Our client was using a fixed rigid rack system for storing rolls of film. The following problems were identified:

• The rigid racking was creating a major bottleneck for the fork truck traffic
• The racks did not have adequate space to hold the production flow coming into storage
• If additional fixed rigid racking was installed, it would further complicate the fork truck traffic into the storage area

Solution

Our solution was to create a racking system that was dynamic in terms of storage volume. Additionally, the racks needed to ensure ease of fork truck entry. A folding rack that would allow for transfer of the rolls of bundling film onto a roll transport/storage roll rack was used. Once the roll was on the movable rack it could be fork trucked into the storage area.

• A folding design would provide space savings to accommodate the flexibility of production volumes adjusted to meet changes in end user demand
• The roll rack had to be easy to operate for the film extruder operators
• Safety was very top of the list – the client has had 4 years with no injuries
• The roll rack would be the first transportable steel roll rack at this plant.
• The roll racks would be stacked 3 high, although they can be safely stacked 4 high

Rack Design Features

The custom designed rack featured:

• Single cable release
• Each corner is vertically secure by a channel section that completely captures the open pivot of the hinged leg
• Hand strap assists in easy lowering of the side section onto the roll rack deck
• Cradle deck protects the film from becoming “blocked” in storage
• Funnel feet provide easy alignment for stacking

Collaborating with SPS Ideal Solutions has allowed our client to make use of cutting-edge technology for development of a product that is dynamic in nature. It offers immense benefits when in use, and can be stored without occupying much space when not in use. With development of a versatile rack, the client was able to solve all the problems they were facing when using traditional tacking systems.

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To make this a more interesting challenge the clients – customer will store the rack with the HVAC outside in the train building yard because of space constraints. The rack and HVAC could sit outside for upwards of 12 months in the Northeast weather. With summer heat and winter freezing cycles, each season will create condensation on and in the HVAC. Condensation will create rust and rust is unacceptable. The material and design is proven successful since 2008. Water may collect and it will exit via the net underbelly of the package.

The tan film is Cortec MilCorr developed for extreme weather, loaded with Cortec VpCI (vapor phase corrosion inhibitors). VpCI molecules are attracted to all of the different metal surfaces. These molecules attach to the metal and repel condensation and oxygen from the surfaces. We used a combination of VpCI materials to create an envelope of protection that is safe for everyone. When the customer is ready to install the HVAC they simply remove the packaging cover, lift the HVAC from the rack. We use foam blocks with VpCI film covers to block the numerous openings on the HVAC. The systems we designed are fast and easy to install. Everything is easily recyclable.

Is your company manufacturing items that are prone to rust, but are stored for long or short periods of time? Warranty claims from items delivered with rust damage will occur if products are not properly protected. We have dry packaging solutions that are laboratory tested, field proven to be effective and priced to be cost effective. Our choice of materials and the design are based on the individual applications needs and the expectations of storage, time, conditions and handling.

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The design needed to be collapsible. The compact design of our Locking Collar Hinge allows the collapsed steel rack to stack flatter. The flatter the rack the more we can stack for return when empty. Utilization of trailer space is Critical to proper cost efficiency in closed loop manufacturing processes that wisely use Sustainable steel racks from SPS Ideal Solutions. Our SOLID WORKS CAD program had already shown us the comparative overlay image of the shorter sizes of the panels. We mounted a second set of Locking Collar Hinge at the appropriate height; SOLID WORKS readily validated the height. Now the ends of the steel rack could be reverse folded to shorten the rack height. One Rack with adjustment for load heights!

We gained a huge benefit for our client by being able to load the taller racks in the trailer and then stack the shorter height panels with the steel racks ends folded down on top of the first. No Dead Space every useable inch of height is used. Improving the load efficiency of transporting panels between the plants allowed the client to meet their cost goal but also the manufacturing rates for final assembly were attained as well.

Does your company ship products with this height configuration dilemma that causes you to have “DEAD AIR”

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• Handles rolls of flexible film up to 133

How it works:

• The spring loaded core supports have indicators on a guide track to show the appropriate core length position
• The spring loaded ends of the rack are slid to the appropriate core length and with a single hand popped up to the vertical position. The slight raising of the end activates the heavy duty spring assembly, which brings to end to vertical. Lift weight is under 10lb at the start of the operators lift action.
• The vertical ends LOCK IN the chosen guide track location.
• With the ends in the up position the exposed steel cores are ready for removal
• The 10

Safe Trailer Transport

• To our knowledge – our rack is the ONLY steel shipping rack designed to meet the US Safety requirement for safe transport of these larger size rolls.
• The US requirement is concerned with preventing the roll from leaving the steel shipping rack and damage to the steel shipping rack, must not occur. We exceed both of these testing points.
• The testing consists of highway speed testing, with an emergency stop within 250′. The roll cannot transition out of the cradles; the ends of the steel rack cannot deflect.
• We meet these requirements with our design. Our client has hundreds in their system with no occurrence of damage to rolls or racks.
• The ROI on this project was easily covered in 6 months use.

We have solutions already completed for hundreds of material handling applications, from rolled materials like this to rigid component parts. We may have just the one you need, if not we will design and supply the perfect system to meet your unique application.

“From Creative Concepts Come Ideal Solutions”

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