Safe, Efficient Die Block Handling with the Packline Compac MK5.1 Lifter
Bespoke Material Handling Solution for Heavy Die Changes and Roll Loading
At Packline, we specialise in designing bespoke lifting and handling solutions for complex manufacturing environments. When a customer in the printing and converting industry required a safe and efficient method for changing heavy dies and loading material rolls within confined machine access areas, our engineering team developed a tailored solution using the Packline ‘Compac’ MK5.1 lifter combined with custom attachments.
This project demonstrates Packline’s expertise in solving challenging industrial lifting applications involving restricted access, heavy tooling, and operator safety.
The Customer Challenge
The customer required a versatile lifting system capable of handling three key operational tasks on their production machinery:
The customer needed to safely remove and install die blocks weighing up to 250kg at two separate positions on the machine.
Key challenges included:
The customer required a lifting solution that could safely manoeuvre heavy tooling within these confined spaces while ensuring quick and ergonomic die changes.
A second challenge involved changing welding dies that had to be installed and supported from underneath the machine.
Requirements included:
This application required a bespoke lifting attachment capable of securely supporting tooling during installation and removal.
The customer also wanted to use the same lifting system for loading material rolls and removing waste rolls at varying heights.
Roll specifications:
Roll positions included:
Again, machine access restrictions created additional handling complexity.
The Packline Solution
After reviewing the application in detail, Packline proposed a customised handling solution based around the:
Packline Compac MK5.1 C300 Lifter
The solution included:
The system was specifically engineered to provide safe, controlled handling of heavy dies and material rolls while operating within the customer’s restricted machine access zones.
Custom Die Block Lifting Configuration
For the upper die handling positions, Packline supplied:
850mm Spindle Boom Assembly
Combined with:
The tooling was lifted using:
This configuration enabled operators to safely remove and install heavy dies from above the machine while overcoming the restricted access caused by guards and machine framework.
Bespoke Platform Attachment for Underneath Loading
To solve the below-machine lifting requirement, Packline designed a special platform attachment based on a modified version of an existing Packline solution.
Platform Specifications
The platform attachment allows the die block to be securely supported during lifting operations, significantly reducing manual handling risks and improving operator safety.
Multi-Purpose Roll Handling Capability
The same Compac MK5.1 lifter was also configured to handle material rolls and waste rolls throughout the production area.
Benefits included:
Key Benefits Delivered
Improved Operator Safety
The bespoke lifting solution minimised manual handling risks associated with heavy die and roll changes.
Increased Changeover Efficiency
Quick and controlled lifting operations helped reduce downtime during tooling and material changeovers.
Bespoke Engineering Solution
Packline adapted standard lifting equipment with custom modifications to meet the customer’s exact operational requirements.
Versatile Multi-Function Equipment
One lifting system now supports:
Why Choose Packline?
Packline designs and manufactures innovative lifting and handling equipment for a wide range of industries including:
Our bespoke handling solutions are engineered to improve safety, productivity, and operational efficiency in demanding industrial environments.
From stainless steel lifters to custom tooling attachments, Packline delivers tailored solutions for complex lifting applications.
Looking for a Bespoke Lifting Solution?
If your production process involves difficult manual handling tasks, restricted access machinery, or heavy tooling changes, Packline can help.
Learn more about our Bespoke Roll Lifting and Handling Equipment or Die Block Handling solutions, or Contact our engineering team to discuss your application.
