In corrugated board plants, roll handling is one of the most delicate and risk-sensitive activities within the production process. The high loads involved, the limited space often available around unwind roll stands, and the need to ensure production continuity require solutions capable of moving rolls in a controlled and safe manner.
For many years, this operation was carried out using forklifts or, in the worst cases, through manual handling. Both approaches present well-known drawbacks: on one hand, the maneuvering difficulties and risks associated with operating heavy vehicles close to the machine; on the other, the exposure of operators to physical strain and potentially dangerous situations.
It is therefore no surprise that roll pushers have become increasingly common in corrugated plants. However, the evolution of production processes and the growing focus on safety have created new requirements. Today, it is no longer enough to simply move a roll; it must be moved while ensuring maximum control, reliability, and operator protection.
These requirements led to the development of ReDrive, the battery powered roll pusher designed by Re S.p.A. to simplify roll handling operations and reduce the risks associated with moving loads weighing several tons.
The project started from an analysis of the main limitations found in existing market solutions. One of the most common issues concerns battery autonomy. For this reason, ReDrive is equipped with a 48 V plug-and-play lithium battery designed to provide up to approximately 15 consecutive shifts of operation. Battery life is further extended by an automatic standby function that reduces power consumption whenever the unit is not in use.
Special attention was also given to maneuverability. Roll handling areas often feature uneven floors, reel stand rails, and limited operating space. ReDrive’s compact design and XL rear wheels ensure smooth and controlled movement even under these conditions, improving positioning accuracy and ease of operation.
Another key aspect is motion control. The electronic control system developed by Re automatically adjusts the torque according to roll weight and operator-selected speed. This allows for progressive and consistent thrust while maintaining full control of the movement, even during the most critical handling phases.
Safety was at the core of the project from the very beginning. During lifting operations, when the roll is not yet fully resting on the ground or support surface, ReDrive maintains its position for a few seconds without rolling backward, preventing unwanted movements that could compromise load stability and operator safety.
Available in several configurations, with pushing forces up to 20 tons and lifting capacities up to 5 tons, ReDrive can be adapted to the different requirements of corrugated plants, from corrugators to internal logistics areas.
In the corrugated industry, safety is no longer just a regulatory requirement; it has become a shared value embraced by companies, production managers, and operators alike. More and more plants continuously monitor and display the number of days without accidents, turning safety into a measurable and tangible objective.
In this context, reducing or eliminating manual roll handling operations means addressing one of the highest-risk activities around the corrugator. ReDrive was developed with exactly this goal in mind: providing operators with a device that allows heavy rolls to be moved in a controlled, safe, and effortless way.
Because when dealing with rolls weighing several tons, technology is not only about moving a load. Above all, it is about protecting the people who work alongside it every day.
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