Custom 120 Ton Gantry Crane Drives Efficiency in Heavy Machinery Manufacturing

In the fast-paced world of heavy machinery manufacturing, efficiency is essential. One of Russia’s top producers of mining and construction equipment approached us with a challenge: they needed a high-capacity gantry crane that could improve efficiency and fit within a height-restricted workshop. Here’s how we turned that limitation into an opportunity to deliver a customized lifting solution.

Client Goal: Boosting Heavy Machinery Manufacturing Efficiency

The client, a market leader in the mining and construction machinery sector in Russia, sought to increase production capacity and improve material handling efficiency in their workshop. To keep pace with rising manufacturing demands, they required a heavy duty gantry crane capable of lifting extremely large and heavy components.

Their primary goals were:

• Achieving smooth and efficient crane operations under heavy loads.
• Ensuring long-term operational reliability to minimize downtime.
• Receiving timely and professional service support throughout the entire project lifecycle.

Key Challenge: Delivering Heavy Lifting Power in a Height-Limited Environment

Despite a strong need for higher capacity and improved efficiency, the client faced several limitations:

• Challenge 1: Limited Height Clearance in the Workshop: The factory’s design offered restricted vertical space, making it difficult to accommodate a traditional heavy-duty crane without compromising lifting performance or undergoing major structural changes.
• Challenge 2: Demanding Lifting Requirements: The crane needed to handle extremely heavy machinery parts – up to 120 tons – with high precision, safety, and frequency, all within the constraints of an indoor environment.
• Challenge 3: Project Timeline and Support Expectations: The client required a quick, efficient installation process to avoid production delays, along with ongoing technical support to ensure the crane’s long-term reliability and safety.

Our Tailored Solution: Low-Profile, High-Capacity Gantry Crane with End-to-End Support

We responded with a custom-designed 120/32t double girder gantry crane solution that addressed every concern:

• Compact Design to Maximize Vertical Space: By adopting a low-headroom structure, we made full use of the available height, allowing the crane to lift efficiently without modifying the building.
• Heavy-Duty Performance Built to Last: With a 120/32 ton load capacity, 18-meter span, and A5 work duty, the crane offers powerful performance for demanding applications – delivering stable and safe lifting operations around the clock.
• Professional Project Delivery: Our team offered complete lifecycle support – from technical consultation, solution design, and manufacturing, to timely delivery and installation guidance. This ensured smooth implementation and minimized disruption.

Delivering Results: 30% Higher Efficiency Without Structural Changes

Thanks to our tailored solution, the client achieved the following outcomes:

• 30% Improvement in Material Handling Efficiency: With the integration of the 120 ton double girder gantry crane, the client reported a 30% reduction in time spent on lifting and transporting large components within the workshop – directly accelerating assembly and production timelines.
• No Structural Modifications Needed: By designing a compact yet powerful crane system, we helped the client avoid costly and time-consuming building upgrades.
• Long-Term Reliability and Safety: The high-performance gantry crane delivered consistent, reliable lifting operations, minimizing downtime and enhancing workplace safety.
• Stronger Partnership Built on Trust: Our responsive, solution-oriented approach not only solved the client’s technical challenges but also built a long-term relationship based on confidence and collaboration.

By focusing on the client’s specific challenges and aligning our solution accordingly, we delivered a crane system that was not only technically sound but strategically valuable to their operations.

Facing similar constraints in your facility? Let us design the right lifting solution for your space, your load, and your business goals. Contact us today to explore how a customized gantry crane solution can improve your efficiency, save costs, and future-proof your operations.