gama headquarters 355 lexington avenue, 15th...

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GAMA Headquarters355 Lexington Avenue, 15th FloorNew York, NY 10017USA

INTRODUCTION

The Global Acetate Manufacturer’s Association is pleased to provide information on the han-dling of Cellulose Acetate Filter Tow Bales. For more information on GAMA and its members please visit the GAMA website on: http://www.acetateweb.com/membership.htm.

This information is provided by the manufacturers of Cellulose Acetate Filter Tow and is based on the best practices for handling and storing of bales known to the industry.

Cellulose Acetate Filter Tow (in the following text “Acetate Tow”) is a crimped, continuous tow made from thousands of filament fibers. These fibers are manufactured from cellulose acetate polymer. Tow is sensitive and requires special handling techniques to ensure that it will process in an acceptable manner on filter rod manufacturing equipment.

Acetate Tow is carefully packed by the manufacturers in so called “bales” for transportation and storage. The bales require careful handling prior to processing, as the packaging cannot completely protect the tow from damage due to mechanical forces or deterioration caused by exposure to harsh environmental conditions.

The bales are heavy and safety precautions are also needed when moving and stacking them.

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CONTENTS

1. Packages of Acetate Tow Bales ...........................................4

2. Transportation .............................................................................5

3. Handling of Acetate Tow Bales..............................................6

4. Storage of Acetate Tow Bales ...............................................8

5. Opening of Acetate Tow Bales .............................................9

6. Handling of Packaging Materials ........................................ 11

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1. PACKAGES OF ACETATE TOW BALES

Acetate Tow Bales can typically weigh from 400 to 900 kg and are supplied in a variety of pack-aging types to protect the tow during transport and storage.

• Cardboard Packaging:

the traditional wrapping using cardboard with plastic straps or bands, for containing the internal forces.

• Reusable Packaging:

bales are wrapped in plastic fabrics fastened with hook and loop material. The reusable packaging is returned to the manufacturer to be used multiple times until it requires re-placement.

• Sealed Film Packaging:

bales are wrapped and sealed in plastic film that does not require strapping.

Bales having cardboard or reusable packaging also have an inner lining of plastic film to further protect the tow.

The packaging does not protect the acetate tow completely from exposure to harsh environ-mental conditions and certain precautions during transportation and storage should be ob-served. Some of these are described below and many are also printed on the packaging (see Fig. 2).

Fig. 2: Awareness pictograms for safe handling of Acetate Tow Bales:

This way up; Keep dry; fragile (in the meaning of sensitive, treat carefully); do not use hooks; do not use sharp objects; do not write directly on the packaging material (for Inner film; for Reusable and for Sealed Film packaging)

Further labels on the bales relate to product identification and logistics. Some manufacturers indicate the beginning of the tow band with a marker.

Cardboard Packaging Reusable Packaging Sealed Film Packaging

Fig.1: The different types of packaging

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2. TRANSPORTATION

Acetate Tow Bales may be shipped in a horizontal (on their side) or in a vertical (upright or “working”) position. The position chosen depends on the loading patterns and the stability of the bales in the truck or shipping container. Bales may be placed directly on the floor or elevat-ed on pallets or spacers. Additional strapping may be used to secure bales to pallets.

Fig.3: Spacers and Pallet

Acetate Tow Bales are typically stacked two high during transport, but may be shipped in a single layer if truck or container weights prohibit stacking. To prevent bales shifting during transport, the bales are arranged to stabilize the load in the truck or container.

• Caremustbetakenwhenloadingandunloadingthebalestopreventdamage.

• Topreventtearingofthepackaging,theplatformofthetrucksorthecontainersshouldbeclean and dry with no sharp edges.

Fig. 4: Loading of bales in containers and trucks

a) on spacers b) on pallets

d) on pallets in taut-liner truck (use of belts)c) on the floor

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3. HANDLING OF ACETATE TOW BALES

General Precautions and Requirements

Personal Safety:

• Duetotheheavyweight,careforpersonalsafetyisparamountwhenhandlingandmovingAcetate Tow Bales.

Quality Considerations

• Balesshouldnotbedroppedorthepackagingmechanicallydamagedbecausedamageto the layering pattern within the bale may prevent proper tow processing. Mechanical damage to the packaging can also lead to contamination of the tow.

Lift Trucks (with Forks/Clamps)

• Electricorpropanegaspoweredlifttrucksarerecommended.Dieselenginesshouldnotbe used in a confined warehouse space, because their combustion products may be ab-sorbed by the packaging material and tow.

• Capacity–Theweightcapacityofthelifttruckshouldbecheckedandrespected.

• Forks–Theseshouldbesizedtoreachfullyunderthebalewithoutextendingtoofarbe-yond the back of the bale to avoid damaging other bales with the tips of the forks.

• Clamps–Thesearenecessarytoolsforhandlingbaleswithoutpalletsandespeciallyforturning bales. Size and surface material of the clamps depend on the type of packaging and on the job requirement. Recommended clamp surface materials

- for Cardboard Packaging: metal or rubber

- for Reusable Packaging: only rubber

- for Sealed Film Packaging: only in exceptional cases (palletized handling with forks is preferred) and only with rubber. Regular quality control checks of the clamp surfaces should be made to ensure the absence of dirt, gouges, burrs (i.e. small pieces of mate-rial) or sharp edges.

Handling Palletized Bales

Bales on pallets can be handled by motorized forklift or hand pallet trucks. (lift trucks with clamp should NOT be used for palletized bales.)

• Theforksshouldreachcompletelyunderthepallet(forforkliftorhandtrucks)whichwillbal-ance the load and keep it from shifting during transport.

• Handpallettrucksshouldtransportonlyindividualbales.Stackedbalesshouldnotbemoved with hand trucks due to instability issues.

Handling Non-Palletized Bales

Handle non-palletized bales with a clamp lift truck when possible. Non-palletized Bales in Reus-able or Sealed Film Packaging should only be handled with a clamp lift truck

• Usethefullareaoftheclampingsurfaceandapplysufficienthydraulicpressureforliftingthe bale(s) safely.

• Thestackingneedstobelimitedtoaheightwhichcanclearlybecontrolledbytheopera-tor and is stable.

Non-palletized bales in cardboard packaging may be moved with fork lifts or hand trucks. These trucks should not be used for stacking cardboard packaged bales.

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• Thesebalesmustberaisedonspacersforuseinhelpingtoinserttheforksunderthebaleto avoid damaging the packaging:

- No more than two stacked bales should be moved at one time using a fork truck;

- only one bale should be moved at a time with a hand truck.

Fig.5: Clamp lift truck with suitable clamps coated with rubber

Turning of Acetate Tow Bales

Bales transported on their side (horizontal) position need to be turned to an upright position before opening the packaging.

The recommended method is using a motorized lift truck which has the additional equipment for rotating the bale by 90 degrees with suitable clamps.

Turning Method Using Clamp Truck with Rack

For the intermediate positioning a stable rack is used. This should be of a size corresponding to the bale size. This process is shown in fig. 7. The use of larger clamps equipped with rubber surfaces (see in fig. 6) helps to take care of the bale and contributes to safe operation.

• Thebaleisclampedandsetupontherack.

• Theclampsareturnedinhorizontalposition,pickingupthebaleandrotatingthebaleabove the rack by 90° and then setting the bale on a pallet in the working position; see the pictures in fig. 7

Fig. 6: Rack and Clamp Truck

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Fig.7:Demonstrationofturningbaleswiththeuseofarack

Turning Method Using Clamp Truck with Rotating Clamps

In fig. 8 the turning is demonstrated by using clamps which can be rotated. Such clamps are special devices offered by some fork lift manufacturers.

Fig.8:Demonstrationofturningbaleswithrotatingclamps

4. STORAGE OF ACETATE TOW BALES

Stacking

The maximum number of bales which can be stacked on top of each other depends on the safety and stability of the stack. Over stacking may impact the quality of the tow due to mechani-cal damage.

The following considerations have to be taken into account:

• themaximumloadingcapacityofthepalletitself(ifbalesarestoredonapallet)

• thepositioningofthebales(i.e.sideoruprightposition)

• theflatnessorcurvatureofthedifferentsidesofthebales(topandbottomofthebale)

• thestabilityandthicknessofthepackagingmaterial(undertheweightofthebaletheboards of the pallets might compress and damage the tow in the bale below).

The recommendations of the tow manufacturers which are specific to the individual packaging type and material, as well as of the palletization should be followed.

Conditions

The packaging of the bale does not protect the Acetate Tow completely from the ambient envi-ronment. Therefore some precautions need to be followed during bale storage.

• AcetateTowBalesshouldbestoredinacleanwarehouseinanenvironmentfreeofodor-ous substances and they should not be stored with toxic materials.

• Balesshouldbekeptdrytoavoidthedegradationofthepackagingmaterialandmouldgrowth.

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Storage time

The shelf life of Acetate Tow Bales stored in a closed warehouse under normal and stable conditions is at least two years, or as confirmed by the tow supplier. The storage time is limited by the possibility that the ester groups in the cellulose acetate will hydrolyze and release acetic acid. The possibility of this reaction can be minimized by controlling the storage conditions to prevent high temperature. Care should also be taken to avoid a high degree of variability in these conditions.

• Firstin-firstoutinventorymanagementisrecommended

• Towstoredforanextendedperiodoftimemaystillbeusedwithsomepre-cautionandafter testing its suitability (sensory and processing evaluation). The user should be guided by his determination about the tow’s suitability for the intended applications.

5. OPENING OF ACETATE TOW BALES

General Recommendations relating to Quality

• Theoutsidepackagingmaterialofthebaleshouldbekeptcleantoavoidcontaminationofthe tow once the bale is opened.

• Usescissorsorahookknifeforcuttingplasticstraps(pointedknivescouldcutthroughthepackaging material and damage the tow causing stoppages of the filter rod maker).

• Avoidanycontactofthebalewithplasticizer(triacetin)sincethismaycausefusingoftowfilaments in the bale and cause processing problems.

Conditioning of Bales before Opening

Bales stored or transported under severe conditions, particularly at low temperature, should be acclimatized or reconditioned before being opened and the outer packaging removed.

Otherwise humidity, particularly in air conditioned work areas, could condense on the cold sides and surfaces of the tow bales and could impact the processing of the tow and the unifor-mity of the filter rods manufactured.

Fig. 9: Temperature change of a +5°C cold bale entering the production floor conditioned at 20°C (temperature measured at the outside, 5cm from the edge and in the center of the bale)

The time needed for acclimatization de-pends on the temperature difference. In fig. 9 the bale temperature versus the time is shown. There is an approximate 3 day half-life before reaching nearly the temperature equilibrium in the center of the bale for a temperature difference of 15°C.

•Acclimatizationofbalestransportedandstored under extreme and particularly under cold conditions before opening (for at least 2-3 days) is recommended.

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Standard Cardboard Packaging (with Plastic Straps)

Safety Considerations

The plastic straps from the cardboard packaging are under tension. Therefore some precau-tions have to be taken and the following personal protective devices and equipment are rec-ommended:

• Safetyglasses(protectiveeyewear)

• Glovesmaybewornforextrasafety

• Hookknifeorscissors(insteadofopenpointedknife)forcuttingplasticstraps.

The area around the bale should be clear of other persons before cutting the straps.

Opening Procedure

• Thebaleneedstobeintheuprightposition.

• Wearingappropriatepersonalprotectiveequipment,andusingthepropercuttingtool,prepare to cut the straps.

• Donotstandinfrontofstrapbeingcut,duetodangerofbeinghitbythecutstrapundertension.

• Ensurethatnootherpersonsarestandingnearthebaleonallfoursideswhenstrapsarecut.

• Cuteachstrapuntilallstrapsarecut.

• Securelooseendsofstrapstoavoidtrippinghazard.

• Removethetopcardboardandthetopplasticwrapmaterial,takingcarenottotanglethetow.

• Incaseofindentationsobservedafterremovingthepackaging,seeinfig.10,softentheupper layer manually. These indentations may result from the straps or from the boards of the pallet where bales were stacked and could create unstable withdrawal of the tow band at the rod maker.

Fig. 10: Indentations on the upper layer of the bale

Other Types of Packaging

For opening procedures for other types of packing, such as Reusable or Sealed Film Packag-ing, please refer to the manufacturer’s specific recommendations.

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Handling and Storage of Opened Bales

If a bale cannot be processed completely to the end and must be stored for some time, the tow should be covered properly to protect the remaining tow from contamination.

It is therefore recommended, that

• thebalesshouldbecoveredwiththeoriginalpackagingmaterial,whichhaddirectcontactwith the tow; this cover should protect the top and sides of the bale.

• forlongerstorageperiodsadditionaloutermaterialsuchascardboardshouldbeused,fixed with straps or tape to provide a tighter and secure protection for the bale (care should be taken that the side in contact with the tow does not have any spots of glue or other sticky material).

Fig.11: Covering of a bale

In case of some impact by triacetin on the tow,

• theaffectedlayersofthebaleatthatparticularheightneedtoberemovedbeforeprocess-ing the tow will be successful.

The general recommendations for the storing of bales should be respected too.

6. HANDLING OF PACKAGING MATERIALS

Reusing and/or recycling the packaging material is Good Practice of waste reduction. This re-quires careful treatment and separation of the materials used for the transportation and packag-ing of Acetate Tow bales.

Recycling

Various parts of the Acetate Tow packaging can be recycled. Cardboard, polyethylene/

polypropylene films and polyester straps are suitable for recycling.

• Anyrecyclingofthepackagingmaterialshouldbemadefollowinglocalregulations.

Reuse

Reusable Packaging

The Reusable Packaging, used by some tow manufacturing sites, can be re-used for the pack-aging of bales again if these are treated carefully:

• Therecommendationofthetowmanufacturerforthehandlingandfoldingofthispackag-ing should be observed so it can be re-used without impacting tow quality.

Care should be taken that bales are not stored in areas in which liquids, particularly triacetin, are handled (triacetin droplets will glue the filaments together and prevent the further processing of the tow).

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Pallets

Towmanufacturersmayusespecific,customizedpallets.Dependingonthedistanceitmaybeworthwhile to re-use these for sustainability and economic reasons.

• Similartotowbales,thepalletshavetobetreatedcarefullyduringstorageandtransporta-tion. Particularly they must be protected from weather conditions, such as snow and rain and from becoming dirty.

Published July 2011© GAMA Inc., 2011

DISCLAIMERAlthough this information is presented in good faith and is believed to be correct, neither GAMA, the GAMA Members, nor those acting on behalf of GAMA or its Members (such as their employees, officers or directors) make any representations or warranties as to its completeness or accuracy. Use of this infor-mation is conditional on users making their own determination as to its suitability for their purposes prior to use. In no event will GAMA, the GAMA Members, nor those acting on behalf of GAMA or its Members be responsible for damages of any nature resulting from the use of or reliance upon this information. Us-ers agree that use of this information is entirely at their own risk and that they will not be entitled to make any claims against GAMA, the GAMA Members, nor those acting on behalf of GAMA or its Members. Nothing contained in this information is to be construed as a specific recommendation to adopt or refrain from any course of action.

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