In the complex world of manufacturing, roll material handling is a crucial yet often overlooked segment. Traditional methods—reliant on manual labor or semi-automated equipment—present persistent challenges related to labor costs, efficiency, and safety.

Key Challenges of Traditional Roll Handling:

• High Labor Costs: Manual handling requires a large workforce. Even with semi-automated tools, the complexity of operational steps continues to drive up labor expenses.
• Low Efficiency: Manual loading and material positioning are time-consuming and unsuitable for high-capacity production lines.
• Safety Risks: Manually handling heavy rolls poses significant accident risks. Narrow pathways and frequent human-machine interaction further compromise safety.

Partnering with a Global Consumer Goods Leader

Lead Intelligent Equipment’s logistics subsidiary, Lead Logistics, has partnered with a major consumer goods conglomerate to develop intelligent handling solutions tailored for water-soluble PVA film rolls. Leveraging its deep technical expertise and extensive experience in the new energy sector, Lead Logistics re-engineered existing systems and developed adaptive technologies, delivering a fully automated roll loading and unloading solution that addresses long-standing industry challenges.

The solution features end-to-end automation across key processes such as auto-feeding, intelligent gripping, and automatic waste recovery. Even under extremely constrained space conditions—with less than 20 cm of clearance above the equipment—Lead Logistics overcame technical limitations to achieve 24/7 unmanned operation and reduced labor requirements by over 50%.

• Cantilever AGV

Lead Logistics’ cantilever-style AGV features a unique telescopic fork design that enables side-access pickup of roll materials, making it ideal for handling and transferring rolls in confined spaces. Its advanced tilt-measurement and dynamic compensation system ensures stable and efficient transport of loads weighing up to 1 ton.

An omnidirectional chassis with 360° obstacle avoidance and multi-sensor SLAM navigation enables precise and efficient docking. Available in single- or dual-arm configurations to support versatile loading and unloading operations.

• Double-Fork Roll Handling AGV

Equipped with a multi-axis dual-fork lifting system, an omnidirectional chassis, 360° obstacle avoidance, and SLAM navigation, this AGV enables high-precision docking and transport of heavy rolls weighing up to 3 tons, and can easily handle long roll shafts over 1 meter in width.

Under dual-station mode, transport takt time is improved by 40%, while independent lift systems boost docking efficiency by 35%. The machine excels in roll and core handling for processes such as unpacking and coating.

Together, these AGVs help enterprises significantly enhance roll transport efficiency, reduce labor dependence, and support 24/7 continuous operation in complex production environments—providing strong support for the intelligent upgrade of roll logistics.

Expanding Across Sectors

Beyond consumer goods and new energy, intelligent roll handling is reshaping material flow across multiple sectors:

• New Energy: Copper/Aluminum Foil & Electrode Rolls

In lithium-ion battery manufacturing, AGVs support logistics throughout multiple stages—from raw material storage and intelligent unpacking, to electrode roll warehousing, cell assembly transport, and logistics for formation and aging processes.

For operations such as material retrieval in unpacking rooms, unwinding/rewinding during coating and calendering, slitting, and electrode stacking, double-fork roll transfer AGVs handle both loaded rolls and empty cores. In notching and stacking stations, cantilever AGVs enable flexible, high-load operations with precision and efficiency.

• Automotive & General Manufacturing: Steel & Rubber Rolls

With strong load-bearing capacity, double-fork AGVs enable fast and efficient handling of heavy rolls, significantly improving material flow and optimizing production processes for heavy equipment manufacturers. Cantilever AGVs ensure precise docking between warehouses and production lines, making material delivery more efficient.

• Materials: Rubber & Plastic Rolls

Cantilever AGVs’ side-access loading enables fast material transfer within workshops, ensuring uninterrupted production.

• Textiles: Cotton & Synthetic Fabrics

Cantilever AGVs automate fabric roll transport between storage and production, including precise pickup and delivery at dyeing stations.

• Food Processing: Film & Paper Packaging Rolls

These AGVs operate in compliance with strict hygiene standards, enabling raw material transport, production line feeding, and packaging logistics in clean environments. They reduce manual contact, minimize the risk of cross-contamination, and help ensure food safety.

With a presence in over 18 countries, Lead Logistics drives smart, flexible manufacturing worldwide. From consultation and custom design to full-system retrofitting, it delivers end-to-end intelligent logistics solutions across industries such as new energy, automotive, chemicals, consumer goods, and food processing—powering the next generation of modern factory ecosystems.