Crane Selection for Packaging Materials: Cardboard, Film & Foam
Cranes for the packaging materials industry (paperboard, film, foam, bubble wrap) are configured along four dedicated production lines. The paperboard line uses an LD Type 5-10t crane with a C-Hook for raw paper rolls; the film line uses an LH Type 5-10t crane with a roll handler for unwinding/rewinding; the foam line uses an LD Type 3-5t anti-static crane; and the bubble wrap line uses an LH Type 5-10t crane for roll handling. Investment ranges from $15,000–$52,000 per line, or $30,000–$119,000 for a complete plant.
Paperboard Lines: C-Hook Handling for 5–15t Paper Rolls
At the heart of a corrugated paperboard line is the replacement of raw paper rolls. These rolls measure 1–1.5 m in diameter, 1.6–2.8 m in width, and weigh 5–15 t each. A single line changes 8–15 rolls per day, placing extreme demands on crane duty cycles. We recommend an LD Type 5–10t overhead crane with a span of 22–31.5 m to cover both the roll storage area and the production line. For handling the rolls themselves, a C-Hook is the ideal lifting spreader—it slides horizontally into the roll core and lifts vertically, offering simple, high-efficiency operation. Kelude's C-Hooks for paper rolls have a lifting capacity of 5–10t with adjustable arm lengths from 1–1.8 m to accommodate varying roll widths. The dry end of the line (slitter-scorer, cutoff, stacker) contains equipment weighing 3–8 t that requires crane coverage for maintenance.
The wet end (single facer, double facer, drying section) operates at high temperatures—steam heating reaches 180°C—so crane electrical components must be designed for heat dissipation. Kelude's cranes for paperboard lines come standard with IP54 electrical cabinets and heat-resistant cables. Given the large footprint of the roll storage area (holding 50–200 rolls) and the long-travel distances involved, we recommend variable-frequency drive (VFD) control on the crane bridge for smooth acceleration and deceleration, preventing roll sway. Investment in a paperboard line crane typically ranges from $22,000–$52,000. For wide-web (2.5 m and above) high-speed lines, a 10–15t crane is recommended.
Film Production Lines: Roll Handling for Unwind and Rewind
Blown film and cast film lines consist of: extruder, die head, cooling, sizing, and winding. Film rolls range from 0.6–1.5 m in diameter, 1–3 m in width, and weigh 500–2,000 kg. We recommend an LH Type 5–10t crane. The most frequent lifting task in film production is changing rolls at the winder station—this happens 1–2 times per hour, requiring the full roll to be lifted off the winding shaft and an empty core to be mounted. Kelude recommends a C-Hook combined with a pneumatic shaft coupling spreader for film area cranes, cutting roll change time from 5 minutes down to 2. Cleanliness is critical in film plants (film surfaces must be free of gels and contaminants), so crane rail lubrication must use food-grade grease.
The extruder and die head are the core of the film line, with die heads measuring 1–3 m in width and weighing 200–1,000 kg. Die head maintenance and cleaning (performed monthly) requires crane assistance. For Kelude's LH Type cranes in film areas, we recommend a two-speed hoisting configuration of 8/2 m/min. Ambient temperatures around the blown film die head can reach 200°C, so remote control operation is advised for crane movements in this zone. Investment in a film line crane typically ranges from $22,000–$45,000.
Foam Molding Lines: Anti-Static Hoisting for EPS/EPP Materials
The molding process for foam packaging (EPS and EPP) involves: pre-expansion, aging, mold pressing, and drying. Individual EPS parts are lightweight (10–100 g), but the molds themselves weigh 200–2,000 kg. We recommend an LD Type 3–5t crane. Static electricity buildup is a serious concern in EPS production—friction from foam materials generates static charges, so crane grounding must be reliable (grounding resistance ≤4 Ω). Kelude's cranes for foam areas come standard with anti-static grounding systems and conductive hoisting ropes. The crane handles the replacement of upper platens and lower molds on foam molding machines (pre-press and molding presses).
EPS raw material (expandable polystyrene beads) uses pentane as a blowing agent—pentane is flammable and explosive (flash point −49°C), so the pre-expansion area requires explosion-proof protection rated Ex d IIB T4. Kelude's explosion-proof cranes for foam applications feature a fully explosion-proof electrical system. The crane must also provide coverage for maintenance of the temperature control system (steam heating at 120°C) and the cooling water circulation system in the molding area. Investment in a foam area crane typically ranges from $15,000–$30,000. For EPP foam (expanded polypropylene), which uses physical blowing agents (no flammable chemicals), the workshop does not require explosion-proof protection.
Bubble Wrap Lines: Light-Load, High-Efficiency Roll Handling
Bubble wrap (bubble film/cushion packaging) production lines consist of: extrusion, bubble forming, cooling, and winding. Bubble film rolls measure 0.8–1.2 m in diameter and weigh 300–800 kg. We recommend an LH Type 5–10t crane. While the rolls are smaller in diameter, line speeds are high (up to 30–60 m/min), resulting in frequent winding changes. Kelude's cranes for bubble wrap areas come standard with a quick-change C-Hook and winding shaft coupling device. Raw materials (LDPE/LLDPE resin) are fed in bulk bags—we recommend a 0.5–1t KBK workstation crane above the extruder for bulk bag loading. Investment in a bubble wrap line crane typically ranges from $22,000–$37,000.
Cardboard Line LD Type5-10t Base Paper5-15t | Film Line LH Type5-10t Coil Material Lifting spreader | Foam Molding LD Type3-5t anti-static+Explosion-proof |
Bubble Film LH Type5-10t Quick Roll Change | C-Hook Base Paper/Film5-15tGeneral Purpose | total plant investment 20-80Multi-Type Line |
Crane Configuration Comparison for Four Packaging Material Product Lines
| product line | Machine Model | tonnage | Lifting spreader | special requirements | investment |
|---|---|---|---|---|---|
| Cardboard | LD Type | 5-10t | C-Hook | Base Paper Roll5-15t | 15-35Universal |
| Film | LH Type | 5-10t | C-Hook+pneumatic shaft | Film Roll500-2000kg | 15-30Universal |
| Foam | LD Type | 3-5t | specialized spreader | anti-static+Explosion-proof | 10-20Universal |
| Bubble Film | LH Type | 5-10t | C-Hook | Quick Roll Change300-800kg | 15-25Universal |
| complete plant | Combination | 3-10t | Multi-Spec | Fullcoverage | 20-80Universal |
Kelude Heavy Industry's crane solutions for the packaging materials sector cover large-tonnage paper roll hoisting on corrugated board lines, precision film roll handling on film production lines, anti-static and explosion-proof designs for foam lines, and high-efficiency roll change systems for bubble film lines. The C-Hook lifting spreaders for paper and film rolls on corrugated board and film lines are Kelude's flagship products—proven across dozens of packaging manufacturers.
Base Paper Roll Hoisting Specialty C-Hook5-15tAdjustable Hook Arm+Remote control operation, Industry-Leading Base Paper Change Efficiency on Cardboard Lines | Film Roll Replacement Solution C-Hook+pneumatic shaft Butt Splicing+variable frequency micro-speed, Film Roll Change from5Minutes Reduced to2Minutes | Foam Explosion-proof Film Roll Replacement Solution Ex d IIB T4Explosion-proof+Conductive Grounding+anti-static System, EPSPre-Expansion Zone Safety Assurance |
FAQ: C-Hook, Lifting Spreader & Crane Configurations
Q: What is the load capacity range for C-Hooks used with paper roll lifts?
A: Kelude Heavy Industry offers standard C-Hooks for paper rolls in 5t, 8t, 10t, and 15t capacities, with hook arm lengths adjustable from 1 to 1.8 m. The C-Hook opening width must exceed the paper roll width. We recommend equipping each crane with 2–3 C-Hooks of different specifications to accommodate various roll sizes.
Q: Which lifting spreader is best for high-frequency film roll changes?
A: For film lines with a roll change frequency of ≥2 times per hour, we recommend a C-Hook paired with a pneumatic shaft docking solution. During a roll change, the C-Hook horizontally inserts into the film roll core, and the pneumatic shaft automatically docks with the winding shaft—no manual lifting required. Kelude's pneumatic shaft docking system handles torques from 500 to 2000 N·m.
Q: Does an EPS foam workshop require explosion-proof equipment?
A: EPS pre-expansion workshops using pentane as a blowing agent must use explosion-proof equipment rated Ex d IIB T4. However, EPS molding workshops (which use steam heating and have no pentane exposure) do not require explosion-proof ratings. EPP workshops (physical foaming with CO₂) also do not need explosion-proof equipment. Kelude Heavy Industry assesses the explosion-proof requirements based on your specific foaming process.
Q: How should a complete plant crane solution be implemented step by step?
A: We recommend a phased approach: ① First, install cranes in the main corrugated board and film production workshops to keep operations running; ② Next, add equipment for the foam and bubble film lines to synchronize new product lines; ③ Finally, install cranes in the warehouse and loading areas to improve logistics efficiency. Kelude Heavy Industry provides a phased implementation plan with a detailed budget breakdown.
