Gelenk-Manipulator für Rollen
Gelenk-Manipulator für Rollen
GUIDE: ROLLER HANDLING
Roll lifter for film rolls, paper and heavy rolls
The complete guide to industrial lifting aids for cylindrical loads up to 800 kg: function, variants, applications and selection criteria.
CHAPTER 1
WHAT IS A ROLLER LIFTER?
A roll lifter is an industrial lifting aid for the ergonomic lifting, rotating, and positioning of cylindrical loads such as rolls of film, paper, or other materials. Unlike conventional cranes or forklifts, a roll lifter offers precise, oscillation-free load guidance via manipulator mechanics, enabling safe work directly on the workpiece.
Roll lifters are a specialized type of roll handling device and are used wherever cylindrical loads need to be regularly moved from a horizontal to a vertical position, rotated, turned, or clamped onto machines. The gripper is individually adapted to the roll material: with a mandrel, expanding mandrel, vacuum gripper, or mechanical clamping mechanism.
The term roll lifter is often used synonymously with: roll handling device, roll manipulator, film roll lifter, paper roll lifter, roll turner . Zeilhofer HHT designs all variants as custom solutions up to 800 kg. In English-speaking countries, it is commonly known as roll lifter, roll manipulator, reel lifter, or coil handler.
CHAPTER 2
FUNCTION AND STRUCTURE
A roll lifter consists of three main components: the support system (column, swivel arm, or linear axis), the lifting mechanism (pneumatic, electric, or hydraulic), and the holding device (gripper for the respective roll). These three elements are individually tailored to the application at Zeilhofer HHT.
The key feature of a roller lifter is its pendulum-free load guidance . This allows rollers to be positioned with centimeter precision, without the load swinging during lifting. This is the crucial difference compared to crane or rope solutions and is particularly important for repetitive handling tasks in production.
CHAPTER 3
APPLICATION AND LOADS
Typical applications range from lightweight film rolls to heavy material rolls. Load capacities vary depending on the industry. The following overview shows the most important application types:
Foil roll lifter
Stretch film, shrink film, packaging films, aluminum foil. Often with expanding mandrel attachment, small to medium diameters.
50-200 kg
Lifting paper rolls
Printing paper, label rolls, corrugated cardboard rolls, hygiene paper. Rotating function often required for machine setup.
100-200 kg
Lifting heavy rollers
Steel coils, plastic rolls, textile bales, nonwoven rolls, rubber. Requires robust construction and usually electric control.
up to 800 kg
CHAPTER 4
VARIANTS IN DETAIL
Zeilhofer HHT offers three main types of roller lifters. Which type is suitable depends on the load, frequency of use, working area, and desired freedom of movement.
Stationary roller lifter
Permanently installed manipulator on a column, ceiling or wall bracket. Ideal for workplaces with a defined range of motion and high repeatability.
Load capacity: up to 800 kg
Drive: Pneumatic/Electric
Radius: up to 4m
Use: Fixed location
Mobile roller lifter
Battery-powered lifting platform on an omniwheel chassis. Maximum mobility for flexible use in warehouses, logistics, and at shared workstations.
Load capacity: up to 100 kg
Drive: Pneumatic/Electric
Radius: Mobile
Use: Flexible
Roller lifter with reversing function
Roller lifter with integrated multi-axis module ZH3 for rotary movements. Turns, swivels, and positions in a single operation. Ideal for machine loading and automation.
Load capacity: up to 500 kg
Drive: Pneumatic/Electric
Rotation angle: 360°
Use: Fixed location
THE CHALLENGE
WHY HV STORAGE IS SPECIAL
The following values are typical specifications. Zeilhofer HHT designs each roller lifter individually for the specific application. Special designs, for example for higher loads or special environments (cleanroom, ATEX), are available upon request.
parameter
Maximum load
Rollendurchm.
working radius
Rotating function
steering
Stationary
bis 800 kg
100 bis 1.500 mm
up to 4 m
Yes, it's possible.
all options
Mobile
bis 100 kg
100 bis 800 mm
Unlimited mobile
Yes, it's possible.
all options
reversing function
bis 500 kg
200 bis 1.200 mm
divers
Yes, it's possible.
all options
CHAPTER 6
INDUSTRIES & AREAS OF APPLICATION
Roller lifters are used in numerous industries, wherever cylindrical loads need to be handled regularly. The most important industries include:
Packaging
Rolls of film, labels and adhesive tape for packaging machines.
textile industry
Bolts of fabric, rolls of nonwoven fabric, spools of yarn, and even carbon fiber rolls.
Metalworking
Stahl-Coils, Aluminiumbänder, Blechrollen, Drahtbunde.
Film production
Stretch, shrink and industrial films, often with expanding mandrel mounting.
Chemistry & Plastics
Plastic films, membrane rolls, filter material, heavy industrial rolls.
Special machine construction
Special applications in machine setup and tool holding.
Paper & Printing
Printing rolls, label rolls, printing materials for rotary printing presses.
logistics
Goods receipt and dispatch, order picking, machine loading.
CHAPTER 7
SELECTION CRITERIA
Selecting the right roller lifter depends on several factors. During the initial consultation, Zeilhofer HHT systematically clarifies the following points:
01 Load and Geometry
Maximum load in kg, roller diameter, roller width, material properties (hardness, sensitivity, coating).
02 Movement sequences
What movements are required? Lifting, rotating, turning, swiveling, moving? What heights and radii need to be achieved?
03 Frequency and operating time
How often per shift? Continuous or occasional operation? Single or multi-shift operation? Load cycles per hour?
04 Work environment
Cleanroom, ATEX, outdoor areas, temperature, contamination? Requirements for material selection and protection class of components.
05 Control and Safety
Manual, collaborative, or fully automated? What safety requirements apply? CE marking and Machinery Directive compliance?
CHAPTER 8
FROM CONCEPT TO DELIVERY
Every roller lifting project with Zeilhofer HHT follows a structured process from the initial consultation to worldwide commissioning.
01 Consultation
Initial technical consultation, analysis of load, movements, environment and safety requirements.
03 Manufacturing
Design and manufacturing in Holzkirchen, Bavaria. In-house technicians, ISO 9001 and TISAX Level 2 certified.
02 Concept
Individual concept including setup plan, equipment, control system and offer with price indication.
04 Commissioning
On-site assembly, training, and commissioning, worldwide. Optional maintenance contract.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 What is a roller lifter?
A roll lifter is an industrial lifting aid for the ergonomic lifting, rotating, and positioning of cylindrical loads such as rolls of film, paper, or other materials. Unlike cranes or forklifts, it offers precise, sway-free load guidance and enables safe work directly on the workpiece.
02 What loads can a roller jack lift?
Industrial roll lifting systems lift loads up to 800 kg. Typical applications include film rolls (50 to 200 kg), paper rolls (100 to 500 kg), and material rolls (up to 800 kg). The system is individually designed based on roll diameter, material, and operating frequency.
03 What types of roller lifters are there?
There are stationary and mobile roll lifters, manual and electrically controlled versions, as well as roll lifters with a rotating function (roll turners). The selection depends on the load, frequency, range of motion, and working environment.
04 For which industries is a roller lifter suitable?
Roll lifters are used in the packaging industry, film production, the paper and printing industry, the textile industry, the chemical industry, and in logistics. The device is individually adapted to the roll material, for example with a mandrel, expanding mandrel, or vacuum gripper.
05 What is the difference between a roller lifter and a crane?
A roller lifter is a manipulator with rigid, pendulum-free load guidance. Unlike a crane, where the load swings on a cable, roller lifters allow for precise positioning, rotation, and swiveling of rollers with centimeter accuracy. This is particularly safer and faster for repetitive handling tasks.
06 How do I choose the right roller lifter?
Key criteria include: maximum load in kg, roller diameter and width, material (film, paper, steel, plastic), movement sequences (lifting, rotating, turning), working area, frequency per shift, and safety and control requirements. Zeilhofer HHT analyzes these points during the initial consultation.
SELECTION
WHEN A MANIPULATOR IS THE RIGHT CHOICE
Manipulators are useful when loads are regularly positioned manually, when precision is required, when ergonomic requirements according to DIN EN 1005 must be met, or when a crane would be too slow or too inaccurate.
Manipulators are now standard in automotive final assembly, the handling of high-voltage batteries, and the assembly of large glass and window elements.
Zeilhofer manufactures manipulators for loads up to 800 kg. The devices are pendulum-free, readily available, and currently serve 18 industrial sectors.
ÜBERSICHT
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