Safe, Hygienic and Efficient Reel Handling Solutions for Modern Food Manufacturing
In the food and drinks industry, operational efficiency, product quality, and workplace safety are critical to maintaining competitiveness. Yet one area that is often overlooked is the handling of reels and rolls used throughout production and packaging processes.
From flexible packaging films and labels to foil, paper, laminates and shrink-wrap materials, reels are a fundamental component of food and beverage manufacturing. However, their size, weight and awkward shape can create significant manual handling challenges.
This guide explores everything food and drink manufacturers need to know about reel or roll handling, including common challenges, health and safety considerations, equipment options, and how modern reel lifting solutions can improve productivity while reducing risk.
What Are Reels or Rolls Used for in Food Manufacturing?
Reels or rolls are used extensively throughout food and beverage production environments, particularly within packaging operations.
Common examples include:
Many food packaging systems operate using continuous reels of material that are unwound, processed, filled, sealed and rewound during production. Packaging machines such as vertical form-fill-seal (VFFS) systems rely on a constant supply of packaging film delivered from reels.
As production volumes increase, so too do the size and weight of the reels being handled.
Why Reel Handling Presents Challenges
While reels may appear straightforward to move, they present several unique handling difficulties.
Heavy Loads
Packaging reels can weigh anywhere from a few kilograms to several hundred kilograms depending on the material and application. Larger industrial reels can become extremely difficult to manoeuvre safely without assistance.
Awkward Shape
Unlike boxes or containers, reels are cylindrical and can easily roll, making them inherently unstable during transportation and positioning.
Precision Positioning Requirements
Reels often need to be aligned accurately with machine spindles, mandrels or unwind stations. Even minor positioning errors can cause production delays or material damage.
Product Damage Risks
Packaging materials such as film, foil and labels are often delicate. Incorrect lifting methods can damage reel edges, deform cores, or compromise material quality.
Hygiene Requirements
Food manufacturing environments require equipment that supports strict hygiene standards. Handling equipment must often be constructed from stainless steel and designed for easy cleaning.
Health and Safety Considerations
Manual handling remains one of the leading causes of workplace injuries across manufacturing industries.
When employees attempt to lift, rotate or position heavy reels manually, common risks include:
The UK’s Manual Handling Operations Regulations (MHOR) place a duty on employers to reduce manual handling risks wherever reasonably practicable.
For food manufacturers, investing in purpose-built reel handling equipment not only protects employees but also helps ensure compliance with workplace health and safety requirements.
Types of Reel and Roll Handling Equipment
Different production environments require different handling solutions. Selecting the right equipment depends on reel weight, dimensions, material type and production workflow.
Reel Lifting Trolleys
Reel lifting trolleys are among the most versatile solutions available.
They enable operators to:
Modern electric lifting trolleys can significantly reduce operator effort while improving changeover speeds.
Mandrel Reel Lifters
Mandrel lifters use a spindle or shaft inserted through the reel core.
Benefits include:
Mandrel systems are particularly effective when loading reels directly onto packaging machinery.
Core Grippers
Core grippers securely grip the inside diameter of a reel core.
These attachments are ideal for:
They provide excellent control while minimising contact with the outer material surface.
Stainless Steel Reel Handling Equipment
Food production environments often require stainless steel equipment due to hygiene and washdown requirements.
Stainless steel reel handlers provide:
Packline’s stainless steel reel handling solutions are specifically designed for food and pharmaceutical environments.
Bespoke Reel Handling Systems
Many food manufacturers operate unique production lines with specific space constraints, reel dimensions or loading requirements.
Custom-designed handling systems can incorporate:
Bespoke solutions ensure maximum efficiency while supporting operator safety.
Key Benefits of Modern Reel Handling Equipment
Improved Operator Safety
The primary benefit is the reduction of manual lifting and associated injury risks.
Purpose-designed lifting systems eliminate many of the hazards associated with handling heavy reels manually.
Increased Productivity
Faster reel changes mean less machine downtime and higher production output.
Operators can move, lift and position reels quickly and accurately without requiring multiple personnel.
Reduced Product Damage
Controlled lifting and positioning help prevent:
Enhanced Ergonomics
Ergonomic reel handlers reduce physical strain, improving operator comfort and reducing fatigue throughout the working day.
Greater Process Consistency
Precise reel positioning ensures smoother machine operation and more reliable packaging performance.
Choosing the Right Reel Handling Solution
When selecting a reel handling system, food manufacturers should consider:
Reel Weight
Determine the maximum reel weight that will need to be lifted.
Reel Dimensions
Consider:
Handling Frequency
High-volume operations may justify more advanced powered systems.
Production Environment
Food-grade environments often require stainless steel construction and hygienic design features.
Machine Integration
Consider how reels will be loaded onto existing production equipment and packaging lines.
Future Flexibility
Choose equipment capable of accommodating changing product formats and packaging requirements.
Why Food and Drink Manufacturers Choose Packline
For over 30 years, Packline has been designing and manufacturing specialist lifting and handling equipment for food, beverage, pharmaceutical and packaging industries.
Our reel and roll handling solutions are engineered to:
From compact reel lifting trolleys to fully customised handling systems, Packline provides tailored solutions that help manufacturers streamline operations while protecting both operators and products.
Conclusion
Reel or roll handling plays a vital role in food and beverage manufacturing. As production demands continue to increase, businesses must find safer and more efficient ways to manage packaging materials throughout the production process.
Investing in the right reel handling equipment can significantly reduce workplace injuries, improve productivity, minimise product damage and support compliance with health and safety regulations.
Whether you are handling packaging film, foil, labels or paper reels, modern lifting and handling solutions can transform your operation and create a safer, more productive workplace.
Speak to the Reel Handling Experts
Looking for a safer and more efficient way to handle reels and rolls in your food or drinks production facility?
Contact Packline today to discuss your application and discover a bespoke reel handling solution tailored to your operational requirements.
