Agricultural machinery manufacturing requires moving heavy and oversized components in tight facility footprints. One manufacturer made the transition from manual material handling to a streamlined workflow to keep production speeds up and meet safety rules.
The Challenge: Congestion and vertical constraints
The plant dealt with two major operational problems. First, the reliance on two portable gantry cranes was inefficient. Moving steel materials and assemblies that weighed 4,000 lbs and stood 16 feet tall required two workers to push and pull loads. This manual process slowed down production. It also increased the chance of worker strain or injury.
Second, the floor space was congested. The footprint of the portable gantries and the 16-foot height of the parts hit a vertical limit that caused problems with overhead obstacles. The company considered moving to a larger building or enlarging the current one to solve these space limits.
The Solution: Custom Gorbel engineering
The manufacturer needed a system with the permanence of a structural crane and the flexibility of a modular design. While they looked at I-beam systems, they selected Gorbel Free Standing Work Station Cranes because the design is relocatable. This modularity allows for expansion in the future. The configuration used double girder bridges to manage 2-ton loads.
Nested trolleys were a specific design choice to increase hook height in a low-headroom environment. The design places the hoist between the bridge girders instead of underneath them.
The Execution: Precision and floor space
The installation team put columns at the outer limits of the work area against the walls. Middle columns support both crane systems to reduce the footprint. High-quality and low-friction trolley wheels allow one worker to move bridges and 2,000-lb parts with ease. Rigid hook electric chain hoists provide stable lifting that clears overhead obstacles.
The Result: Throughput and safety
The cranes offered immediate results. Labor requirements for lifting fell by half because the task became a single-worker operation. Production speeds increased as staff positioned loads with more accuracy. The design reduced physical exertion and the risk of injury. By using vertical space better and removing portable gantries, the manufacturer avoided the need for a building expansion.