Label Manufacturing Crane Configuration Guide
The label manufacturing crane system is configured around four process stages: silicone coating, printing, die cutting with waste removal, and slitting/rewinding. The coating area uses an LH-type 3–5t crane with a roll-handling spreader and solvent-resistant sealing; the printing area is served by a KBK 0.5–2t workstation crane; the die cutting area uses an LD-type 3–5t crane for mold changes; and the rewinding area is equipped with a KBK 0.5–1t crane for finished rolls. Total plant investment ranges from $15,000 to $52,000. Since the coating process uses solvents, the crane in that zone must be explosion-proof to Ex d IIB T3.
Silicone Coating Zone: Explosion-Proof Roll Handling
The face stock for pressure-sensitive labels (coated paper, thermal paper, PET, or BOPP) receives a silicone release coating and a pressure-sensitive adhesive layer. Coating machines range from 1.6 to 2.2 m in width, with unwind/rewind roll diameters of 1 to 1.5 m and roll weights between 500 and 2,000 kg. Because the coating process uses organic solvents (toluene, ethyl acetate) to formulate the silicone, the workshop must be explosion-proof. We recommend an LH-type 3–5t overhead crane rated Ex d IIB T3. Roll loading, unloading, and transport require a dedicated roll-handling spreader — a C-Hook or shaft-type lifting spreader is recommended. The crane also covers maintenance hoisting (200–800 kg) for the coating head and oven sections of the coating machine. Kelude's LH-type crane for the coating area comes standard with a roll C-Hook and an explosion-proof electrical system.
The solvent recovery system keeps solvent concentration within the safe range (LEL ≤ 25%), but since solvent vapors are denser than air (2–5 times heavier), they tend to accumulate near the floor in the event of a leak. The crane's electrical cabinet is mounted in the upper part of the workshop, where solvent vapor concentration is lower, allowing the explosion protection class to be reduced to Ex e (Increased Safety). Kelude assesses the required explosion protection class based on the specific ventilation conditions of each workshop. Oven sections of the coating machine operate at 80–150°C, and the area above the ovens runs hotter — the crane's temperature resistance must account for this. Crane investment for the coating zone is approximately $15,000 to $37,000.
Printing Zone: KBK Workstation Cranes for Climate-Controlled Shops
Label printing equipment includes rotary presses (letterpress, flexographic, and offset) with web widths typically ranging from 330 to 670 mm. A single printing press weighs 3–8t, and the printing shop must maintain constant temperature and humidity (23±2°C, 55±5% RH). We recommend a KBK 0.5–2t workstation crane system covering the press maintenance area. Printing rollers (plate cylinders and impression cylinders) weigh 50–200 kg and require frequent changes (1–3 times per day); a KBK workstation crane can quickly transfer plate cylinders to the washing station. Kelude's KBK rails in the printing area are made of stainless steel. Since the printing shop is enclosed with stable temperature and humidity, crane material selection and lubrication must ensure long-term stability under these constant conditions.
The UV curing units and corona treatment stations are the most frequently serviced components of a printing press. UV lamp replacement (monthly) requires extracting the entire lamp unit — weighing 30–80 kg — which a KBK workstation crane can assist with. Kelude's KBK system in the printing area comes standard with a manual trolley and electric hoist, arranged along the press line for full coverage. The printing shop maintains a dustproof rating of approximately Class 100,000 (ISO 8); the KBK system uses a sealed-gearbox electric hoist to prevent lubricating oil vapor from contaminating printed products. KBK investment for the printing zone is approximately $7,500 to $22,000.
Die Cutting & Waste Removal: Crane Setup for Mold Changes
Die cutting trims the printed web into individual label shapes and removes the waste matrix. Die cutting tools (rotary die cylinders or flatbed die plates) weigh 30–200 kg and require frequent changes (2–4 times per day). We recommend an LD-type 3–5t crane covering the die cutting area. Kelude's die cutting crane comes standard with a C-Hook and nylon slings for rapid die cylinder changes. The tension control system and waste removal unit of the die cutter weigh 200–500 kg and require crane assistance during maintenance.
Die cutting generates substantial waste — approximately 20–30% of raw material becomes scrap — and the automatic waste collection system requires regular cleaning and maintenance. Repairs to the waste strapping machine (motor and hydraulic power unit) also require crane support. Kelude uses an LD-type crane in the die cutting area to cover 2–4 die cutting machines. The crane's lifting speed is recommended as two-speed 6/1.5 m/min, with creep speed for precise positioning during die cylinder changes. Crane investment for the die cutting zone is approximately $15,000 to $30,000. For label plants with multiple die cutters, we recommend a long-span crane arranged along the machine line so a single crane can cover all die cutting machines.
Slitting & Rewinding Zone: KBK Handling for Finished Rolls
After die cutting, label rolls are slit and rewound to the customer's specified widths. Finished rolls weigh 5–30 kg each, with 100–500 rolls per batch. We recommend a KBK 0.5–1t manual trolley with electric hoist configuration. Bottom and top knife changes on the slitter (once per shift) involve components weighing 10–30 kg. Kelude's KBK rails in the slitting area cover both the slitter and the finished-goods staging area. Quality inspection of finished label rolls (appearance, dimensions, and color consistency) is performed at an inspection station, and the KBK crane assists in transferring rolls to the station. After inspection, rolls are labeled and boxed — each carton weighs 10–25 kg — and the KBK crane, in combination with a pneumatic balancer, handles carton palletizing.
Coating Explosion-proof LH Type3-5t Ex d IIB T3+Web C-Hook | Printing Station KBK 0.5-2t stainless steel rail+Constant Temperature | Die Cuttingdie LD Type3-5t Die Roll Change |
Slitting & Rewinding KBK 0.5-1t Finished Small Rolls | Web Lifting spreader C-Hook/Sleeve-Type 500-2000kg | total plant investment 10-35All-Inclusive Process |
Crane Configuration Comparison Table for Label Manufacturing
| All-Inclusive Process | Machine Model | tonnage | Environment | Specialconfiguration | investment |
|---|---|---|---|---|---|
| Coating | LH Type Explosion-proof | 3-5t | explosion-proof zone | Web C-Hook+Explosion-proof | 10-25Universal |
| Printing | KBK | 0.5-2t | Constant Temperature & Humidity | stainless steel rail+sealed hoist | 5-15Universal |
| Die Cutting | LD Type | 3-5t | Standard | nylon sling+C-Hook | 10-20Universal |
| Slitting | KBK | 0.5-1t | Standard | manual trolley+Pneumaticdynamic balancing | 3-10Universal |
| complete plant | Combination | 0.5-5t | Zone Control | Fullcoverage+Web | 10-35Universal |
Kelude Heavy Industry's crane solutions for the self-adhesive label industry cover the full process—from explosion-proof coating and KBK printing to die-cutting mold changes and slitting/rewinding. Each application addresses label-specific crane requirements: solvent explosion protection and web lifting spreaders in the coating line, temperature- and humidity-controlled cleanroom solutions in the printing workshop, and rapid mold-change hoisting for die-cutting presses.
Coating Explosion-proof With Web LH Type Explosion-proof Ex d IIB T3+C-Hook Web Lifting spreader, Coating Line Safety & Efficiency Enhancement | Printing Cleanroom Solution KBKStainless Steel Rail+sealed hoist+CTH Adaptation, Printing Workshop Consistent Quality | die Quick Changeover LD Type Two-Speed+remote control+C-Hook, Die Roll Changeover Time Reduced by50% |
FAQ: Explosion Protection, Lifting & Material Handling
Q: What explosion protection class is required for the adhesive coating area?
A: Coating processes using solvents (toluene/ethyl acetate/MEK) require explosion-proof equipment rated Ex d IIB T3. If only water-based pressure-sensitive adhesive (solvent-free) is used, the coating area may not require explosion-proof protection. Kelude evaluates the actual solvent types used during the solution design phase.
Q: Should printing roller changes use a KBK system or fixed lifting points?
A: A KBK system is recommended. Printing rollers weigh 50–200 kg, and a KBK rail allows the hoist to travel along the printing line to any press position. Fixed lifting points only cover a single machine. The flexibility of a KBK system makes it the better fit for multi-press printing workshops.
Q: What is the die change frequency and recommended crane configuration?
A: Die rolls are changed 2–4 times per day, with each die weighing 30–200 kg. An LD Type crane rated 3–5 t is recommended to cover all die cutting machines, serving 4–6 units simultaneously. Kelude suggests reserving a dedicated die storage rack in the die cutting area so the crane can directly access both the rack and the machines.
Q: How should finished small rolls be handled in the slitting and rewinding area?
A: Finished rolls weigh 5–30 kg each, with 100–500 rolls per batch. A KBK system with a manual trolley (500 kg capacity) is recommended, paired with pallet handling. Operators manually attach the rolls to the KBK hook and push them along the rail to the packaging area. This approach is roughly 3 times more efficient than manual handling.
