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FullSharp · since 1991

FullSharp installed an overhead 5T rail rated at 200 kg with its own air balancer and a roll clamp tool for material rolls of several tens of kilograms. The balancer keeps the roll floating at any height, so one operator pushes it to the exact spot without scuffing edges or bumping nearby machines.

Material rolls weighing tens of kilograms are hard to position accurately even with two people carrying them. Doing it by hand all shift tires the shoulders, scuffs the roll edges and risks hitting nearby machines.

FullSharp installed a 5T rail rated at 200 kg overhead, with a trolley running along the work area. An air balancer paired with a roll clamp tool keeps the load suspended, so the operator only needs a light push to bring the roll to the right spot.

5T 200kg Rail with Air Balancer and Roll Clamp Tool

5T rail rated at 200 kg overhead, with air balancer and roll clamp tool installed at the production area.

Equipment Installed

  • 5T rail rated at 200 kg: overhead steel rail hung with threaded rods and hanger brackets, trolley runs smoothly, one person pushes to move the load.
  • FullSharp air balancer: pneumatic balancing keeps the roll steady at any height, the operator's hand only guides direction.
  • Roll clamp tool: jaws wrap around the roll body, gripping firmly with air pressure without denting the edges.
  • Air supply and control valve unit: filters and regulates pressure before the balancer, with a shut-off valve for maintenance.

Key Specifications

  • Load capacity200 kg
  • Rail system5T rail
  • Balancing deviceFullSharp air balancer
  • ToolRoll clamp

Benefits for the Plant

One-person operation

The load stays balanced so two people are no longer needed to carry it, easing shoulder and back strain during the shift.

Rolls stay undamaged

Jaws grip the roll body precisely, limiting dents and scuffing on the outer layer during handling.

Uses overhead space

The rail runs high up, keeping the floor clear so aisles and machines below stay unobstructed.

Actual Installation Photos

5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 1 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 2 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 3 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 4 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 5 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 6 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 7 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 8 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 9 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 10 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 11 5T 200kg Rail with Air Balancer and Roll Clamp Tool - photo 12

Click a photo to enlarge. Album of 12 photos taken on site.

Suitable Applications

  • Printing, film laminating and flexible packaging shops loading rolls onto machines
  • Textile and nonwoven plants moving rolls between process stages
  • Roll material stores picking stock from shelving levels
  • Labeling and slitting lines with continuous roll changes

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Frequently asked questions

How does an air balancer help place a roll accurately?

It keeps the roll steady at any height, so the operator's hand only guides direction. That makes it easier to line up a roll than with two people carrying it.

Will a roll clamp dent the roll edges?

The jaws wrap around the roll body and grip with air pressure without denting the edges. FullSharp sizes the clamp to the real roll diameter.

What supports the air balancer?

An overhead steel rail rated at 200 kg, hung with threaded rods and hanger brackets. An air supply unit filters and regulates pressure, with a shut-off valve for maintenance.

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Installation Consultation for Your Plant

FullSharp visits the plant to measure ceiling height, check the supporting structure and test-weigh an actual roll to size the rail load. We then lay out the rail route along the machine aisle and select the clamp tool size based on roll diameter and width. Send us your roll dimensions and floor plan, and our engineers will draft an installation plan.

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