Vacuum Lifting Solution for Manual Box Handling
Customer Requirement
A customer within the drinks industry approached Packline seeking an ergonomic lifting solution to improve the handling of boxed mini kegs and tubs. The products were packaged in cardboard boxes secured with plastic tape and arrived on an unpowered conveyor belt before being manually palletised by operators.
The customer was looking to reduce the physical strain associated with repetitive lifting while maintaining operator control throughout the palletising process.
Application Details
The boxes varied in weight from 5kg to 30kg and were available in three different lengths:
Although the box length varied, the height and width remained consistent across all product types.
The existing process required operators to manually lift boxes from the conveyor and stack them onto pallets, creating potential risks associated with repetitive lifting, fatigue, and workplace injuries.
The Challenge
The customer required a lifting aid capable of:
Packline’s Solution
Packline recommended the Vac-line Vacuum Lifter fitted with a specialised box lifting head.
The Vac-line system is specifically designed for lifting cardboard boxes and cartons quickly, safely, and with minimal operator effort. Using vacuum technology, the system enables a single operator to lift and manoeuvre loads effortlessly while maintaining precise control.
Following an assessment of the application, Packline proposed:
Custom Box Lifting Head
A vacuum box lifting head designed to securely grip the taped cardboard boxes.
Initial evaluations indicated that a single pad design may be suitable for all three box lengths. However, Packline recommended testing sample boxes during the design phase to ensure optimum vacuum pad configuration and maximum lifting reliability.
Where required, an adjustable four-pad box lifting head could also be supplied to accommodate the different box lengths.
Large Working Area
The Vac-line vacuum lifter incorporates a standard 3-metre articulated arm reach.
The two-joint arm design provides full 360-degree rotation, creating an effective working area of up to 6 metres, allowing operators to move products freely between the conveyor and pallet locations.
Portable Configuration
Packline was able to offer an optional counterbalanced base plate.
This eliminates the need for permanent floor fixings and provides a portable vacuum lifting solution that can be repositioned easily as production layouts evolve.
Extended Lifting Range
The vacuum lifter provides a standard lifting range from approximately:
This makes the system ideal for palletising applications where products must be stacked at varying heights throughout the pallet build.
Benefits Delivered
By implementing the Vac-line Vacuum Lifter, the customer gained:
Why Choose Vac-line Vacuum Lifters?
Packline’s Vac-line range of vacuum lifting equipment is designed to improve safety, productivity, and efficiency across manufacturing, food and beverage, logistics, and warehouse environments.
Whether handling cartons, boxes, sacks, tubs, drums, or containers, Packline can provide bespoke vacuum lifting solutions tailored to individual operational requirements.
Looking for a Vacuum Lifter for Boxes?
If your business requires a safe and efficient solution for lifting boxes from conveyors, palletising products, or reducing manual handling risks, contact Packline today to discuss your application.
Our engineers can design a bespoke vacuum lifting system to suit your products, workspace, and operational requirements.
