Efficient handling of large paper cores is critical in high-volume converting and finishing environments. To address this challenge, Plymouth Industries engineered a Core Rack with Strap Unloader System designed to improve safety, consistency, and throughput for a major paper and packaging manufacturer.
This integrated material handling solution combines heavy-duty core storage racks, strap-assisted unloading, and a powered conveyor system to streamline how paper cores are staged, unloaded, and transferred downstream, reducing manual handling and process bottlenecks.
Engineered for Demanding Paper & Packaging Environments
Paper mills and converting facilities require rugged equipment that can withstand repetitive loads and continuous operation. The custom core rack system was designed around these realities, using carbon-steel construction and production-ready finishes to ensure long-term durability in an industrial setting.
Each rack securely stores multiple large-diameter paper cores while remaining stackable when full or empty, maximizing floor space utilization. Integrated strap reliefs allow controlled unloading without shifting or core damage.
Strap Unloader System for Controlled Core Release
At the heart of the system is a strap unloader that allows operators to release and meter paper cores in a predictable, controlled manner. This design minimizes the risk of sudden roll movement while supporting consistent downstream flow.
Key functional elements include:
- Strap-based unloading to reduce manual intervention
- Adjustable metering gate for precise core release
- Fully assembled and tested mechanical and electrical components
- Push-button/manual operation for straightforward use
The unloader integrates seamlessly with the core racks, ensuring alignment and smooth transitions during unloading cycles.
Integrated Conveyor System for Process Flow
To complete the solution, the system incorporates zoned CDLR conveyors that transport loaded racks and released cores efficiently through the unloading area. Center guides ensure accurate rack positioning at the unloader, while guarded sections support safe operation in active production zones.
The conveying layout was engineered to match the customer’s workflow, helping maintain consistent material flow without slowing upstream or downstream operations.
Benefits of a Custom Core Handling System
This Core Rack with Strap Unloader System delivers measurable advantages for paper and packaging manufacturers, including:
- Improved operator safety during core unloading
- Reduced labor and manual handling
- Consistent, repeatable unloading cycles
- Better space utilization with stackable racks
- Equipment tailored to exact core sizes and production demands
Every component, from the racks to the unloader frame and conveyors, was designed as a unified system rather than off-the-shelf equipment adapted after the fact.
Built to Fit Your Operation
No two paper operations handle cores the same way. That’s why Plymouth Industries designs custom core racks, strap unloaders, and conveyor systems to fit specific production layouts, core dimensions, and throughput requirements. The result is equipment that integrates cleanly into existing processes while supporting future growth.
Ready to Improve Core Handling Efficiency?
If your facility is looking to enhance safety, reduce handling time, and improve workflow around paper cores, a custom-engineered solution may be the right fit. Contact Plymouth Industries today to discuss a Core Rack with Strap Unloader System designed specifically for your operation.
