We used to need two people to lift the panels. Today, one person can handle it alone, more ergonomically and much safer.∼ Lukas Züfle, Owner of Robert Züfle Carpentry
Vacuum Lifter Optimizes Panel Handling at Züfle Carpentry
At Robert Züfle Carpentry, large-format wooden panels measuring up to 5,000 × 2,000 mm are part of everyday operations. For a long time, handling these panels required a high level of manpower and involved significant physical strain. With the VacuMaster Wood from Schmalz, one person can now lift and position the panels safely, ergonomically, and efficiently. Workplace safety, throughput times, and productivity have all improved noticeably.
Characteristics of the success story
| Industry | Wood |
|---|---|
| Workpiece | Wooden boards |
| Product group | Vacuum Lifting Device VacuMaster Wood |
| Type of handling | Manual Handling |
With Schmalz
50
percent
less labor costs
250
kilograms
move ergonomically
The Customer: Robert Züfle Carpentry
Robert Züfle Carpentry is a family-owned business in its fourth generation, located in the Northern Black Forest. It combines traditional craftsmanship with modern processes and a state-of-the-art machine park. At Baiersbronn, the team led by owner Lukas Züfle delivers high-quality wood solutions, from custom interior fittings and bespoke furniture to kitchen concepts, as well as shopfitting and hotel interiors. With a team of six employees, the workshop processes and finishes large-format wooden panels and heavy workpieces on a daily basis. Quality and reliability are at the core of its operations, alongside a strong commitment to efficient, ergonomic, and future-oriented production. This is exactly where Züfle consistently relies on smart technology that provides tangible support for craftsmanship.
The Challenge
At Züfle, large-format wooden panels are part of everyday operations. Formats up to 5,000 × 2,000 mm and a variety of surface texture, from smooth to rough, placed high demands on handling. Safe gripping, lifting and precise positioning of the panels was physically demanding and required a lot of manpower. Previously, the team handled the workpieces manually and with a forklift: up to ten panels per shift, depending on the order volume. Typically, two people were required at the same time to lift and align the panels. As order volumes increased, it became clear that this approach was time-consuming, tied up valuable labor resources, and placed a noticeable strain on employees. For owner Lukas Züfle, it was clear that manual lifting was no longer a sustainable solution. “One person should be able to lift the sheets. Until now, two were needed,” he says, describing the core challenge. The goal was to significantly improve ergonomics, enhance workplace safety, and at the same time optimize productivity and throughput times. “We were looking for a solution that not only reduces strain but makes the entire process safer and more efficient,” says Lukas Züfle.
Schmalz's Solution
To optimize the handling of large-format wooden panels, the Züfle Carpentry opted for a coordinated handling system from Schmalz. The system includes a VacuMaster Wood in combination with a wall-mounted jib crane and an integrated chain hoist, ready for operation and designed for ergonomic, safe and precise lifting directly at the workstation. The VacuMaster Wood was specifically developed for woodworking applications. It is suitable for both airtight and porous wood-based materials and reliably handles MDF, OSB, and particleboard panels, regardless of whether their surfaces are smooth or rough. With a load capacity of up to 250 kg and the ability to move sheets up to 5,000 mm in length, the system fully covers the typical workpiece dimensions at Züfle. Special suction plates with high shear force absorption ensure a safe grip, while integrated warning devices and a vacuum reservoir enhance workplace safety. The vacuum lifter is guided by a wall-mounted jib crane with a swivel angle of up to 180°. The lightweight aluminum jib provides excellent smooth operation and precise positioning with minimal effort. A perfectly matched electrical chain hoist handles vertical lifting and lowering, quietly, smoothly and with high repeatability. The result: What previously required two people can now be done by a single person. Coordination effort, physical strain and waiting times are eliminated. Material flow becomes more consistent, throughput times are reduced and employees experience noticeably less strain. The system is completed by Schmalz’s straightforward service. An initial transport damage was resolved quickly and without any issues, a detail that confirms the reliability of the partnership for the Züfle Carpentry.
Vacuum lifter and crane form a coordinated material-handling system.
Intuitive operation of the VacuMaster Wood for safe panel handling.
Customer benefits through the Schmalz solution
ErgonomicsReducing physical strain on employees and optimizing workplace safety
EfficiencyFaster material flow and order processing
Seamless integrationQuick integration into existing workflows and a low-maintenance system
Products used in the application
Vacuum Lifting Devices VacuMaster Wood
- Handling of wooden boards and other porous workpieces
- Operator handle with integrated control of the lifting device and the chain hoist
- Controlled vacuum generator to reduce energy consumption for airtight workpieces
- Lift capacity up to 250 kg
Wall-Mounted Jib Cranes
- Mounted using a wall bracket or clasp bracket
- Lift capacity up to 1,000 kg