MRM – Manual Roll Manipulator:
Roll Handling Equipment for Gripping and Turning Lighter Rolls

Manual roll handling is not as straightforward as it may seem. Photo of a man, a worker, carrying a large paper roll over his shoulder.

For an outsider, manually handling rolls may seem straightforward, but moving rolls and reels can actually be quite tricky. It comes with a range of risks that can endanger not only workers but also the loads and operations themselves. Manual lifting without the proper equipment – or with inadequate equipment – can lead to musculoskeletal injuries, such as sprains, strains, and even more serious conditions like herniated discs. Additionally, improper handling may damage the roll and slow down production, wasting time, money, and reducing overall efficiency.

That’s where our manual roll manipulator (MRM) steps in to make a significant difference. Designed to handle lighter rolls, the MRM will make lifting, moving, and repositioning much easier and safer.

The manual roll manipulator grips the roll through its inner core using a mandrel that expands with a simple flip of a handle. Once the roll is securely gripped, it can be lifted vertically using a remote control. When the desired height is reached, the manipulator can be manually rotated to a horizontal position, making it ready for placement – e.g., onto a mandrel. For even easier gripping and placement, the roll manipulator can be combined with a swing unit (SU), which allows the roll to swing on the horizontal plane.

Collage of a lifting solution for roll handling. One picture of the electric lifter. Another image of the swing unit. And finally the illustration of the manual roll manipulator.

Using the Right Roll Handling Equipment for Easy Lifting, Tilting, and Positioning

When rolls need to be moved from one location to another in an industrial setting, simply lifting the roll up and down vertically often isn’t enough. In industries like manufacturing, logistics, textiles, or even printing, rolls frequently need to be repositioned – whether it’s shifting from a ‘standing’ position on a pallet to a ‘lying’ position on a mandrel, or vice versa.

This type of handling requires more than just basic lifting equipment. You need a roll manipulator – something that can not only lift but also tilt or tip the roll into the required position.

For heavier rolls or situations where there’s limited space around the lifter, we recommend an electric roll manipulator (ERM). Such an electrical solution is perfect for handling large, heavy rolls with ease. However, if the roll is lighter and there’s enough room for an operator to stand beside the lifter, a manual roll manipulator (MRM) might be the ideal solution. It offers a more tactile, hands-on approach while still making the job safe and efficient.

Photo series of how to operate manipulative roll handling equipment. The photos show an operator lifting a roll electrically from a pallet and rotating it manually.

How Exactly Does the Manual Roll Manipulator Work?

Component overview of the manual roll manipulator showing the meaning and function of the individual parts.

The manual roll manipulator is designed to lift and tip rolls with a tube-shaped core.

The gripping mechanism features a tooth plate that sits on an expander unit, which expands inside the roll’s core tube to secure it firmly in place.

Once the roll is gripped, the manipulator allows it to be manually tilted into either a horizontal or vertical position with precision and ease.

What Is Required by the Rolls?

Photo of a lage pile of rolls with film in a workhouse / factory setting.

The manual roll manipulator (MRM) is specifically designed to handle rolls with an inner tube wrapped tightly in material. For the MRM to function properly, the inner tube must be strong enough to withstand the gripping force, and made from a material that allows the gripper teeth on the expander to securely latch onto it. Core tubes made of thick cardboard or soft plastic are ideal for this purpose.

The diameter of the inner tube can vary slightly, with standard inner diameters being 3” (76 mm) and 6” (152 mm). It’s essential that the core’s inner diameter doesn’t differ by more than ±3 mm from the nominal diameter that the gripper teeth are designed for. If there’s a slight variation, it can be easily adjusted using a shim plate or additional gripper teeth, ensuring a secure grip and smooth operation.

Swinging Function

To make placing the expander into rolls with the core in a vertical position easier, the MRM can be mounted on a swing unit (SU). This setup allows the expander unit to swing freely in the horizontal plane once the lock pin is released, providing greater flexibility and ease when positioning the roll.

Photo series of how the swing unit works in combination with the manual roll manipulator. The photos show the operator pulling the roll handling equipment towards himself, placing the expander into the roll, lifting the roll, and pushing the manipulator back to default position.

Special Solution to Telescoping Challenges

Image of manual roll handler with special anti-telescoping attachment.

Some rolls may be prone to telescoping, a phenomenon where the core of the reel pulls the sheet material with it as it’s lifted, causing the reel to resemble a telescope.

Several factors contribute to telescoping, including loosely wound material on the roll, a short roll length with a large diameter, and roll material with a low coefficient of friction. These conditions can make handling more challenging, as the material tends to shift or slide, affecting stability during lifting.

To address these challenges, we’ve developed a variety of simple yet effective anti-telescoping solutions that can be easily attached to the MRM. This attachment applies pressure to the outside of the roll, stabilizing the roll layers and preventing the material from shifting or telescoping during handling.

This added feature ensures smoother and more reliable lifting, even with rolls that are prone to telescoping.

Photo series of how to use the anti-telescoping attaching on the roll handler. Photos show how the roll is telescoping, how to fasten the anti-telescoping attachment, and how the roll can now be lifted without telescoping.

Features

Self-locking gripper holds the roll safely in place – the heavier the roll, the more the gripper expands.
Adjustable gripper position makes it easy to rotate the roll around its centre of gravity.
Large handle allows for rotation of the roll from any position.
Rugged construction for industrial use. With its all-stainless steel construction, the MRM is built to last and for use in demanding industrial environments.
Handles loads up to 400 kg and roll dimensions of up to ø1000 mm.