduce the accumulation of debris in the engine Hydraulic accumulator to help minimize product damage, especially when lift trucks are traveling over unimproved floors or carrying large, unsteady loads Determine the needed capacity of a lift truck by understanding the average and maximum load weights.

8 Solutions for the Paper Industry Page 8 8,000 to 12,000 pound and 135,000 to 155,000 pound capacity trucks Choice of cowl-mounted levers or e-hydraulic minilevers Engine modifications can boost powertrain ability to withstand high-heat applications Oil-cooled wet disc brakes offer added protection against intrusion of debris or other contaminants, while minimizing service requirements Hydraulic accumulator to help minimize product damage, especially when lift trucks are traveling over unimproved surfaces or carrying large loads A radiator lint screen provides an easy clean out alternative for the radiator core. The paper application kit (described further below) can help reduce the accumulation of debris in the engine Swivel, full-suspension vinyl seat provides easy operator entry and exit and additional operator comfort through shock absorption while traveling with heavy loads over various surfaces Carriage side thrust rollers help reduce potentially damaging side-to-side mast sway There are some other options that make sense for paper roll handling applications. Among these, return to set tilt, extended wear tires, premium monitoring, powertrain protection, traction speed limiter and operator pre-shift checklist are all helpful options that have good benefits for the paper industry. Always make sure that the nameplate is correctly updated when an attachment is fitted. Paper roll clamps are heavy! Always consider the weight of a clamp attachment and the load weight when choosing the capacity range of a paper roll truck. Several lift truck options are available aimed at increasing operator comfort and reducing product damage to help improve productivity.

9 Paper Application Kit A paper application kit may include a vented hood, hightemperature hydraulic oil and exhaust wraps. A radiator lint screen option is often recommended by lift truck providers with paper application kits. Paper application kit options are recommended for any truck used in a paper application where substantial loose paper material is present. Understanding Materials Handling Applications, Solutions for the Paper Industry Page 9 Recycling Recycling is considered one of the most abusive industry subsectors. Rough, dirty, high-hour environments are normal operating conditions. These types of operations should be considering a truck that can perform under these grueling conditions with minimal downtime. Combi-cooler radiator and vented hood help improve engine and transmission cooling in heavy-duty applications, minimizing the risk of overheating or damage to components

10 A radiator lint screen provides an easy cleanout alternative for the radiator core. The paper application kit can help reduce the accumulation of debris in the engine Oil-cooled wet disc brakes offer added protection against intrusion of debris or other contaminants, while minimizing service requirements Rear drive handgrip with horn button and dual rear view mirrors assist the operator in surveying the operating environment when carrying large loads Engine modifications can boost powertrain ability to withstand high-heat applications Carriage side thrust rollers help reduce side-to-side mast sway and accelerated mast wear Premium monitoring, powertrain protection and operator preshift checklist are also helpful options that have good benefits for recycling applications. Understanding Materials Handling Applications, Solutions for the Paper Industry Page 10 It can be a rather complex task to not only select the right lift truck, but also specify the right options to meet an operation s needs. Hyster Company has developed a number of packages and bundles specifically designed for the paper and pulp handling applications, making it easier to get the right options on the right truck for the right application. All of these packages come with recommended transmission, hydraulic and mast options. Rather than list every option in each package, we have focused on some of the key options available and how these are designed to meet specific operational performance expectations. Hyster Company has developed a number of packages and bundles specifically designed for the paper handling applications, making it easier to get the right options on the right truck for the right application.

11 Solutions for the Paper Industry Page 11 Lift Truck Attachments Because of the unique operational challenges with the paper industry, many lift trucks may require specialized attachments to accommodate oversized, bulky or oddlyshaped loads. It is best to work with someone who understands and has experience with attachments before attempting to specify and fit an attachment to a lift truck. Understanding attachment types is critical to knowing how they could help productivity in a particular paper application. Forks Features Rotating forks are used in a variety of manufacturing, receiving, warehousing and shipping environments that require both clamping handling and pallet handling. Arms are able to rotate to the vertical position for clamping or to the horizontal position for pallet handling. A sideshifter maximizes the maneuverability of a lift truck s forks by allowing the operator to quickly position the forks for efficient pallet entry and exit or load pick-up, potentially saving time for each load moved. This can be especially beneficial in tight cross-docking storage areas or for adapting between various transport modes. Similar to sideshifters, fork positioners make it easy to quickly adapt to changing load widths and load types without the time-consuming necessity of the operator having to adjust the forks manually. To maintain productivity, they are a critical handling feature for operations moving a wide variety of product. Sideshifters and forkpositioners make it easy to adapt to changing load types by reducing manual adjustments of the forks.

12 Solutions for the Paper Industry Page 12 Clamps The goal of a paper roll clamp is to move product as effectively as possible with minimal or no product damage. Product damage can include tearing, denting and pushing a roll out of round. Out of roundness occurs when too much pressure is used to clamp the paper roll for transport, while tearing can result from incorrect or worn padding on the clamp s inside surface. Paper roll clamps are designed to move product as effective as possible with minimal damage. Typically, it is sufficient if a paper roll clamp has a 180 degree turning radius, allowing an operator to pick up a roll from bilge position and standing it up for storage or stacking. Some manufacturers offer clamps with a full 360-degree turning radius so a clamp can be spun around to position the roll in either direction. Other clamps are specifically designed to handle nearly any type of bald material. Other types of clamps include bale clamps, pulp bale clamps and recycling clamps. Bale clamps can boost materials

13 handling efficiency through palletless handling of nearly any type of baled product translates into savings in time and storage costs. Pulp bale clamps are typically seen in more high-volume pulp applications such as mill, warehousing, and transporting operations. Recycling clamps must provide a more durable solution for clamping needs in order to deal with the harsh operating conditions and payloads found in recycling applications. Understanding Materials Handling Applications, Solutions for the Paper Industry Page 13 Bin Dumpers Bin rotators and dumpers are an economical way of handling and dumping bins for wood chips or other products. These attachments allow operators to quickly dump or invert a load and then return the forks to the pick-up position. The Hyster Solution Paper applications are dominated by Class IV and Class V lift trucks and are often very harsh applications with rough, dirty, high-hour usage. Because of these demands, operations are looking for equipment that can withstand the abuse with minimal downtime. One leading provider of lift trucks to the paper industry is Hyster Company, who manufactures and distributes a full line of lift trucks, both electric and ICE as well as warehouse product and counterbalanced sit-down lift trucks with a lifting capacity to up to 115,000 pounds. Hyster lift trucks are built with industrial-grade components that are designed, engineered and manufactured for strength, dependability and reliability. Hyster is capable of delivering the lift truck, attachments and options needed to make any operation more productive. Hyster stands apart through the features contained in its

14 Solutions for the Paper Industry Page 14 advanced cooling, electrical and hydraulics systems. Hyster s cooling system solution optimizes airflow to lower operating temperatures, minimizing overheating in tough applications and increasing component life. The 100 percent shock-mounted radiators feature aluminum cores, which are more durable that traditional copper cores. Hyster also has robust paper application kit options and solutions, and these should be carefully considered for potential use. Linking the major truck nerve centers together, the electrical system of a lift truck must be durable and reliable for demanding hotcold-wet-dry operations and must be sophisticated and intelligent with responsive truck functionality. Employing digital technology, the Hyster CANbus electrical system solution reduces wiring and electrical connections, resulting in improved reliability and excellent serviceability. Since hydraulics are the muscles of the lift truck providing the force necessary to lift heavy loads all shift long, all Hyster lift trucks feature industrial grade hydraulic components. The O-ring face seals are designed with leakfree hydraulic connections to eliminate pipe fittings and thread sealants. The system s control valve is also located away from heat source for a lower system temperature. The paper industry continues to be a challenging environment for materials handling equipment. The harsh operating conditions and round-the-clock operations demand the very best in lift truck durability and features to ensure the best productivity. With the right lift truck and the right attachments and options, any paper and pulp operation can be well equipped to successfully meet its materials handling needs ultimately benefitting the operation s bottom line.