World of Vacuum Technology
Press Release
February 2014
Vacuum Tube Lifter from Schmalz Optimizes Raw Material Handling in Paper
Factory
Forklifts drive tons of pallets with heavy sacks into the halls of the Koehler Kehl GmbH
paper factory in Kehl, Germany. The raw material must be commissioned and then
transported to the paper machines. Previously, this work was done manually, placing the
employees under great physical strain. Now, an innovation from J. Schmalz GmbH
provides assistance: The vacuum tube lifter JumboFlex 50 ensures faster materials
handling while taking the burden off the employees.
The history of the Koehler paper factory goes back to the early 19th century in the town of Oberkirch, which
was then located in the German state of Baden. With his purchase of a paper mill, Otto Koehler laid the
foundation for what is now a worldwide corporation. Today, the August Koehler SE paper factory produces
many different types of paper and is the global market leader in thermal paper, which is processed further to
make cash register rolls or self-adhesive labels. Koehler is the number-one producer of non-carbon paper in
Europe. The group generates an annual turnover of 725 million euros and sells over 500,000 metric tons of
paper each year. This makes Koehler one of the few independent German companies in the paper industry.
Over 1,700 employees produce the paper using state-of-the-art production systems.
In Koehler Kehl GmbH’s branch in Kehl, thermal paper, non-carbon paper and decor paper are produced
using high-performance machines. Its customers include print shops, treatment and painting companies,
wholesalers and major furniture and kitchen manufacturers. Dying the paper – for example for decorations –
requires special pigments based on iron oxide. This raw material is delivered by the ton in heavy sacks and
must be quickly commissioned and then transported to the machines. Previously, the material was
recommissioned and palletized by hand, often placing considerable strain on the employees. Afterwards, the
sacks were driven to the production area and then unloaded by hand. Since 2005, Koehler has been using a
vacuum tube lifter JumboSprint 45 from Schmalz at its Kehl location to make handling the sacks much faster,
and to protect its employees’ health.
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However, a major expansion of production and the increasing number of types of paper pushed the model to
the limits of its capacity. The result was that Koehler employees had to start working by hand again to handle
the extra work. An internal analysis showed that it was not worthwhile to have an automated system in this
production area. So the paper experts started looking for a suitable handling solution to take the strain off the
employees in the long term. Concrete inquiries were made to two companies, one of which was J. Schmalz
GmbH, whose tube lifters had already impressed Koehler in practical applications. Only the vacuum
specialists were able to offer a solution that would work reliably and safely, even under difficult conditions.
After all, the devices at Koehler work in environments with high dust levels and considerable contamination.
Not long after, system consultants from J. Schmalz GmbH were on site to perform lifting tests with sample
sacks. For Koehler, the cooperation ran smoothly and the results of the testing under real-life conditions
were impressive. In late 2011, another vacuum tube lifter of type JumboFlex 35 was installed in the existing
crane system and used successfully.
Around the same time, Schmalz was considering expanding the JumboFlex series for higher loads, and the
idea for the JumboFlex 50 with one-handed operation and a load capacity of 50 kilograms was born. While
developing the new lifting device, Schmalz contacted Koehler Kehl GmbH. The vacuum specialist was sure
that the paper experts were the ideal candidate to test the innovation in extensive field tests in a difficult
environment. In March 2013, Koehler received the first prototype for use in everyday production. The two
companies cooperated very closely during this time. Results from the field tests were even incorporated into
the product design. For example, the feel of the operator handle was improved based on practical
experience. A few months later, Schmalz installed a product that was already ready for mass production and
met all the employees’ requirements.
The JumboFlex 50 handles small to medium-sized loads very quickly and ergonomically. The easy-to-grip
operator handle can be operated intuitively with one hand. Depending on the employee’s preference, it can
be operated with one or two fingers on the right or left hand. The different suction pads can be replaced
quickly for a wide variety of applications. The round suction pad with a special skirt to seal the workpieces is
ideal for powerful, safe handling of sacks. The lifting speed can be precisely regulated depending on the
practical requirement and the amount of work. The JumboFlex 50’s optimized ergonomics allow the
employees to work with a back-friendly posture. This keeps the handling speed at a consistently high level
and reduces absences due to health problems.
Now Koehler Kehl GmbH doesn’t want to do without this innovation from Schmalz. The goal of the
responsible parties was to handle the considerable expansions in production and the increasing variety of
products. The JumboFlex 50 allowed them to meet this goal. “Our experiences with the vacuum tube lifter
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have been very good across the board,” says factory manager Manfred Bähr, who is responsible for reliably
supplying raw materials to paper machine 6 in the Kehl factory. He adds that using the JumboFlex 50 has
dramatically boosted productivity and taken the burden off of employees. “Our employees can handle the
increased amount of work in less time.” Even more important: According to Manfred Bähr, work is now easier
because of the improved ergonomics that take the strain off the employees’ backs and joints. “Without the
JumboFlex 50, we couldn’t have achieved this high output level.” He also says that they have achieved a
high safety standard despite the very fast handling processes. Schmalz treated the company as an equal
partner from planning to implementation. “All in all, we were very satisfied with the cooperation,” Bähr says.
He adds that his company is also interested in getting involved in additional development projects with
Schmalz.
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Images
Image 1:
The vacuum tube lifter JumboFlex 50 from Schmalz
improves handling of heavy sacks at the Koehler Kehl
GmbH paper factory – even in difficult conditions with high
levels of dust.
Image 2:
Ergonomics and functionality make the JumboFlex 50 an
effective handling solution. The tube lifter can be operated
intuitively with just one hand.
Image 3:
The round suction pad with skirt has a secure grip on the
sacks of goods.
Images: J. Schmalz GmbH
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World of Vacuum Technology
The Company
Schmalz is the worldwide leading provider of automation, handling and clamping systems, providing
customers in numerous industries with innovative, efficient solutions based on vacuum technology.
Schmalz products are used in a wide variety of production processes – for example, as grippers on robot
arms in the production of car bodies, in CNC machining centers as clamping solutions for furniture pieces,
or used by an operator to lift items ranging from boxes to solar modules. Schmalz customers can either
choose from a diverse line of components or they can benefit from a complete solution that is customtailored to their requirements. Schmalz is dedicated to its customers, providing groundbreaking
innovation, exceptional quality and comprehensive consultancy. The company is headquartered in
Glatten (Black Forest region of Germany) and is active in 15 additional countries with their own
subsidiaries. Schmalz employs a total of around 800 persons worldwide.
30 Years of Vacuum Technology
Schmalz has been working in the field of vacuum technology for three decades now. 1984 marked the
company’s entry into this sector with the development of a vacuum table. As pioneers in vacuum
technology, Schmalz employees still strive to look to the future and offer innovative solutions customers
will love. Their focus is on being as close to customers as possible. The company achieves this with its
own international subsidiaries in all the world’s key markets, as well as sales partners in over 40 other
countries. This enables Schmalz to offer personal, on-site consultations and excellent service. In the past
30 years, Schmalz has become a leader on the worldwide vacuum technology market – and plans to
continue writing this success story in the future.
Contact for questions
J. Schmalz GmbH
Marketing Communications
Aacher Strasse 29, 72293 Glatten, Germany
Phone
+49 (0)7443 2403-367
Fax
+49 (0)7443 2403-9367
presse@schmalz.de
www.schmalz.com
Further press releases are available on our website
http://www.schmalz.com/aktuelles/presse/
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