Bridge cranes and jib cranes are widely used in various factory workshops. Dongqi Crane supplies thousands of lifting equipment to various factories around the world every year. Today Dongqi Crane shares with customers a case of a Danish mattress manufacturer’s customized crane. Due to the complex working conditions, the local crane company designed a jib crane and a bridge crane for this customer. At the same time, the limited space in the mattress manufacturing factory increased the difficulty of installing the crane. By studying this case, Dongqi Crane can more easily cope with the same type of installation environment in the future and better provide customers with perfect crane solutions.

Crane solution for handling aluminum foil rolls in mattress manufacturing plant

The company develops and produces mattresses, pillows and other leisure products for more than 90 markets around the world.

These cranes are used to handle aluminum foil rolls in packaging machines

The first crane was a column jib crane with a capacity of 250 kg, equipped with an electric chain hoist and radio controller. It was chosen because of its 360° unlimited electric slew function for maximum mobility.

The second crane is a single light crane solution with a capacity of 250kg and a track length of 9.5m. It also has a carrying capacity of 250kg and comes with an electric chain hoist and radio controller.

“This [monocoque] crane is a good option in tight spaces where the rails/rails can be tied off the existing building and using struts on the ground – it’s a great solution scheme because we don’t need to use part of the total height of the building,"

Both cranes use electric chain hoists with a lifting speed of 2/8m per minute, a lifting height of 5m and a working load limit (WLL) of 250kg, plus an electric trolley.

What can we learn from this

When designing a crane solution to adapt to manufacturing plants with complex working conditions, multiple aspects need to be considered to ensure the safety, efficiency and economy of the solution. Here are some key takeaways:

Understand specific working conditions and needs:

• Gain an in-depth understanding of the factory's production processes, material handling needs, space layout, and potential obstructions.
• Analyze the particularities of the working environment, such as temperature, humidity, corrosiveness, etc., to determine the protection and performance requirements required for the crane.

Choose the right crane type and size:

• Select the appropriate crane type (e.g. overhead crane, gantry crane, mobile crane, etc.) based on the weight, size and frequency of materials being moved.
• Consider the crane's lifting capacity, lifting height, working speed and other specifications to meet the actual needs of the factory.

Security and stability:

• The design plan should fully consider the stability and safety of the crane, including structural strength, wind resistance, electrical safety, etc.
• Consider installing safety measures such as guards, security alarm systems, and emergency stop buttons.

Flexibility and adaptability:

• Due to the complex working conditions of the factory, the crane solution should have a certain degree of flexibility and adaptability in order to cope with changes in the production process.
• Consider using programmable controllers and sensor technology to achieve automated and intelligent control of cranes.

Maintenance and care:

• The design scheme should facilitate the maintenance and upkeep of the crane, including easily replaceable parts, convenient access to repairs, etc.
• Consider developing a regular maintenance and inspection plan to ensure long-term stable operation of the crane.

Economical and cost-effective:

• In the design plan, the purchase cost, operating cost and maintenance of the crane must be fully considered.

Comply with regulations and standards:

• Ensure design solutions comply with national and local regulations, standards and industry specifications.
• Consider obtaining the necessary certifications and permits to ensure the crane is used legally.

In summary, multiple aspects need to be considered when designing a crane solution to ensure the feasibility, safety and economy of the solution. By deeply understanding the actual needs and environmental characteristics of the factory, selecting appropriate crane types and specifications, and taking effective safety and maintenance measures, we can provide efficient and reliable material handling solutions for manufacturing factories with complex working conditions.

Danish Mattress Manufacturer Customizes Jib Crane and Overhead Crane