Ten More CDD15 Electric Roll Handling Stackers for Lithium Battery Electrode Roll Handling

A repeat order says more than a product brochure ever can.

After the successful delivery and commissioning of the first batch of custom electric roll handling stackers for lithium battery manufacturing, the customer returned to SINOLIFT with a new requirement. The earlier machines had performed well in real production. Operators were satisfied. The handling method proved practical. The customer therefore ordered a second batch of ten customized CDD15 units for a broader deployment across its lithium battery manufacturing facility.

These are not standard pallet stackers with a simple pole welded to the mast. Each machine is a purpose-engineered Electric Roll Handling Stacker for transporting electrode rolls and loading or unloading them at production equipment. Two mandrel lengths were built around the customer’s roll formats: 370 mm and 600 mm. Both versions handle rolls up to 900 mm in diameter and use an air expanding mandrel to grip the roll from inside its core.

The project again uses the CDD15 platform from SINOLIFT’s premium M-Series walkie electric stacker range. That choice matters. A proven compact chassis, responsive powered travel, electric lifting, and a tight turning circle provide a reliable base, while the customized load interface, height limits, contact materials, and guarding adapt the machine to delicate roll handling.

For buyers considering similar equipment, this case offers more than a delivery story. It shows which roll data must be confirmed, why an expanding mandrel can protect valuable material, how narrow-aisle maneuverability affects the design, and where a dedicated roll stacker offers a better fit than manual handling or a general-purpose forklift.

Why a Second Order Is the Strongest Site Test

The first delivery gave the customer something no drawing or factory test could provide: operating data from its own production floor.

The machines had to travel through the actual aisles. They had to approach real winding, coating, slitting, or transfer equipment. Operators had to align the mandrel with real roll cores. Maintenance teams had to manage charging and daily inspections. Most importantly, the stackers had to handle valuable electrode rolls without introducing unnecessary impact, surface contact, or unstable movement.

The customer’s decision to purchase ten more units followed that practical validation. It also changed the nature of the project. The first batch proved the concept. The second batch turned the solution into repeatable production equipment.

Fleet expansion requires consistency. Operators should not have to relearn a different control logic at every station. Spare parts and charging arrangements should be predictable. Safety points must remain familiar. Using the same M-Series CDD15 foundation across the additional machines helps standardize operation while still allowing the mandrel length to match the roll used at each workstation.

This is the central value of a well-designed custom machine. It is specialized where the load demands specialization. It remains standardized where standardization supports reliability, training, and service.

CDD15 electric roll handling stacker.

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A Lithium Electrode Roll Is Heavy, Fragile, and Difficult to Approach

Electrode rolls create an unusual handling problem.

They can weigh hundreds of kilograms. Some production rolls exceed one tonne. Yet the wound foil and coated material may be vulnerable to edge damage, telescoping, denting, contamination, and misalignment. A small handling incident can affect far more than the roll’s appearance. It can interrupt feeding, create downstream process problems, or turn high-value material into scrap.

The shape adds another challenge. A cylindrical load can roll. It does not sit naturally on flat forks. Its center of gravity is influenced by roll diameter, width, core position, and how far the load sits in front of the mast. As the roll becomes wider, the load center moves outward and creates greater overturning moment, so a machine suitable for a 370 mm roll cannot automatically be assumed suitable for a 600 mm roll of the same weight and diameter.

Floor layout matters too. Battery production equipment is often arranged closely to use valuable manufacturing space efficiently. The handling truck must turn in constrained areas, line up squarely with a horizontal core, and stop without striking nearby equipment. A bulky counterbalanced forklift may need too much room. Standard forks may also require a pallet or cradle, adding transfers and contact points.

Manual handling is not a realistic answer for these weights. Even when cranes or hoists are available, slings and hooks can require extra setup, overhead clearance, and more hands around a suspended load. A dedicated Electric Roll Handling Stacker keeps the roll supported on a controlled, mobile machine from pickup to placement.

The requirement is therefore not simply “lift 1,500 kg.” The real requirement is to grip a specific core, support a specific roll, remain stable at the actual load center, fit the aisle, reach the machine centerline, and release the roll smoothly.

The CDD15 M-Series Became the Engineering Base

SINOLIFT selected the CDD15 M-Series walkie stacker as the base vehicle for this second batch.

The M-Series is designed for powered travel and lifting in warehouse and production environments. Its compact chassis provides dynamic handling and a tight turning circle. The walk-behind format also gives the operator a clear view of the travel path and load interface during close positioning.

For this project, the nominal CDD15 platform was converted from pallet handling to horizontal roll handling. The fork arrangement was replaced by a dedicated cantilevered mandrel system. The structure and stability configuration were matched to the customer’s roll data. Protective components were added around the mast and mandrel. Lift limits were set around the required pickup and loading heights.

Both custom versions retain an R1435 mm turning radius. This supports maneuvering in narrow production areas and reduces the amount of floor space needed to approach a station. It does not remove the need for an aisle study, however. Buyers should check the complete operating envelope, including machine length, roll overhang, operator position, approach angle, and clearance needed to withdraw the mandrel after unloading.

The power package is shared across the two versions. Each stacker uses a 25.6 V, 105 Ah lithium battery and a 25.6 V, 50 A external charger. This arrangement supports convenient fleet charging and avoids tying the truck to a built-in charging location. Actual runtime will depend on travel distance, lift frequency, load weight, floor condition, temperature, and shift pattern, so a duty-cycle review should always be completed before fleet quantities are finalized.

Two Roll Widths, Two Purpose-Built Mandrels

Custom CDD15 configurations for lithium battery electrode rolls.

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The second batch includes two configurations.

The first is an Electric Roll Handling Stacker with Air Expanding Mandrel for 370 mm roll length. It is designed around a roll measuring 370 mm in length and up to 900 mm in diameter. The shorter mandrel reduces unnecessary overhang and provides an interface suited to the narrower material format.

The second is an Electric Roll Handling Stacker with Air Expanding Mandrel for 600 mm roll length. It handles a roll measuring 600 mm in length and up to 900 mm in diameter. Its longer mandrel reaches through the wider roll core, while the truck configuration accounts for the different load geometry.

The 304 stainless-steel mandrel is a key element on both machines. Stainless steel offers a clean, durable surface and good corrosion resistance. It is also suitable for controlled production settings where painted or easily corroded load-contact components may be undesirable.

Soft-contact details further reduce avoidable impact. The 370 mm configuration includes an anti-impact rubber ring with a limiting function. Nylon locking pins and nylon end plugs are used instead of hard, unprotected metal contact at sensitive points. These parts help locate or retain the roll while reducing the chance of scratching the roll core or striking adjacent surfaces.

The mast uses non-metallic lifting guide rollers. This choice reduces metal-to-metal contact at the guide interface. It can also help lower noise and avoid metallic wear particles from that contact point, although the complete cleanliness requirement of any facility must still be evaluated as a system rather than inferred from one component.

Clear acrylic panels and a protective mesh guard cover relevant moving areas while preserving visibility. Operators can observe alignment. They are also discouraged from reaching into the mast mechanism. Guarding is especially important during repetitive loading work, when familiarity can otherwise encourage unsafe shortcuts.

How the Air Expanding Mandrel Holds the Roll

An air expanding mandrel, also called an air shaft, grips the roll through its core.

Its typical construction includes a shaft body, an internal rubber bladder, external lugs or expansion elements, an air valve, and the shaft end. Before inflation, the bladder is relaxed. The lugs retract. The mandrel’s outside diameter is smaller, allowing it to enter the core with clearance.

The operating sequence is straightforward.

This internal gripping method avoids clamping the coated outer circumference. The sensitive wound surface remains untouched by the gripping mechanism. It also creates a positive connection between the roll core and the truck, reducing the risk of the load sliding along a plain pole.

The core still has to be suitable. Its inner diameter, wall strength, roundness, width, and material must tolerate the expansion force and carried load. Buyers should provide core drawings and sample cores during engineering validation whenever possible.

Lift Limits Protect the Process, Not Just the Truck

The custom lift range was defined around the customer’s pickup and machine heights.

The low position is 270 mm. A mechanical hard stop controls this point. The high position is 1,850 mm and is controlled by a travel limit switch. Electronic limiting is also incorporated into the design.

These limits keep the mandrel within the planned operating window. They help prevent an operator from lowering into the chassis or floor interface. They also reduce the risk of lifting beyond the height needed for the receiving equipment.

For a buyer, the lesson is simple: quote requests should include centerline heights, not just “maximum lift height.” The required data should cover the lowest pickup center, highest discharge center, machine shaft diameter, surrounding guarding, and any vertical clearance needed during insertion. A catalogue mast height alone does not prove compatibility.

Electronic and mechanical limits also have different roles. A limit switch stops powered movement at a defined point. A mechanical stop provides a physical boundary. Using both at critical positions creates layered protection, but neither replaces operator training, inspection, or a safe approach speed.

From Roll Storage to Machine Loading

The ten stackers are intended for two main tasks: electrode roll transport and production-line loading or unloading.

A typical cycle starts at a storage rack, transfer stand, or process output station. The operator first checks the roll identification and confirms that its dimensions and weight match the assigned truck. The route is inspected. The mandrel and safety pins are checked. The stacker then approaches the roll squarely.

Alignment comes next. The operator adjusts lift height until the mandrel is centered with the core. Small corrections are made before insertion. Forcing a misaligned mandrel can damage the core, so visual access and controlled travel are essential.

After insertion, the air shaft is inflated to the approved pressure. The operator verifies engagement. The roll is lifted only enough to clear its support. A low travel height keeps the combined center of gravity lower and improves stability during transport.

At the production machine, the sequence is reversed. The stacker approaches at a controlled speed. The mandrel centerline is matched to the machine shaft or receiving fixture. The roll is transferred only when the receiving structure is ready to carry it. Air is then released, the expansion lugs retract, and the truck withdraws without dragging the core.

The same logic applies during unloading. The Electric Roll Handling Stacker enters the empty or finished roll core, grips it internally, removes it from the machine, and carries it to the next approved location. One mobile unit can therefore connect storage, work-in-process areas, and multiple compatible production stations.

What the Customer Gains Across Ten Units

Ten similarly configured units support consistent fleet operation.

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The most visible gain is time.

Manual rigging can require several people, repeated adjustments, and waiting for shared lifting equipment. A customized powered stacker allows one trained operator to travel, align, lift, and place the roll through a consistent workflow. The exact saving depends on plant layout, but fewer transfers and less rigging can shorten each handling cycle and reduce labor demand.

Product protection is equally important. Outer-surface clamps, makeshift poles, and uncontrolled manual contact can damage a roll before it reaches the machine. The air expanding mandrel grips inside the core. The rubber buffer and nylon contact parts soften critical interfaces. Defined lift limits support repeatable alignment. Together, these features reduce handling-related risks that can contribute to scrap, rework, or production interruption.

Safety improves because people no longer need to support or guide a heavy roll by hand. The load stays on a purpose-designed carrier. Guards separate the operator from mast movement. Powered travel and lifting reduce physical strain. A compact turning radius also helps the operator navigate without making excessive multi-point maneuvers near equipment.

Fleet-level consistency adds another benefit. Ten similarly configured machines can be assigned to production zones, reducing traffic and waiting. Shared battery and charger specifications simplify energy planning. Familiar controls shorten cross-training. Standard inspection points also make daily management easier.

These gains should still be measured. A buyer can compare average handling time, people required per move, near-miss frequency, roll damage incidents, waiting time at each machine, and monthly maintenance hours before and after deployment. That turns “improved efficiency” into an operational business case.

Is This Electric Roll Handling Stacker Right for Your Rolls?

This solution is a strong candidate when the roll is transported horizontally, has a suitable hollow core, must be picked or placed at different centerline heights, and should not be gripped on its outer surface. It is particularly relevant to lithium battery electrodes, film, foil, paper, nonwoven materials, textiles, and other valuable wound products.

It may not be the right configuration in every case. A weak or closed core cannot accept an expanding mandrel. A roll that must be turned from vertical to horizontal needs a rotating attachment or roll turner. A roll without a core may require an external clamp, cradle, or V-block. Very wide or unusually heavy rolls may demand a different chassis, counterbalance, straddle geometry, or dual-arm support.

Before requesting a quotation, prepare the following information:

Roll weight alone is not enough. The supplier must evaluate load moment, which is influenced by both weight and horizontal distance from the truck’s support geometry. A wider roll can place the center of gravity farther from the mast, so capacity must be verified for the real roll position rather than assumed from the CDD15 model name.

A sample roll or core can make validation more reliable. A site drawing is helpful. A video of the current process often reveals approach restrictions that measurements miss. For higher-risk applications, a factory acceptance test using a representative test load and a documented site acceptance procedure should be agreed before shipment.

Ten Machines Delivered, One Handling Method Proven Again

This second order marks a practical step forward for the customer’s electrode roll logistics.

Ten customized CDD15 units now extend a handling method already validated by the first delivery. The 370 mm and 600 mm air expanding mandrels match two key roll formats. The 304 stainless-steel load interface, non-metallic guide rollers, nylon protective parts, acrylic panels, mesh guarding, controlled lift range, lithium power system, and R1435 mm turning radius respond to the realities of repeated production-floor use.

More importantly, the project demonstrates how customization should work. Start with the roll. Study the core. Measure the machine interface. Check the aisle. Calculate stability at the real load center. Then adapt a proven powered stacker around those facts.

That process produces more than a truck. It produces a repeatable connection between material storage and production equipment.

If your plant handles electrode rolls, paper, film, foil, textiles, or other cylindrical materials, SINOLIFT can develop a standard or custom solution for your load and workflow. Share your roll drawing, core specification, weight, lift height, and aisle layout with our engineering team to identify the right Electric Roll Handling Stacker for your application.