Whitepapers Archives - Material Handling Wholesaler

Honeywell’s Warehouse Exit: The Intelligrated Story

Wed, 20 May 2026 13:22:54 +0000

On the 23rd April 2026, Honeywell officially announced that it had sold its Warehouse & Workflow Solutions (WWS) division – consisting of Intelligrated and Transnorm – to private equity firm American Industrial Partners. This came just three days after Honeywell announced the sale of its Productivity Solutions and Services – its Automatic Identification and Data Capture (AIDC) arm – to Brady Solutions for $1.4 billion, representing a 1.3x revenue multiple and 8x trailing EBITDA (earnings before interest, taxes, depreciation, and amortization) multiple. Honeywell acquired Intelligrated in 2016 for $1.5 billion, representing a 12x EBITDA multiple and a 1.6x revenue multiple. A few months earlier, KION acquired Dematic for $3.25 billion, representing a 19x EBITDA multiple and a 1.8x revenue multiple, suggesting a higher valuation for Dematic. Fast forward to today, Honeywell’s WWS group has grown just 3.9%, from approximately $0.9 billion to $0.93 billion, while Dematic’s revenue has increased 86%, from roughly $1.8 billion to $3.3 billion. Adjusting for approximately 35% inflation between 2016 and 2025 — and considering that a portion of Honeywell’s WWS growth came through acquisitions such as Transnorm — Honeywell’s Intelligrated business is effectively generating less revenue in real terms than it was at the time of the 2016 acquisition. The Covid-19 boom and bust However, to analyze the group on such a long time horizon misses the bigger picture. As the chart below shows, Honeywell was caught squarely in the boom vs bust Covid-19 cycle. Our analysis shows that Honeywell’s strong vendor concentration with a small number of major e-commerce retailers (e.g. Amazon) was the main catalyst for the boom-bust cycle; as e-commerce sales cooled, so too did Honeywell’s WWS revenue growth. High reliance on key customers seems to have likely led to a ‘boom-bust’ profile for Honeywell Honeywell therefore acts as a cautionary tale for over-reliance on key customers. Amazon has historically been one of the key customers for large conveyor companies, presenting both risks and opportunities. With Amazon’s new One MHS initiative, aimed at standardizing the hardware, software, and controls used in its fulfillment centers, automation vendors face even heavier commoditization. This approach eliminates lock-ins, proprietary software, and service opportunities (as Amazon technicians will be trained on a single operating standard, making it far easier to service in-house). It’s not precisely clear what AIP paid for Honeywell’s WWS group. However, we can assume that AIP likely bought the WWS group at a discount given the significant growth contraction, coupled with the fact that the operating group was publicly stated as an ‘asset held for sale’, increasing AIP’s negotiating power. Furthermore, Honeywell reported an impairment charge related to the PSS and WWS to the tune of ~$350 million (although it’s unclear how much was attributed to WWS). Going full circle AIP’s previous acquisition of TREW Automation (TREW) was likely a key driver for the decision to acquire Intelligrated (and Transnorm). Ironically, TREW was founded by ex-Intelligrated employees and we’ve heard many Intelligrated employees have since jumped ship to join TREW. TREW was founded in 2019, quickly acquiring Hilmot (a motorized roller conveyor manufacturer) and Tech King Operations (a warehouse software and controls specialist). The company positions itself as a pure-play system integrator, bringing together multiple third-party equipment (along with its in-house conveyors) using its proprietary software solutions. Acquisitions have strengthened TREW’s combination of software and hardware competencies The merging of Intelligrated and TREW won’t necessarily fill portfolio gaps. Indeed, Intelligrated’s key offerings are its conveyor and sortation products, along with its Momentum software suite, mirroring both Hilmot and TKO’s core offerings respectively. Therefore, the key synergy is likely to be scale, particularly around the installed base, conveyor production, and integration capabilities. How can AIP be successful? For AIP to be successful, it can’t fall into the same trap that Honeywell did. This is particularly true around customer concentration, which we’ve heard anecdotally was a key issue for Honeywell Intelligrated. Amazon, for example, has significantly increased its spending on automation since 2024, but its spending volatility, coupled with its increased pricing pressure from the One MHS initiative, will be a significant risk to future growth and profitability. Furthermore, with more plug-and-play equipment, integration is becoming commoditized as it becomes easier to install equipment, lowering the barrier to entry. Therefore, software is going to be the key differentiator. How well AIP is able to bring together TREW’s software and controls with Intelligrated’s Momentum suite is going to dictate the success of the synergy. AIP could go one step further by acquiring or developing a pure-play/stand-alone WES solution that has a true resource agnostic/multi-agent approach. This would hedge against a future driven more by robotics than by mechatronics. Dematic, for example, recently announced it would be partnering with GreyOrange, integrating its GreyMatter software solution into its portfolio. While this is a partnership, it nonetheless highlights the direction of travel. To this end, we believe AIP should separate software and steel for its go-to-market strategy. One of TREW’s core competitive advantages is its pure-play integrator model, with the ability to ‘stitch’ together multiple systems from different OEMs (illustrated by the diagram below). TREW has a diverse array of third-party partners By acquiring Intelligrated, it has the potential to effectively dilute TREW’s agnosticism towards hardware. Through a separate go-to-market strategy (and potentially branding) for both its integration and software capabilities, as well as its hardware OEM business, the company could avoid any value proposition ambiguity. As an example, Momentum could transition to TREW, while Hilmot’s conveyor offering could be brought under the Intelligrated banner. Final thoughts Over the last three months, we’ve seen a flurry of M&A activity as the market recalibrates ahead of its next phase of growth. Understanding where the opportunities lie and where the traps exist is paramount for success. Our extensive portfolio of research covering the warehouse automation market can help ensure you’re prepared for the next evolution of market development. To learn more about our research, contact us today.

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Optimal Performance: A Practical Guide to Vertical Reciprocating Conveyor Preventive Maintenance

Thu, 14 May 2026 15:02:56 +0000

Even the most dependable equipment benefits from regular inspections by a qualified technician. These inspections can help prevent unexpected downtime and keep your operation running smoothly. Crush Downtime with Preventive Maintenance Preventative maintenance is your secret weapon against downtime. It’s like that ounce of prevention that saves you a pound of trouble (and a hefty repair bill). Here’s why a well-defined preventive maintenance program is a game-changer: Dodge the Downtime Demon: Say goodbye to unexpected breakdowns that halt production. Slash Repair Costs: Catch small issues early to avoid expensive repairs later. Extend Your VRC’s Lifespan: Regular care keeps your equipment running smoothly for years to come. Safety First: Reduce the risk of accidents caused by malfunctioning equipment. Peak Performance, Maximum Efficiency: Regularly maintained machinery operates at its best, leading to optimized productivity. Let’s break down the key steps involved in a thorough, scheduled inspection. Eight Critical Steps to Keep Your VRC Running Smoothly While inspection protocols can vary depending on your specific VRC model and any custom features, here are some key steps that apply to any VRC. Please note that preventive maintenance should be conducted only by a qualified and trained service technician. Consult a Playbook Don’t wing it! Following a detailed preventive maintenance checklist or playbook for all VRCs ensures you’re doing the right maintenance at the right time. Put Safety First Before you get started, prioritize safety by following safety protocols located in owner’s manuals and preventive maintenance checklists. Scrutinize Safety Components The most important place to begin is with inspecting all safety components/devices. Interlocks, gates, safety cams, chains, brake gap/wear (mechanical VRCs), down solenoid and hydraulic hose connections (hydraulic VRCs), and DeckLocks (if applicable) to ensure they are working properly. Check All Operational Components After inspecting the VRC’s safety components, direct your attention to reviewing operational components such as wheel blocks and chain tensioners to ensure they are within proper tolerance and adjust if needed. Electrical Check-Up Inspect all electrical components, checking for signs of wear/damage, or loose connections and frayed wires. Inspect all push-button stations and/or HMIs, ensuring that the VRC operates as intended. Make sure all moving parts are operating properly with no signs of improper friction or wear. Incorrectly aligned or loose moving parts will become worse if not fixed and can damage other parts or cause excessive wear or strain on your system. Ensure Level Stops Verify that the VRC stops flush with the floor or ramp at each level. Misalignment can lead to loading and unloading issues and may also indicate that the unit has been overloaded or operated incorrectly. Make it Clear Inspect and clean areas under and around the VRC to remove debris or obstructions that could hinder operation. Document and Report Keeping accurate records is crucial. It ensures that issues are addressed promptly and helps you track maintenance history and identify potential problems early. Remember to document and correct any unsafe conditions immediately. Preventive Maintenance Protocols This list provides a solid overview, but real-world VRC inspections are detailed and equipment-specific. As a leading VRC manufacturer, PFlow has developed a comprehensive set of preventive maintenance protocols for each of its VRC models. The Human Factor Regular inspections in VRCs are about more than just checking for broken wires or malfunctioning equipment. They’re crucial for identifying potential human error. Imagine users skipping safety briefings or rushing through calibration steps. This can lead to damaged equipment, hinder equipment performance, and most importantly, create unsafe situations for users. Regular checks ensure everything is being used as intended. This involves verifying users follow safety protocols and that the area surrounding the equipment is clear of obstacles. These are essential preventative measures, forming the backbone of a safe and smooth VRC operation. Preventative Maintenance is Key to Safety and Performance Preventive maintenance is key to keeping your equipment running safely and at optimal performance. As previously stated, preventive maintenance should be conducted only by a qualified and trained service technician. About the Author Beth Mueller, PFlow Industries

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J. J. Keller Study Highlights Shift Toward Proactive Fleet Management Strategies

Wed, 13 May 2026 14:58:24 +0000

2026 State of Fleet Management report shows growing focus on prevention, visibility and early intervention The J. J. Keller Center for Market Insights has released its sixth annual State of Fleet Management study, revealing a growing shift among fleet managers toward prevention, early detection and real-time visibility to address ongoing safety and compliance challenges. The study highlights how today’s fleet managers are balancing regulatory complexity, operational demands and cost pressures while working to reduce risk across their operations. Key fleet manager concerns included: Effectively managing preventative maintenance to avoid breakdowns or accidents Staying up to date on changing regulations Ensuring training results in fully qualified and compliant drivers Knowing quickly when a driver is non-compliant Identifying repair needs before breakdowns or incidents “Fleets are shifting from reacting to issues to preventing them,” said Daren Hansen, senior compliance expert at J. J. Keller & Associates, Inc. “With tighter margins and higher risk, there’s a clear focus on catching problems early, whether that’s identifying non-compliant drivers or addressing maintenance needs before they lead to breakdowns or violations.” The findings also show that compliance is evolving beyond documentation toward real-time awareness and action. While accurate recordkeeping remains important, fleet managers are placing greater emphasis on visibility into driver performance, regulatory impact and day-to-day operations. Despite these advancements, the role remains demanding. Two-thirds of fleet managers describe their job as very or moderately challenging, citing regulatory changes, hiring and retention, documentation and maintenance as ongoing pressures. “Small gaps in compliance, training or maintenance can quickly turn into major issues,” Hansen added. “A structured safety and compliance program helps fleets stay ahead of risk and operate with greater confidence.” The full study is available as a free download.

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JLG® Whitepaper Explores the Future of Autonomous Job Sites

Tue, 28 Apr 2026 16:02:19 +0000

“From Access Equipment to Autonomous Work Systems” is now available on #DirectAccess. JLG Industries, Inc. has released a new whitepaper, From Access Equipment to Autonomous Work Systems, detailing its vision for the future of construction: Connected, coordinated and increasingly autonomous job sites. The paper outlines how advances in robotics, machine perception, connectivity and cloud-based intelligence are transforming the role of access equipment, from simply lifting workers to height to actively contributing to task execution. “Access equipment has traditionally enabled work at height,” says Shashank Bhatia, chief technology officer and global vice president of engineering, JLG, in the new JLG whitepaper. “Today, we’re redefining that role. By integrating robotics and connectivity, we’re creating intelligent systems that not only support work but help perform it.” The From Access Equipment to Autonomous Work Systems whitepaper also explores how automation can help address some of construction’s most pressing challenges, including persistent labor shortages, increasing project complexity and the need for greater productivity. Rather than replacing workers, these technologies are designed to extend skilled labor, reduce physically demanding tasks and improve job site safety. Key topics covered in the whitepaper include: The evolution from standalone machines to connected job site ecosystems Real-world applications of robotic systems, including drywall finishing and work-at-height automation The role of connectivity platforms in enabling machine-to-machine coordination How automation is reshaping workforce roles and attracting new talent to the industry “As job sites become more complex, the need for smart, connected equipment continues to grow,” Bhatia says in the whitepaper. “JLG’s vision provides a look at how those technologies can come together to deliver greater efficiency, consistency and visibility across the entire project.” Highlighting JLG’s ongoing innovation efforts, including connected fleet technologies and emerging robotic solutions that enable machines to communicate, coordinate tasks and operate as part of a synchronized workflow, this new whitepaper reinforces the company’s commitment to advancing the construction industry through innovation and delivering solutions that help customers work safely and efficiently. The full whitepaper, From Access Equipment to Autonomous Work Systems, is available now for download on JLG #DirectAccess: https://www.jlg.com/en/directaccess/from-access-equipment-to-autonomous-work-systems-a-new-era-for-job-sites

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Caldwell low-headroom lifting beam elevates safety and efficiency in steel coil handling

Wed, 01 Apr 2026 13:40:45 +0000

The Caldwell Group Inc. has engineered a 7.5-ton-capacity, low-headroom multiple-spread lifting beam that is helping JEC Service Company, Inc. handle steel coils with greater safety and precision. Designed for use below-the-hook of a top-running double-girder crane system, the Model 20S beam plays a critical role in a fully integrated lifting solution supplied by Mass Crane & Hoist Services, Inc. Measuring 77 inches in length and featuring a custom single-pin bail, the beam is purpose-built to safely load 60-inch sheet metal coils into a Vicon coil processing machine. At JEC’s sheet metal fabrication facility, where ductwork for the HVACR industry is produced, safety was the driving force behind the investment. “Our entire mission in purchasing this system was safety—minimizing hazards and keeping material handling contained within a controlled area,” said Al Seelig, head of sheet metal operations at JEC. “This beam delivered exactly what we needed.” Each coil cradle handled by the crane weighs approximately 10,000 lbs., requiring consistent, reliable lifting performance as production demands shift. With limited headroom in the facility, maximizing vertical space was essential—not just for efficiency, but for safe operation. That’s where Caldwell’s design made a measurable difference. JEC is the latest organization to benefit from the wide-ranging capabilities of what remains a standard line of beams. “We engineered the crane system complete with columns and runways, but the challenge was ensuring JEC could safely maneuver coils within a confined space,” said Ryan Sullivan, project manager at Mass Crane. “Caldwell’s low-headroom beam allowed them to maximize hook height, making it possible to lift and position coils safely—even stacking one over another on the rack.” To further enhance performance, Caldwell collaborated closely with Mass Crane to ensure seamless integration with the hoist system, modifying the connection point from a standard lifting eye to a single-pin bail to gain additional headroom where it mattered most. When vertical space is limited, solutions like Caldwell’s Model 20 multiple spread lifting beam don’t just improve workflow; they reduce risk. By enabling safer positioning of heavy materials and minimizing unnecessary movement, the system supports a more controlled and efficient operation. Notably, there are 150 sizes in the Model 20 / Model 20H family, with additional options for hole placement, faspins, extra hooks, bail type, shackles, etc. This means that users can get thousands of combinations in a standard beam, eliminating the need to source a custom solution from the drawing board. The Model 20 has 90-plus sizes, in capacities up to 40 tons and spreads up to 30 feet; the Model 20H has the same beam for higher capacities and offers over 75 standard sizes, with options including extra shackles and swivel hooks and a built-in stand. The Model 20HC, meanwhile, is available in 50 to 80-ton capacities with spreads from 10 to 20 feet. Fully custom-engineered products are also available. At JEC, the beam feeds into a Vicon coil line, which is a semi-automatic system that de-coils, punches, notches, shears, and roll-forms sheet metal into finished ductwork components. With each lift supporting both material and equipment, capacity and reliability are essential. “The beam had to account for the weight of the coil, the spindle, and the lifting device itself,” Seelig added. “It’s a critical part of keeping our operation running safely and smoothly.” With a long-standing legacy in manufacturing below-the-hook lifting solutions, The Caldwell Group, Inc. continues to deliver engineered equipment built around safety, reliability, and performance. By partnering with industry leaders like Mass Crane & Hoist Services, the company remains committed to advancing material handling practices—helping customers move critical loads with greater confidence, efficiency, and control. The Caldwell Group engineered a 7.5-ton-capacity, low-headroom multiple-spread lifting beam for handling steel coils with greater safety and precision.

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The Strategic Advantage: Why Modularity Defines the Future of Sheet Metal Automation

Wed, 18 Mar 2026 10:00:11 +0000

In sheet metal manufacturing, the transition to automation has evolved from a competitive edge into a fundamental operational imperative. In a landscape defined by razor-thin margins, persistent labor shortages, and an escalating demand for high-level customization, the strategic question for fabricators is no longer whether to automate, but how to execute that transition with precision. The advantages of automation are clear: it reduces the need for manual labor, minimizes human error, increases throughput, and ensures consistent quality. Conversely, fabricators reliant on manual processes encounter bottlenecks that hinder productivity and growth, limiting their ability to adapt to market shifts. Despite these benefits, many businesses remain hesitant to adopt automation. The inhibiting factors are understandable. There is a palpable apprehension surrounding the costs, risks, and perceived complexity of overhauling a production line. The fear of “getting it wrong” often leads to paralysis. Much of this complexity stems from the sheer number of pathways available. Should a shop begin by installing a single high-performance machine to achieve the biggest immediate return? Should they pursue incremental process improvements, adding one component at a time? Or is the right answer a full-scale “greenfield” project that creates or converts the entire production line in one fell swoop? The answer is that there is no single right answer for everyone. For most manufacturers, the most effective path is a phased, modular approach that lets them start small, build confidence with early wins, and expand as production requirements and budgets grow. This is where the concept of how you automate becomes as critical as how much or how fast you do it. A key success factor in navigating this effectively, whether you are installing a single laser cutter or building a fully automated factory, is modularity. Modularity: The Architecture of Flexibility At its core, modularity in sheet metal automation is about architectural foresight. It is not just about buying machines that can physically connect to one another; it is about a design philosophy that governs the entire manufacturing ecosystem. It also creates a practical roadmap for phased automation, so shops can move from a single machine to a fully connected system over time, instead of in one disruptive leap. In practice, modularity operates on two distinct levels. First, it concerns the attributes of each individual component. Each asset, from laser and punching machines to automated loading, unloading, and sorting components, must be designed for seamless integration. This ensures that both the flow of material and flow of information are synchronized with precision. This “future-proof” architecture allows individual units to function as part of a cohesive, evolving system rather than as isolated tools. Second, it concerns the nature of the whole ecosystem. The system itself must be engineered to accept new modules without requiring a complete teardown or conflicting with existing workflows. When we view automation through the lens of modularity, we stop seeing machines as isolated islands of production. Instead, we see them as building blocks in a fluid, evolving organism. This perspective is critical because it shifts the focus from short-term capacity fixes to long-term strategic capability. The Key Benefits of a Modular Approach Why is this architectural approach so critical for modern fabricators? Modularity directly impacts the bottom line by enhancing flexibility, equipment effectiveness, and business process optimization. 1. Flexibility The primary advantage of modularity is flexibility. In the past, rigid automation lines were designed for high-volume, low-mix production. If the market shifted or a product line was discontinued, the entire line often became obsolete. A modular solution, however, can be tailored to meet a fabricator’s unique needs and resources. It allows a business to adapt to evolving demands without discarding previous investments. If a shop starts with a standalone laser and demand grows, they can add a loading/unloading robot. In markets like data centers, for example, a fabricator might begin with enough capacity to produce a few hundred racks per day, with a clearly defined plan to add modules as orders climb into the 400–600‑unit‑per‑day range. Modularity makes that growth a series of manageable steps instead of a binary choice between “too little” and “far too much” automation. If demand shifts toward complex forming, they can integrate a panel bender. This ability to scale and adapt protects capital investment against market shifts, ensuring that the factory floor remains relevant regardless of what the sales team brings in. 2. Accelerating Material Flow Modularity enhances Overall Equipment Effectiveness (OEE) by speeding up material flow and increasing valuable “green-light time” for sheet metal fabricators, no matter their automation path or stage. Removing Bottlenecks Fabricators typically begin their automation journey by addressing their single biggest bottleneck or most labor-intensive process. This targeted approach avoids large, multimillion-dollar commitments in favor of a modest initial investment that delivers the most significant impact. It allows them to demonstrate ROI, gain experience, and build confidence. Modularity then enables them to protect and build on this investment in the future as they add components like load/unload systems and additional machines. The process is controlled and incremental, not an all-or-nothing leap, ensuring that the first step is designed for future adaptability and growth. A Journey from Cells to a Connected Line One HVAC manufacturer, for instance, began with dozens of standalone punching machines, shears, and press brakes arranged in traditional cells, each staffed by an individual operator. Over several years, they transitioned to a modular line anchored by automated panel bending, followed by a punch‑shear combination machine and a Night Train–fed material handling backbone. Today, a small team runs what used to require many more operators across multiple cells, with panels moving from raw sheet to finished form in a fraction of the time and with far less manual handling. Automating Material Handling Consider a standalone laser cutter. Without automation, a significant portion of its available time is spent waiting for an operator to load a raw sheet or unload finished parts. By layering on material handling capabilities, such as a compact loading/stacking system, fabricators can dramatically shift this dynamic. In typical implementations, green‑light time can climb from roughly

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New Study Reveals Robust Polystyrene Recycling Infrastructure Across North America

Tue, 10 Mar 2026 13:55:38 +0000

Resource Recycling Systems (RRS) identifies 126 companies and 169 facilities processing recovered polystyrene in the U.S. and Canada The Polystyrene Recycling Alliance (PSRA) has released a comprehensive study examining end-market landscapes and recovery pathways for four major polystyrene resin types across the United States and Canada. Conducted in partnership with Resource Recycling Systems (RRS), the study includes primary interviews and a vetted facility catalog to develop a national inventory of companies receiving, processing, and reclaiming different forms of polystyrene across North America. Overall, the study identified 126 companies operating a total of 169 facilities across 30 U.S. states and four Canadian provinces that are either actively receiving, processing, or reclaiming some form of polystyrene, including general purpose polystyrene (GPPS), high impact polystyrene (HIPS), expanded polystyrene (EPS), and extruded polystyrene (XPS). The research reveals there is established recycling infrastructure for recovering all forms of polystyrene and is positioned for continued growth with appropriate interventions. Specifically, the study reveals significant maturity in recovery systems for EPS and XPS within commercial business-to-business supply chains. Researchers identified 81 companies handling recovered EPS and/or XPS, representing a total of 119 facilities across 30 U.S. states and four Canadian provinces, with more than half operating as manufacturing end markets using recycled feedstock. Today, more than 700 drop-off locations support EPS collection across North America. Recovery pathways include manufacturer take-back programs, self-backhaul through distribution centers, and deployment of densification equipment at construction and retail sites. For GPPS and HIPS, the research identified 45 companies across 22 U.S. states and four Canadian provinces handling these recovered materials, with approximately thirteen percent representing manufacturing end markets using recycled feedstock. Medical plastics currently dominate post-use streams being reclaimed as post-consumer recycled content, alongside electronics captured through specialized e-waste programs. The study underscores the dual need to build reliable demand for post-consumer recycled GPPS and HIPS and expand consistent post-use supply streams through partnerships with plastic recovery facilities (PRFs), MRF operators, and chemical recyclers. “The polystyrene industry is committed to accelerating recycling and recognizes that robust end markets are essential to enabling a circular economy,” said Justin Riney, Chair of the Polystyrene Recycling Alliance. “This study provides the critical insights and data we need to have a fact-based discussion with stakeholders and inform strategic investments in the collection and recovery infrastructure.” At its core, the study emphasizes building reliable demand signals that encourage investment in reclamation infrastructure and establishing dependable supply chains through partnerships with plastic recovery facility operators and chemical recyclers. “The research conducted by RRS provides a comprehensive picture of the current state of polystyrene recycling in the United States and Canada, demonstrating that different degrees of infrastructure exist to support a circular economy for polystyrene,” said Anne Johnson, Vice President and Principal at Resource Recycling Systems. “Our findings show that with strategic investments in collection and continued growth in market demand, the Polystyrene Recycling Alliance and its members can significantly expand polystyrene recovery rates.” This framework reinforces PSRA’s central focus on enabling scalable, market-driven recovery pathways for polystyrene across North America for infrastructure investment, end-market development, and industry collaboration.

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Cyngn advanced site-wide autonomy with DriveMod Tugger Operations across connected facilities

Wed, 25 Feb 2026 15:52:51 +0000

Cyngn Inc. continued expansion of DriveMod Tugger deployments across large, connected industrial facilities, reflecting growing customer demand for site-wide autonomy that supports end-to-end material movement. DriveMod is increasingly being used in workflows that span multiple buildings and outdoor transit corridors, helping organizations reduce bottlenecks, improve throughput consistency, and redeploy labor toward higher-value operations. As warehouses and manufacturing campuses grow larger—often exceeding 200,000 square feet and operating across multiple structures—transport between zones becomes a persistent source of inefficiency. DriveMod helps automate these repetitive movements, enabling smoother transitions between storage, production, and distribution areas and supporting more scalable facility-wide automation. “Customers are increasingly looking for autonomy that fits into their entire operation, not just a single aisle or point solution,” said Marty Petraitis, Cyngn’s VP of Sales. “As industrial sites grow larger and more interconnected, the ability to move materials reliably across a full facility becomes a meaningful lever for efficiency and scale.” “DriveMod is built to perform in real production environments and support site-wide automation as a long-term capability,” Petraitis added. “This broader deployment scope strengthens the foundation for sustained customer expansion as organizations scale autonomy across multiple workflows and facilities.”

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Gerrity Corrugated Expands Capabilities and Efficiency with LMC Equipment and SUN Automation Support

Wed, 31 Dec 2025 12:00:22 +0000

Gerrity Corrugated is strengthening its position in the corrugated packaging market through targeted investments that drive growth, improve efficiency, and enhance customer responsiveness. As a sheet converting plant serving food, pharmaceutical, and manufacturing customers, Gerrity depends on machinery that performs reliably and keeps pace with increasing demand. That focus led the company to the partnership between Latitude Machinery Corp. (LMC) and SUN Automation Group. A Partnership Built on Value and Performance Gerrity’s relationship with LMC began two years ago with the purchase of an 89-inch Jumbo Die Cutter. The results of that first installation set the stage for an expanding partnership. “We were really impressed with what the Jumbo could do,” says Chris Maisonneuve, Operations Manager at Gerrity Corrugated Paper Products Ltd. “Once we saw the capabilities and the value LMC offered, it made sense to explore their flexo options. The PP1 is our second LMC machine in as many years, and both have delivered exactly what we needed.” SUN Automation, the exclusive North American representative for LMC, worked closely with Gerrity to identify the right solutions and align the project with ambitious timelines. The collaboration reinforced Gerrity’s confidence that LMC equipment would support both immediate production needs and long-term growth. Meeting the Metrics That Matter When Gerrity evaluated new equipment, the company had clear requirements for performance, price, and lead time. LMC met all three. The LMC Jumbo Die Cutter expanded the plant’s capabilities immediately. With its 89 x 189 capacity, Gerrity could take on larger-format work that previously required outsourcing. “Jumbo allows us to enter new markets as we did not have that capability before,” says Maisonneuve. “This machine has been instrumental in helping us keep up with increased demand.” The PP1 Mini Flexo Folder Gluer added another layer of efficiency. Designed for speed, accuracy, and fast setup, the Mini introduced major workflow improvements. Its full-servo architecture, dual vacuum transfer, ball screw slotting system, Windows-based control platform, and rapid order change features provides operators control and consistency across jobs. “The PP1 Mini allows us to run more efficiently and convert one job to another much faster than our prior machine,” Maisonneuve explains. “The rapid set reduces changeover time significantly.” Both machines have supported Gerrity’s operational goals to such a degree that the company already plans to bring another unit online. Installation and Support That Stand Out For Gerrity, the installation and onboarding experience confirmed the strength of the partnership. Having worked with a variety of suppliers over the years, the team quickly recognized the differences in approach that SUN and LMC provided. “We were able to collaborate and work around our ambitious timelines. We were consulted on every step, and the communication was second to none,” says Maisonneuve. “SUN and LMC rank at the top for installation and onboarding.” Ongoing service has been equally impactful. “The technical support is top shelf, and parts are readily available. Every time we needed assistance, the response was immediate with prompt corrective action,” Maisonneuve adds. Technology That Aligns with Growth LMC equipment is engineered for converters seeking reliable, user-friendly machines that deliver consistent, high-quality results. Features such as servo-driven sections, computer-controlled axes, Windows-based order presets, and efficient folding and die cutting systems help plants like Gerrity maintain uptime and expand production capacity with confidence. “As SUN Automation’s authorized agent for Canada, we see Gerrity as a converter that knows exactly what it needs to support its growth,” says Mikah Thorne, President of Canadian Corrugated Systems. “Their focus on value, throughput, and customer responsiveness makes them an ideal fit for LMC equipment, and it’s rewarding for our team to support their continued expansion alongside SUN and LMC.” Looking Ahead With two LMC machines already in operation and a third planned, Gerrity sees its partnership with LMC and SUN Automation Group as an essential part of the company’s future. “We’ve received great value, exceptional customer service, and support. Both our machines are workhorses; you cannot lose,” says Maisonneuve. “We are looking forward to the next install.” As Gerrity Corrugated continues to expand capacity and serve new markets, its partnership with SUN Automation and LMC demonstrates how the right combination of equipment, support, and collaboration can elevate performance and customer experience across the modern box plant.

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Keeping auto parts manufacturing running with Atlas Copco’s E-Air V1100 air compressor

Tue, 30 Dec 2025 14:39:05 +0000

In the fast-paced world of automotive manufacturing, downtime is not an option. When a leading auto parts manufacturer in Greenville, South Carolina faced unexpected breakdowns on their stationary compressors, they needed a reliable solution to keep production running. Atlas Copco’s V1100 portable air compressor stepped in to deliver the power and performance required to maintain operations without disruption. Ensuring continuity during critical repairs The auto parts facility operates on tight schedules, supplying essential components to major automotive brands across the country. Their production lines depend on a steady supply of compressed air to power tools, machinery, and critical processes. When their stationary compressors required urgent maintenance, the risk of halting production loomed large. Every hour of downtime could lead to missed deadlines, contractual penalties, and significant financial impact. The stakes were high. The team needed a dependable, high-capacity air solution. And they needed it fast. Power and reliability Atlas Copco’s E-Air V1100 air compressor was deployed to bridge the gap during repairs. Known for its robust performance and mobility, the V1100 delivers the airflow and pressure necessary for demanding industrial applications. Its quick setup and easy transport allowed the manufacturer to resume operations almost immediately, minimizing disruption and safeguarding production schedules. Unlike conventional diesel-powered compressors, the E-Air V1100 runs on electricity, offering a quieter, and more cost-effective solution with no local emissions. Because the unit can operate outdoors, it doesn’t take up valuable production space inside the plant. It was also quick to deploy with virtually no installation time, making it an easy, hassle-free solution. Working reliably out of sight, it delivers peace of mind without interfering with daily operations. Operational efficiency and peace of mind By leveraging the E-Air V1100 air compressor, the manufacturer avoided costly downtime and maintained their commitment to customers. The compressor’s reliability ensured consistent air supply for the manufacturing processes, while its energy efficiency helped control operating costs. The E-Air V1100’s variable speed drive technology optimizes energy consumption based on demand, reducing waste and lowering the total cost of ownership. Atlas Copco’s responsive support team played a crucial role in the success of this solution. From the initial consultation to on-site setup and ongoing guidance, the team provided expert assistance every step of the way. This level of support reinforced confidence in the solution and allowed the manufacturer to focus on what they do best: producing high-quality automotive components. A solution that goes beyond the immediate need While the E-Air V1100 was initially deployed as a temporary measure, its capabilities demonstrate why E-Air compressors are an ideal replacement for stationary units in industrial environments. In sectors where uptime is critical, having a flexible, high-performance solution available for planned maintenance or unexpected repairs can make all the difference. Electric compressors like the E-Air V1100 offer clear advantages over traditional alternatives. Built to withstand harsh environments and outdoor conditions, they deliver reliable performance where durability is essential. Their robust design ensures consistent operation even in challenging settings, making them a dependable choice for industries that cannot afford interruptions. The value of a reliable solution When unexpected repairs threaten production, having access to a dependable, high-performance air solution can make all the difference. The E-Air V1100 portable compressor combines advanced technology with practical benefits that matter in real-world operations: minimizing downtime, ensuring consistent air supply, and delivering efficiency even in challenging environments. Solutions like the E-Air V1100 are designed to keep businesses moving forward. In tougher industrial manufacturing conditions, they are often the better choice over traditional air compressors. They do not just solve short-term challenges but help reduce the risk of unexpected repairs and downtime in the long run. Built for demanding environments and outdoor conditions, these units deliver consistent performance where traditional compressors might struggle. Its ability to operate outdoors is a significant advantage: freeing up valuable indoor space for production, which ultimately drives revenue. With more uptime and fewer issues in tough working conditions, the E-Air V1100 can fully replace conventional stationary compressors, providing flexibility without compromising reliability. In many facilities, relocating compressors outside can even enable production expansion without costly building modifications, making it a smart strategic move. For manufacturers, this translates into greater operational continuity and confidence in their compressed air supply. A reliable way to keep production moving In automotive manufacturing, every second counts, and when standard compressors fail, production facilities can face significant challenges that threaten schedules, customer commitments, and overall efficiency. Having access to a dependable, high-performance alternative ensures that operations continue without interruption, reducing the risk of costly downtime and providing a solution that supports both short-term continuity and long-term reliability in demanding industrial environments. This proactive approach not only safeguards productivity but also helps companies maintain their reputation for delivering on time, even under unexpected circumstances.

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Flexibility in Manufacturing

Marcie Palmer — Tue, 23 Dec 2025 13:31:51 +0000

How Modular Conveyor Systems Support Agile Production in Plastics Applications In a manufacturing environment defined by frequent change, operational flexibility is now a competitive necessity. Product lines shift frequently, facility layouts change, and customer demands can pivot overnight. For operations leaders, one of the most essential components of flexibility is the conveyor system. Once viewed as a static component of plant infrastructure, conveyors have evolved into highly configurable tools that can support rapid change, streamline processes, and drive long-term cost savings. This shift is being driven by the rise of modular conveyor systems—customizable, reconfigurable platforms that adapt alongside production needs. Unlike traditional fixed systems that require substantial effort to modify, modular conveyors are designed to change with minimal downtime, labor, or capital expense. The Flexibility Imperative Traditional conveyor systems, while robust, often lack the adaptability necessary for modern manufacturing in plastics applications. In the past, introducing new product lines or adjusting production cells typically meant costly and disruptive overhauls. Modular conveyor systems solve these problems by enabling users to easily add, remove, or rearrange components. Labor challenges underscore the need for flexibility. With labor costs rising and high turnover, manufacturers need systems that reduce manual labor and simplify training. Modular conveyors minimize downtime through quick reconfigurations and automate product handling. Additionally, modular conveyors can be precisely tailored to product specifications. For example, a production line initially designed with flat conveyors can integrate incline modules to maximize space utilization or adapt to new equipment configurations. It is helpful to think of these modular systems as “building blocks,” allowing manufacturers to adapt their infrastructure without a major overhaul incrementally, improving manufacturing efficiency and reducing waste. Maintenance, Cost, and Safety Benefits A key advantage of modular systems is their low maintenance components. Components are typically off-the-shelf, enabling rapid replacement and minimal downtime. Parts standardization significantly reduces maintenance and inventory costs, and manufacturers benefit from volume pricing and straightforward spare parts management, enhancing the overall cost-effectiveness of these systems. Equally important, modular systems deliver significant safety benefits. Modular conveyor systems inherently reduce ergonomic risks by automating tasks traditionally performed manually. Modular systems mitigate pinch points while protective covers, hoppers, and modular safety accessories minimize injury risks. Conveyor systems can be made to comply with the specifications of OSHA, UL, and NFPA, ensuring the equipment meets local regulatory requirements and your company’s production needs. Supporting Smarter Automation As automation expands across industries, modular conveyors have become essential for flexible, future-ready production lines in the plastics industry. Their value lies in both their ability to adapt quickly to new processes and the range of accessories that enable seamless integration with automated systems. Modular conveyors with plug-and-play controls and accessories, such as metal detectors, hoppers, chutes, ionizers, and reject arms, can be easily configured for new products or regulatory needs. For example, hoppers and chutes help plastics manufacturers contain and guide molded parts or products, minimizing scrap and ensuring controlled flow during handling and packaging, while metal detectors in plastic lines prevent contaminants from damaging downstream equipment. Belt options like anti-static or easy-release surfaces allow facilities to handle diverse products and fit conveyors into tight areas with changing production layouts. These accessories address real operational challenges. Additional automation accessories such as integrating sensors and vision systems enables automated quality checks, such as counting, leak detection, or short-shot detection, supporting one-piece flow and reducing defects. By enabling quick adaptation, whether adding a cooling fan, swapping a belt, or installing a diverting arm, modular conveyors help operators maintain productivity and meet KPIs. Seamless integration with automation also supports real-time data flow, predictive maintenance, and Corporate & regulatory compliance needs. With the right accessories, a conveyor becomes more than a transport tool-it’s a dynamic platform that helps manufacturers optimize efficiency, quality, and safety as their operations evolve. ROI Considerations Though modular conveyors may cost more upfront than fixed systems, their long-term value is greater, especially for companies with uncertain or seasonal demand. Manufacturers can build in phases, scaling systems as needs grow, which spreads out capital costs through fiscal cycles and allows for more accurate planning, risk mitigation, and adaptability. From an engineering perspective, modular systems, like those designed by Dynamic Conveyor, an industry leader in conveyor technology, are built on standardized, interchangeable modules. This allows engineers to quickly reconfigure layouts, add incline or decline sections, or adapt to new equipment heights by simply inserting or removing specific modules without the need for custom fabrication or extended downtime. For example, if a production process changes from handling flat items to taller products, engineers can swap in taller flights or switch to a different belt surface to maintain throughput and product integrity. Scalability is particularly valuable for operations navigating fluctuating order volumes or evolving workflows. A facility can quickly add modules to accommodate peak season demand, or reconfigure existing lines to support new products-without the disruption and expense of a complete system overhaul or replacement. This flexibility ensures that conveyor investments remain aligned with actual business needs, reducing the risk of over- or underspending on automation infrastructure. Maintenance costs also tend to be lower with modular systems. Standardized, off-the-shelf components can be quickly replaced, minimizing downtime and simplifying spare parts management. Many modular designs are engineered for tool-less maintenance, allowing plant staff to perform repairs or adjustments without specialized training or lengthy shutdowns. For engineers and maintenance teams, this means less time troubleshooting and more time focused on optimizing production. Energy efficiency further enhances long-term ROI. Modern modular conveyors often feature variable-speed drives and high-efficiency motors, which help reduce energy consumption and operating costs over the system’s lifecycle. And because modular systems can be reconfigured or expanded without replacing the entire line, the total cost of ownership remains lower, even as production requirements change. For manufacturers evaluating these investments, seeking companies with decades of experience offers a useful benchmark. For more than 30 years, Dynamic Conveyor has helped companies in sectors from plastics to food processing realize rapid ROI by scaling systems as their needs evolve. In one case, a

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Irish drinks manufacturer increases speed, efficiency and safety with Prorunner mk5

Mon, 22 Dec 2025 15:42:14 +0000

A beverage manufacturer has installed a Qimarox vertical conveyor in its Irish factory. This Qimarox Prorunner mk5 ensures smooth transport of beverage packaging from the production floor to higher levels, where the next stage of product processing takes place. The Irish Qimarox partner Noreside Engineering is responsible for the implementation of the project. The result: smoother flow, a safer working environment and increased efficiency. Due to increasing demand, the beverage manufacturer has expanded production capacity, putting pressure on existing processes. This is particularly applicable to vertical transportation from the production floor. Moving cardboard boxes to higher levels was done largely manually and with forklifts. This resulted in inefficiencies in the process, delays in throughput, and unsafe situations. What the company needed was a robust vertical transport system that would seamlessly integrate with its existing conveyors and meet the stringent requirements of food production. To this end, Qimarox has partnered with Noreside Engineering, a Kilkenny-based system integrator with extensive experience in process automation in both the food and pharmaceutical sectors. Noreside provided the local expertise and project management, Qimarox the proven vertical transport technology. High capacity, compact footprint Noreside designed and integrated a stainless steel conveyor system into the final packaging process for the beverage manufacturer. This system handles the transport of beverage packaging from the production floor to higher levels, where the boxes are further processed and finally palletised. The heart of this system is the Prorunner mk5 from Qimarox. The Prorunner mk5 is a continuous vertical transport system that offers high throughput and a compact footprint, low energy consumption, and low maintenance. The modular design makes integration into the Noreside conveyor system easy, resulting in a smooth and reliable connection between the different levels. Thanks to the modular design, capacity can easily be scaled up in the future. All components are made of stainless steel and comply with Good Manufacturing Practice (GMP) and European Hygienic Engineering & Design Group (EHEDG) guidelines. Significant improvements Manufacturers around the world use the Prorunner mk5 for their vertical transport challenges in high-volume environments. In this project, this proven solution from Qimarox was selected for several reasons: It moves packaging of various shapes and sizes, from boxes to crates. It enables continuous high-capacity transport. It saves valuable floor space thanks to its compact design. It consumes little energy, requires little maintenance, and has a long lifespan. Since the installation, the Irish drinks manufacturer’s operations have significantly improved in several areas: Greater flow without stagnation during vertical transport. Safer working environment by reducing manual work. Compliant with GMP and EHEDG standards due to hygienic design in stainless steel. Optimal use of space compared to the use of forklifts. The end result is an improved final packaging process with a smooth flow of goods from the packaging machine through to the distribution process, taking the beverage manufacturer’s supply chain performance to the next level.

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Nord: A Heavy Lift

Mon, 15 Dec 2025 14:54:22 +0000

How OMi Crane Systems works with NORD DRIVESYSTEMS to keep manufacturing moving Whether it’s moving a coil of sheet steel to a stamping line or setting a massive cast iron forging onto the bed of a CNC boring mill, manufacturers depend on cranes, trolleys, and hoists to lift and transport heavy objects. This is the job of OMi Crane Systems, a company that’s been designing, building, and servicing industrial lifting systems since 1969. Founded in Dallas, Texas, the manufacturer has long since moved to nearby Royse City, where it now boasts a 76,000-square-foot manufacturing facility, more than 100 skilled employees, and a support network that includes three full-service branches in Houston, Dallas, and Alabama, along with satellite service teams operating out of Florida and Ohio. OMi sells many of its cranes to companies in its home state, but as Vice President of Operations Brandon Rue proudly points out, the manufacturer has customers in New York, Washington, Ohio, and many places in between. “We ship all over the country,” he says. Unlike companies focused on ports or marine work, OMi specializes in indoor overhead cranes—mainly electric overhead traveling cranes that operate inside steel warehouses, coil handling plants, and metal fabrication facilities. Its products aren’t mass-produced, however. “Everything we make is engineered to order,” Rue explains. “That’s because every facility is different, and every customer calls for different lifting capacities, travel speeds, duty cycles, and so on. That said, probably 95% of the gearmotors on our heavy duty OEM components come from NORD DRIVESYSTEMS.” Tightly Focused It’s a relationship that spans more than 25 years. At first, OMi began using NORD gearboxes and motors on a fairly selective basis, but the partnership deepened around 2011 when OMi started building its own hoists. That move called for bigger gearboxes and more horsepower—and it made ready-made drive solutions even more critical. NORD provides a complete, preassembled unit that fits neatly into OMi’s production flow. “We didn’t start using NORD almost exclusively until we started offering a complete hoist that we build in house,” Rue says. “A lot of suppliers in this industry will make a gearbox and then put a motor on it, and sometimes vice-versa, but not only does that slow everything down, it also makes it harder to get parts. We didn’t want to go that route, so we decided to standardize on NORD gearmotors—motor, brake, and gearbox—roughly 15 years ago. Since then, we’ve found that using pre-engineered drive units directly from the catalog makes it easy to customize to our customers’ needs, which is where we differentiate ourselves from the competition.” At its core, OMi specializes in the design and manufacturing of electric overhead traveling cranes. Unlike many suppliers that offer off-the-shelf systems, OMi takes a customized approach, tailoring every crane to the exact specifications of the building and the application it serves. “Yes, there are similarities between jobs and customers, but every crane fits a specific building layout and a specific application, so the ability to optimize each one is hugely important.” Most of OMi’s cranes are designed for indoor environments such as manufacturing plants and coil handling facilities. While the company can also produce outdoor gantry cranes, its primary focus remains on precision indoor lifting, with steel processing and warehousing centers representing its largest market share. The demands of these industries are unique. Steel coils, for example, can weigh tens of thousands of pounds, and facilities often run 24/7 operations where a stalled crane can halt production. Many of OMi’s customers require cranes that not only lift heavy loads but also perform a high number of cycles each day without overheating or wearing down prematurely. That makes the engineering behind each crane and its components critical to long-term reliability. One of the standard and most requested options on an OMi crane is the company’s “built-up hoist and trolley” system. As Rue explains, these assemblies are often the most customized and technically demanding parts of the crane. “The hoist does all the work, which is why we’ll often use one of the bigger NORD units, such as the SK 10 with a hundred-horsepower motor.” Customization Conundrum This broad horsepower range—from half-horsepower travel motors to the 100-horsepower hoist drive just mentioned—gives OMi the ability to spec out each crane’s lifting capacity exactly to the application. Yet speed is also crucial. In high-throughput environments like coil warehousing, even minor differences can significantly impact production, which is why it’s not uncommon for customers to request lifting speeds tailored to the flow of their assembly lines or staging areas, where even seconds shaved off a cycle can add up to meaningful gains over time. “We cater the hoist to our customers’ needs, “Rue says. ” For instance, a couple of feet a minute on a hoist, when spread out over several days or a week, makes a big difference in the number of picks they can make. So, if they want the hoist to go 21 feet per minute instead of 19 feet per minute, we make it go 21.” As any manufacturer knows, delivering this level of customization day after day can be expensive. Piecing together motors and gearboxes from different vendors wasn’t an option for a company focused on delivering made-to-order systems at scale. Eliminating assembly steps inside OMi’s factory also reduces risk during final crane assembly, since every matched set arrives from NORD already configured for integration. “To remain competitive, we need to build a crane as quickly and efficiently as we can,” Rue says. “Ease of manufacturing played a big role in our decision to partner with NORD.” Using standardized components also helped to streamline OMi’s engineering process. The company’s design team can size and select drives from NORD’s catalog without relying heavily on external technical support, and they routinely use myNORD online customer tools to quote units, download 3D models, and generate drawings directly compatible with OMi’s internal CAD libraries. “We size it, we pull the drawings, and we drop it into our models,” Rue explains. “It’s simple and

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JLG invests in the future of skilled trades

Wed, 10 Dec 2025 20:35:44 +0000

JLG is rebuilding the trades from the ground up. Building talent, growing communities, and upskilling craft professionals JLG Industries, Inc. is addressing skilled labor shortages and workforce development by taking an intentional, people-first approach to rebuilding the industrial talent pipeline in America. As many manufacturers are feeling the strain of a shrinking skilled labor force, JLG’s story is unfolding differently — one rooted in classrooms, welding and paint booths, factory floors and trade schools. JLG is not waiting for workforce solutions to arrive; it is creating them. Through partnerships with high schools, technical colleges, trade associations and industry organizations, the company is helping students discover careers in the trades while giving current workers opportunities to advance their craft. The result is a growing community of homegrown welders, painters, assemblers, manufacturing and robotics engineers, maintenance professionals, service technicians and equipment operators ready to power the future of construction and manufacturing. “In America today, there are more students who want hands-on technical education than there are classroom seats available,” said Andy Tacelosky, chief operating officer at JLG. “We saw an opportunity, not just to hire talent but to help create it one student, one trainee and one craft professional at a time. These programs give people a pathway to build a career, earn a living and stay in the communities they love.” School-to-Work: Cultivating New Craft Professionals in Pennsylvania JLG’s School-to-Work (S2W) program allows high school juniors and seniors local to its manufacturing facilities in McConnellsburg, Shippensburg, Bedford, Greencastle and Chambersburg, Pennsylvania, to earn school credit while working paid roles in welding, assembly, painting, fabrication, warehouse support and more. Students receive real-world experience, mentorship and the chance to transition into full-time roles after graduation. S2W+ — an advanced extension of the program — places students in specialized roles like maintenance, robotics, machining, engineering and testing for deeper technical exposure. “Our School-to-Work program gives young people a real opportunity to help us rebuild the future of the skilled trades,” says Tacelosky. “These are students who want to work with their hands and solve real problems, but the classroom alone can’t always give them that experience. Through S2W and S2W+, they earn school credit, a paycheck and the chance to work alongside experienced professionals. We’re creating more skilled workers in the Pennsylvanian communities where our team members live and work, as well as shaping the next generation of craft professionals and manufacturing leaders.” TCAT Partnership: Developing Technical Talent in Tennessee Starting in 2025, JLG established a partnership with the Tennessee College of Applied Technology (TCAT), which is in close proximity to the company’s manufacturing facility in Jefferson City, Tennessee, to integrate technical education with real-world factory experience. After campus visits, interviews and plant tours, several students are now working part-time on JLG’s maintenance team while attending school. These students rotate between first and second shift to learn from specialists across multiple disciplines “This is what modern technical education should look like,” said Tacelosky. “Students are learning in class and applying it in real-world situations the same day.” Upskilling the Trades: Investing in Team Members While JLG is deeply committed to developing future talent through schools, the company is equally focused on investing in those already working in the trades. Through its internal trainee programs, JLG is helping current team members and new hires advance into high-demand skilled positions — particularly in areas like welding and industrial painting, where manufacturers across the country struggle to hire experienced workers. JLG’s Weld Trainee Program provides entry-level team members and external candidates with the opportunity to become certified welders. Participants complete three to four weeks of classroom and lab-based instruction, followed by three weeks of on-the-job training alongside experienced JLG welders. Similarly, the Paint Trainee Program is designed to develop industrial painters from within the workforce. Through hands-on training and mentorship, participants gain the skills needed to move into full-time painter roles. “Welding and painting require skill, safety, precision and pride in craft, and these are often some of the most difficult roles in manufacturing to fill,” says Tacelosky. “Instead of waiting for talent to come to us, we’re choosing to grow it — building careers and strengthening our workforce for the future.” Beyond JLG: Partnering to Build the Industry JLG’s workforce commitment goes beyond its own facilities. The company partners with trade associations, unions, training schools and equipment rental providers to upskill craft professionals across North America in operating and servicing MEWPs (mobile elevating work platforms) and telehandlers. These partnerships include organizations such as: Associated Builders & Contractors (ABC), Association of General Contractors (AGC), Association of the Wall & Ceiling Industry (AWCI), Mason Contractors Association of America (MCAA), Steel Erectors Association of America (SEAA), regional apprenticeships, trade unions, community colleges and correctional/vocational programs. “We know we can’t solve the skilled labor shortage on our own. That’s why we’re partnering with trade associations, unions, technical schools and industry groups to help upskill these professionals to bring real-world equipment, certified training and industry standards directly to the people who need it most,” says Tacelosky. “Working alongside these organizations, we’re not just training people; we’re helping them build lasting careers. It’s good for workers, it’s good for employers and it’s good for the future of the trades.” Through JLG® University, the company delivers hands-on operator training, telehandler service instruction and ANSI/OSHA-compliant safety education to thousands of workers each year — helping contractors and employers employ safe, capable crews. Creating the Future, Together These investments are not short-term initiatives; they are part of a long-term vision for American manufacturing. “We’re not just preparing people for jobs,” said Tacelosky. “We’re helping them build meaningful careers. And in doing so, we’re helping strengthen the trades, the industry and the communities we’re proud to call home.”

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MIT–Mecalux study finds AI now embedded in 60% of warehouses, reshaping productivity and workforce models worldwide

Mon, 01 Dec 2025 16:49:17 +0000

Research from Mecalux and the MIT Intelligent Logistics Systems Lab, based on a survey of 2,000+ logistics leaders, shows rapid automation and AI adoption, 2–3 year payback periods, and rising demand for high-skill warehouse roles. As retailers brace for the annual surge of Black Friday demand, a new study from Mecalux and the MIT Intelligent Logistics Systems (ILS) Lab at MIT’s Center for Transportation and Logistics reveals that the warehouses powering today’s global supply chains have entered a new era of intelligence. The research, drawing on responses from over 2,000 supply chain and warehousing professionals across 21 countries, shows that artificial intelligence and machine learning are no longer experimental tools but core drivers of productivity, accuracy, and workforce evolution. With more than 9 out of 10 warehouses now using some form of AI or advanced automation, the sector has reached a surprising level of maturity. Over half of surveyed organizations report operating at advanced or fully automated maturity levels, especially among larger businesses with complex multi-site logistics networks. Warehouses have moved well beyond isolated pilots in that AI increasingly supports day-to-day workflows, including order picking, inventory optimization, equipment maintenance, labor planning, and safety monitoring. “The data show that intelligent warehouses outperform not only in volume and accuracy, but in adaptability,” says Javier Carrillo, CEO of Mecalux. “As peak season approaches, companies that have invested in AI aren’t just faster — they’re more resilient, more predictable, and better positioned to navigate volatility.” The study also finds that AI investments are paying off more quickly than many expected. Most businesses now dedicate between 11% and 30% of their warehouse technology budgets to AI and machine-learning initiatives, and the typical payback period is just two to three years. These returns stem from measurable gains in inventory accuracy, throughput, labor efficiency, and error reduction. They also reinforce a shift from exploratory spending to long-term capability building. Cost savings, customer expectations, labor shortages, sustainability goals, and competitive pressure all drive these investments, demonstrating that AI’s value extends far beyond automation alone. Despite this progress, organizations continue to face challenges as they scale AI across their operations. “The hard part now is the last mile: integrating people, data, and analytics seamlessly into existing systems,” says Dr. Matthias Winkenbach, Director of the MIT ILS Lab. The leading barriers include technical expertise, system integration, data quality, and implementation cost, reflecting the underlying work required to connect advanced tools with legacy systems. Even so, companies report strong foundations in data and project management, and they identify better tools, clearer roadmaps, expanded budgets, and stronger internal expertise as key accelerators for continued adoption. Crucially, the report challenges persistent fears about automation replacing human workers. Rather than supplanting human workers, AI is contributing to higher productivity, greater job satisfaction, and expanded workforce opportunities. More than three-quarters of surveyed organizations saw a rise in employee productivity and satisfaction after implementing AI tools, and over half reported growing the size of their workforce. New roles are emerging across the board, including AI/ML engineers, automation specialists, process-improvement experts, and data scientists — evidence that intelligent automation is expanding, rather than reducing, the human role in warehouse operations. Looking ahead, nearly every company surveyed plans to scale up its use of AI over the next two to three years. An overwhelming 87% expect to increase their AI budgets, and 92% are currently implementing or planning new AI projects. The next frontier, the report shows, will center on decision-making technologies — especially generative AI. Businesses identify generative AI as the single most valuable method in today’s logistics facilities, citing applications such as automated documentation, warehouse-layout optimization, process-flow design, and even code generation for automation systems. As these capabilities advance, AI will help a growing number of warehouses move from predictive insight to automated action. “Traditional machine learning is great at predicting problems, but generative AI actually helps you engineer the solution,” says Dr. Winkenbach. “That’s why companies see it as the biggest value generator in the warehouse today. Ultimately, the measurable gains from automation are productivity wins, making existing systems work smoother, faster, and with fewer disruptions.” The study underscores that as the logistics sector enters the year’s busiest season, the warehouses behind Black Friday orders are not only becoming more automated, but also more intelligent systems. With AI boosting performance, supporting workers, and enabling new capabilities across global networks, the coming years propose even deeper integration of data and decision-making into the core of warehouse operations.

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Patika and Wiferion enable flexibility and agility in modern intralogistics

Wed, 26 Nov 2025 14:55:10 +0000

More orders, fewer staff: more and more production and logistics companies are turning to automation to meet the current challenges of the market. Mechanical engineering companies offer a broad portfolio of solutions, but a coherent overall package is crucial for efficient warehouse processes. Patika Robotics offers a new, innovative generation of automotive transport robots – which the Turkish company combines with Wiferion’s inductive charging solution to create a powerful complete solution. There are many methods for maximizing a company’s profits. In Turkey, five tech-savvy friends saw one solution in particular: intelligent robots. Driven by a shared passion, they founded Patika Robotics in 2018 and developed their first autonomous vehicle. Six years later, the company, headquartered in Istanbul, Turkey, has grown to 15 employees and is leading a new generation of autonomous mobile robots (AMR) with a payload capacity of up to 4 tons for use in the automotive, textile, energy storage and metal industries. As a new in-house supplier to a major German corporation, Patika Robotics has opened a second production site in Germany in addition to its plant in Sakarya, Turkey: The company’s European customers are now supplied from the service and production center in Neuwied. They receive a high-performance dual package that combines an intelligent transport system with an efficient charging structure. The cooperation between Patika and Wiferion shows how promising a common innovative denominator can be. Non-invasive and flexible: Patika and Wiferion bring movement to the industry Unlike some other driverless transport vehicles, the PTK1350 autonomous transport robot from Patika does not require a network of magnetic strips to define its movement routes, but can navigate freely and maneuverably even through narrow aisles. “We wanted to develop a robot that does not require any adjustments to the existing infrastructure or special markings,” says Halil Ibrahim Doksanoglu, General Manager bei at Patika. “The PTK1350 can be installed without much effort. This makes it easy and cost-effective to use. This is precisely why we opted for Wiferion’s cahrging solution. etaLINK 3000 can be integrated into existing warehouses just as easily and without complications.” Wiferion’s inductive charging system for the latest generation of intelligent and autonomous robot systems does not require any major structural changes. Instead, the charging pads are placed in a few strategic locations in the warehouse so that they are easily accessible for AMR and ensure a reliable power supply. In this way, Wiferion enables the intermediate charging of batteries without plug and sliding contacts. With “in-process charging”, companies not only save time, but also potential dangers that can arise from open charging contacts, for example. Charge efficiently, work efficiently: inductive charging for continuous operation The combination of PTK1350 and etaLINK 3000 is not only easy to implement, but is also characterized by high efficiency. Thanks to patented adaptive fieldset technology, the PTK1350 maneuvers quickly around people and corners and can navigate dynamic and changing environments without compromising safety. Integrated cameras, scanners and intelligent software enable seamless navigation through doorways, tunnels and elevators. Targeted control of the charging pads is also possible without any problems. As a charging pad from Wiferion can be approached omnidirectionally by a large number of different vehicles, a high positioning tolerance is guaranteed. With an efficiency of 93% and energy transfer from the first second of contact, etaLINK is a particularly efficient charging solution. The lightweight chassis of the PTK1350 and its cladding made of 100 percent recyclable aluminum , which makes it robust despite its low weight, ensure additional efficiency . Secondly, the PTK1350 has a long operating time of at least eight hours. Short charging interruptions are sufficient to keep the robot in continuous operation – the perfect prerequisite for etaLINK 3000, which enables short charging phases without affecting the operating process. The icing on the efficiency cake is provided by Patika’s specially developed software for autonomous navigation and fleet management at . With Patika Fleet Manager, companies can track and manage the battery performance and job list of their robots at any time. The intuitive visual interface makes it particularly easy to define jobs, assign routes, monitor the status of individual robots and adapt to changes in the plant. Patika and Wiferion: a symbiosis for maximum efficiency in intralogistics An agile transport system with a small footprint and minimal infrastructural adjustments offers companies a wide range of opportunities to make their logistics processes more efficient. Patika and Wiferion combine efficiency, agility and safety in an intelligent robot solution with an inductive charging structure and support companies in optimizing their operational processes. The success of the cooperation is primarily due to the high compatibility of both systems . Both AMR and the charging system are non-invasive, flexible and low-maintenance. The inductive charging solution supports the flexibility of the PTK1350 while maximizing uptime. “With our autonomous transport robots from the PTK1350 series, we automate all intralogistics processes within a company facility and thus contribute to greater efficiency. Fully automated operation allows warehouse employees to focus on tasks other than manual transportation, which saves time and personnel costs,” says Halil Ibrahim Doksanoglu. ” The etaLINK system is an important sales argument for us, which we use as standard hardware in all our robots. The high efficiency resulting from the combination of both systems has another key benefit: the use of our AMR and Wiferion’s inductive charging solution has a positive impact on a company’s CO2 balance.”

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Empowering Yale, Hyster & TCM Forklift Operations in Europe with ROYPOW Lithium Forklift Batteries

Sat, 22 Nov 2025 20:13:46 +0000

As the material handling industry across Europe continues to embrace electrification, more forklift fleet operators are turning to advanced lithium battery solutions to meet the growing demands for efficiency, safety, reliability, and sustainability. ROYPOW’s lithium forklift batteries are driving this transition, delivering reliable power to a wide range of forklift brands, including Yale, Hyster, and TCM, across diverse industrial sectors. Boost the Material Handling Productivity of Yale Forklifts for A Factory At a busy European factory, Yale ERP 50VM6 forklifts are mainly used for internal logistics and material handling. However, the fleet is powered by lead-acid batteries, which pose ongoing challenges, including frequent maintenance and long charging times. These issues have disrupted daily operations and reduced overall manufacturing productivity. To address these challenges, the factory upgrades its Yale forklifts with ROYPOW 80V 690Ah lithium batteries. Designed for high-performance industrial applications, ROYPOW lithium batteries offer drop-in replacement, deliver consistent power output, support fast opportunity charging, and require zero daily maintenance, eliminating the operational issues associated with lead-acid solutions. With the battery upgrade, maintenance and charging downtime have been minimized, contributing to significant improvements in operational efficiency and forklift availability at the factory, supporting uninterrupted shifts. ROYPOW’s product quality and professional, responsive service have also been highly appreciated. Optimize the Operation Efficiency of Hyster Reach Trucks for A Warehouse Over one hundred Hyster R1.4 reach trucks are deployed for intralogistics operations in a European warehouse. In such an environment, where uptime is critical, these forklifts require reliable, efficient power to support the workflow. To enhance performance and reduce downtime, the warehouse transitions its fleet to ROYPOW 51.2V 460Ah lithium forklift batteries. These batteries are engineered for heavy-duty warehouse use, supporting both fast charging and opportunity charging. With the new lithium batteries in place, the warehouse has a more flexible charging schedule. The fleet can recharge between shifts and breaks, maximizing productivity and operational efficiency without disrupting workflows. Enhance the Outdoor Performance of TCM Forklift Operations A European logistics operator deploys TCM FHB55H-E1 forklifts powered by lead-acid batteries for outdoor operations in challenging environments, where exposure to dust and moisture demands reliable and durable battery solutions. To overcome it, the operator retrofits their TCM forklifts with ROYPOW lithium batteries. Engineered for durability and high performance, ROYPOW lithium batteries feature IP65-rated protection, ensuring reliable operation in demanding outdoor environments. They are drop-in replacements for lead-acid batteries, requiring no modifications to the forklifts. In addition, they eliminate common drawbacks of lead-acid batteries, such as a short lifespan, slow charging, and frequent maintenance. As a TCM operator noted, “One lithium battery replaced three lead-acid units—our productivity soared.” Why Choose ROYPOW Power Solutions for Modern Material Handling ROYPOW has always focused on developing cutting-edge lithium forklift battery solutions that deliver superior reliability, efficiency, and safety, and advancing the transition from lead acid to lithium, making it the preferred choice among global top forklift brands, with thousands of successful custom deployments every year. ROYPOW lithium forklift batteries, with a wide range of voltage systems for different forklift models, feature industry-leading product performance, including high-quality grade-A automotive-grade LiFePO4 cells, UL2580 certification across all voltage platforms, intelligent BMS management, and built-in unique fire extinguishing systems. To meet demanding applications, batteries for cold storage and explosion-proof batteries are designed for premium safety and performance in extreme conditions. These solutions have been proven to help lower the total cost of ownership and enhance long-term operational profitability, making the investment more worthwhile. Supported by strong strengths covering R&D, manufacturing, quality control, and testing, as well as an expansive global presence with subsidiaries in the USA, the UK, Germany, the Netherlands, South Africa, Australia, Japan, Korea, and Indonesia, ROYPOW is well-positioned to serve the evolving needs of the global material handling market. Looking ahead, ROYPOW will continue to drive innovation, helping forklift fleets worldwide to advance smarter, safer, more efficient, and more sustainable operations. About the Author: For further information and inquiry, please visit www.roypow.com or contact marketing@roypow.com.

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Ensuring packaging excellence: How PAC Strapping Products transformed SmartCap’s Packaging Process

Mon, 17 Nov 2025 15:23:27 +0000

SmartCap is revolutionizing the truck accessory industry with the world’s first modular stainless steel truck cap system. Its 5-piece modular design allows customers to configure their truck beds exactly as needed, seamlessly integrating accessories to build an organized and functional space. With a focus on high-quality craftsmanship and innovation, SmartCap’s products are designed to endure and excel in the toughest conditions. After seeing much success, SmartCap decided to expand its reach to the U.S. to better reach its North American customers, and as part of that expansion, it sought alternative packaging solutions for its new state-of-the-art facility in Fort Worth, Texas. Packaging and Labor Challenges Lead to Automation Advancements While SmartCap’s South African plant produced high-quality products, the company faced the common industry challenges of labor turnover and inconsistencies in packaging that were a result of some manual processes. With the U.S. expansion, SmartCap saw an opportunity to shift from labor-based packaging methods to an even more automated approach, ensuring greater efficiency and consistency across all operations. This decision was key to maintaining their competitive edge and overcoming the challenges posed by labor shortages in the packaging industry. The U.S. plant in Fort Worth was designed with automation in mind, taking advantage of PAC Strapping’s expertise in machine-based strapping solutions to streamline processes. Working with PAC, SmartCap was able to see how products were coming off the assembly line and implement an automated packaging process to enhance consistency, reduce manual labor, and address industry-wide issues such as high turnover rates. PAC Strapping’s Customized Solutions for SmartCap’s Needs PAC Strapping stepped in to address SmartCap’s packaging challenges by transitioning from a manual to a machine-based strapping process. This change significantly reduced the variation in packaging quality. PAC Strapping took a comprehensive look at SmartCap’s existing processes and made personalized recommendations to suit their specific needs. PAC installed two strapping machines at two different stations, strategically designed to handle products based on their size and weight. Since SmartCap was setting up a new plant, they wanted a lot of forethought in their packaging process to avoid the mistakes of the past. The collaboration between PAC Strapping and SmartCap was not a one-off transaction; it has been a continuous partnership. PAC Strapping has maintained its connection with SmartCap to thoroughly understand SmartCap’s processes and provided ongoing support. SmartCap chose PAC Strapping’s top-seal strapping machine for their long boxes. This machine uses a thicker polyester strap to hold SmartCap’s two truck caps securely in place. The packaged boxes, which often hold imbalanced loads, required a thicker strap to maintain stability during shipping. This solution not only increased the stability of the packages but also significantly reduced the risk of damage during transit, ensuring the high-value product’s safety. How Machine Strapping Solutions Bolster Business Bottom Lines The switch to machine-based strapping solutions provides several benefits to businesses’ bottom line: Reduction in Workers Compensation Claims: Manual steel strapping is notoriously dangerous, posing significant risks to workers. By using machines and safer strapping materials, PAC greatly reduced SmartCap’s risk of workplace injuries. Improving workplace safety not only helps retain talent but also boosts the company’s bottom line. Fewer injuries mean lower workers’ compensation costs and higher employee morale, both of which are integral to a healthy, productive working environment. Increased Efficiency and Reduced Costs: Automation directly contributes to higher efficiency. With fewer company resources required for training and recruitment, SmartCap can redirect these savings toward more productive activities. The lack of skilled workers in the packaging industry is a pain point felt industry-wide. Automated strapping systems require less manual input, reducing the time needed to package and strap materials effectively and the number of hands necessary to do so. Fewer Product Returns and Claims: Improved packaging consistency means fewer products are damaged during shipping, reducing the number of returns and associated costs. The cost of returns due to damaged products can be substantial. According to Forbes, the cost of a return for a $50 product is estimated at $33. Plus, damaged goods are one of the most common reasons a consumer returns a product. For a large, high-value product like SmartCap’s, this cost is significant. Not only do damaged goods cost companies financially, they also tarnish brand reputation which can have significant long-term impact. By automating packaging processes, ensuring each package meets the same high standards, SmartCap can now confidently ship products without worrying about damage or defects. PAC Strapping’s Customer-Centric Approach to Packaging Solutions PAC Strapping’s approach to tailoring strapping solutions for customers is comprehensive and client-focused. They begin with an in-person assessment to observe the client’s current processes, identify pain points, and listen to the customer’s pain points. During these assessments, PAC takes detailed notes and photographs to ensure they fully understand the challenges faced by the customer. Once the assessment is complete, PAC presents multiple options tailored to the customer’s needs, providing detailed quotes with line-item breakdowns. They offer both immediate solutions and scaled options for future growth, ensuring clients like SmartCap can start with a practical solution that fits their current needs while also planning for future scalability. Conclusion The partnership between SmartCap and PAC Strapping showcases the importance of customized, automated solutions in overcoming packaging challenges. By transitioning to a machine-based strapping process, SmartCap improved packaging consistency, reduced labor costs, and enhanced worker safety. “From the packing of our roofs to our sub-assemblies, our final packaging is large and quite bulky. Using PAC’s automated solutions has been a game changer for us in North America—reducing our reliance on labor and increasing our efficiency,” says Jan Strydom, Vice President of Manufacturing Technology. “Plus, PAC’s detailed approach not only solidified our trust in them, but enabled us to make empowered decisions for our business.” As industries continue to navigate the complexities of post-pandemic workforce dynamics and the ongoing challenges of labor shortages and turnover, the benefits of automation become increasingly clear. For companies like SmartCap, these solutions are not just about improving the bottom line; they are about building a resilient, future-ready operation that can adapt

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Dam wall proves no obstacle for Hoist & Winch

Mon, 17 Nov 2025 13:24:18 +0000

With many successful water industry infrastructure projects under its belt, leading industrial lifting equipment supplier Hoist & Winch was once again approached to provide a comprehensive and robustly tested lifting solution for a specialist marine subcontractor. This demanding reservoir application required the transfer of three large-diameter pumping station pipes – each weighing 30 tonnes – across the reservoir waters and up the inclined slope of its dam wall. As always, Hoist & Winch proved up to the task. This complex hire equipment project required a triple-aspect approach. Firstly, to move each pipe across the water, Hoist & Winch had to supply, install, commission, load-test and LOLER-certify two air-powered chain hoists offering 20-tonne safe working load (SWL). The company proposed a pair of JDN top-hook suspension air hoists, each with its own load chain collector box, air service unit and air supply hoses. The hoist units are each controlled by an individually connected, heavy-duty, air-powered pendant control. They were fixed to the customer’s free-standing fixed gantries on two fabricated floating pontoons (20t SWL), which Hoist & Winch also had to load-test and LOLER-certify. Secondly, Hoist & Winch was tasked with providing a similar package of services for a large-capacity hydraulic winch system. Here, the company recommended a 12t SWL floor-mounted hydraulic winch with wire rope, diesel-powered hydraulic power unit, joystick control stand and interconnecting hoses. The winch was required to pull each pipe up the inclined slope of the reservoir’s dam wall in conjunction with two rail-mounted travelling gantries (20t SWL) fabricated by the customer. Lastly, the customer wanted Hoist & Winch to supply four 15t SWL manual chain blocks. The Tiger top-hook suspension type manual chain blocks proposed by Hoist & Winch would support each pipe from the rail-mounted travelling gantries following transfer from the air hoists in readiness for winching up the slope of the dam wall. Hoist & Winch technical support experts partnered closely with the main contractor’s civil and mechanical engineers throughout this safety-critical project, with strict approval procedures in place. Load testing of the two air hoists and their supporting gantries was facilitated by a 20t/25t skid-mounted dynamic proof-test load. Working closely with the marine subcontractor’s dive team, the test weights were initially positioned on the reservoir bed. Dynamic load testing of the hydraulic winch took place in two stages, firstly using an interim site test load comprising lighter concrete components, which also required winching up the reservoir’s dam wall. A further dynamic test was performed on the day of winching the first pipe. This activity was closely monitored to check all aspects of the winching system installation as work proceeded. Indeed, Hoist & Winch was tasked with operating the winch for the full duration of the first pipe lift up the dam wall slope while maintaining constant radio communication with the overall lift supervisor. As the night time closed in the very precise lifting operation had to continue and so the work was completed under floodlights. Hoist & Winch also provided various other aspects of technical consultancy, including guidance on lifting equipment legislation, lifting operation planning/management, the specification and procurement of a portable diesel-powered compressor, and operator handover training. “The final outcome was the highly successful movement up the reservoir dam wall of all three pipes in a finely controlled and smooth manner, which delighted both our customer and the end client,” says Hoist & Winch Director Andy Allen. “It’s yet another successful example of how our extensive experience and deep technical knowledge can provide the optimal solution for some of industry’s most challenging lifting and transfer operations.”

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Maximum performance for pouch filling machines

Mon, 27 Oct 2025 16:15:56 +0000

FAULHABER drive technology brings dynamics, precision and high availability in the tightest of spaces for packaging machines from Scaldopack. Speed is of the essence for packaging machines: Products must be filled, reliably sealed and prepared for shipping in the shortest possible cycles. Moreover, if food is being packed, the hygiene requirements are also high. To keep the total cost of ownership low, maintenance should rarely be necessary, and unplanned downtime avoided. The list of requirements is, thus, long and applies not only for the packaging machine itself but also to the components that are used, such as the drive technology. This article describes pouch filling machines that are used to pack both high viscosity foods and non-foods as well as products with particles. The Belgian company Scaldopack develops, produces, and services advanced spout-inserting machines and pouch-filling and sealing machines. Important here to the Belgians is that the manufactured packages be of very high quality, with a low error rate, stable production speeds as well as a high availability of the machines. At the same time, flexibility is also very important to them. Their systems can easily be converted from one batch to the next in just a short time. Depending on the system and application, changeover times range from just a few hours to less than 30 minutes in some cases. Moreover, all systems were constructed so that maintenance is rarely necessary and can be performed quickly. This also serves to keep the total cost of ownership of the machines low. Filling foods and non-foods Scaldopack offers a number of systems for the filling of pouches: several pouch filling machines and spout inserting machines, which insert the pouch closures into pouches of various sizes (figure 1). The filling machines differ in terms of throughput, i.e., how many containers can be filled per minute, and the type of the filled container: The Smartfiller Ecoline, for example, convinces with its flexibility. In addition to pouches, it can also fill bottles and containers. The Monofiller Multihead 4, on the other hand, can output 120 packages per minute thanks to the multi-head. Both food,s as well as other high viscosity products or products with particles, can be filled. Typical non-foods include gels, shampoos, lotions, soaps, conditioners, cleaning agents, plasticizers, auto oils or adhesives. Among the classic foods that can be filled with the system are baby foods, dips, hummus, sauces, peanut butter, honey, yogurt, juices, and alcoholic beverages. Manufacturers of sport gels, for example, also use systems from Scaldopack. These sport gels are used primarily by endurance athletes who need to perform at a high level and require a targeted, fast supply of energy and a reliable electrolyte balance. The Belgian company Scaldopack develops, produces, and services advanced spout inserting machines and pouch filling and sealing machines. Important here to the Belgians is that the manufactured packages be of very high quality, a low error rate, stable production speeds as well as a high availability of the machines. At the same time, flexibility is also very important to them. Their systems can easily be converted from one batch to the next in just a short time. Depending on the system and application, changeover times range from just a few hours to less than 30 minutes in some cases. Moreover, all systems were constructed so that maintenance is rarely necessary and can be performed quickly. This also serves to keep the total cost of ownership of the machines low. High performance for packaging But the packaging machines themselves need to perform at a high level as well. They often work around the clock, seven days per week. Breaks for maintenance, whether planned or unplanned, quickly become costly and, thus, need to be avoided. Anyone purchasing such a system also always has an eye on the TCO. In addition to the acquisition costs, there are also the maintenance costs, production quality and the avoidance of variables that can contribute to production errors. What applies for the system applies for the installed components as well. High performance is likewise demanded of the drive technology that is used (figure 3 a-c). Direct linear drives with built-in Hall sensors For smooth and efficient operation of the machines, Scaldopack uses BLDC motors from FAULHABER (figure 4). The direct linear drives with built-in Hall sensors enable a position accuracy of up to 0.1 mm with an acceleration of up to 4 g. This allows the pouches to be moved both quickly as well a precisely to the proper filling position. There, they are filled and sealed with the correct quantity of sport gel and then stacked in displays for shipment or sale. Because floorspace in production facilities is often expensive and, thus, limited, the used systems also need to occupy as little space as possible. In the compact machine, it is advantageous for the drive unit to have minimal installation space requirements. With a volume of 22 x 22 x 74 mm, it still achieves a peak force of 27 N and offers exceptional long-term reliability: Unlike conventional pneumatic components, it can operate continuously for nearly three years without maintenance. This fits in very well with the wishes of the equipment manufacturers to offer systems with low maintenance requirements. In addition to the reliability of the drives, system integration and operability of the machines are also decisive factors. The highly dynamic MC 3603 motion controllers used (Figure 5) perform the position control. Using standardized communication interfaces such as RS232, EtherCAT or CAN, set-points for control can easily be set or the drive can be integrated in the automation system. In the actual application, the CiA402 compatibility of the used motion controller enables simple integration in the EtherCAT control system of the filling system. The motion controller significantly simplifies not only the integration but also the necessary tests. This allows drive systems and machines to be optimally matched to one another to achieve peak performance. The application makes clear what a decisive role dynamic, precise, compact, low-maintenance and easy-to-integrate drive technology plays

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