As easy as riding a motorcycle: The twist grip allows you to guide and move the heavy spools with precision.

Vacuum Tube Lifter Simplifies Plastic Spool Handling

SCHEUERMANN + HEILIG GmbH previously handled heavy plastic spools manually. By implementing a Schmalz vacuum tube lifter, the company sustainably improved ergonomics and workplace safety by significantly reducing the physical strain on employees during daily operations.

Products used in the application

Characteristics of the success story

Industry	Plastics
Workpiece	Plastic spools
Product group	Vacuum Tube Lifter JumboErgo
Type of handling	Manual Handling

With Schmalz

kilograms

move ergonomically

The Customer: SCHEUERMANN + HEILIG GmbH

SCHEUERMANN + HEILIG GmbH is an internationally active metal forming company headquartered in Buchen, Baden-Württemberg, Germany. For nearly 70 years, this second-generation family-owned business has been developing and manufacturing highly precise stampings, metal stampings and formed parts, technical springs, and assemblies made from metal and plastic for demanding applications. Its key customer industries include medical technology and healthcare, automotive manufacturing, as well as electrical and consumer applications. Around 430 employees work every day to deliver cost-effective, quality-focused solutions and to ensure stable manufacturing processes for both high-volume production and specialized applications.

The Challenge

In day-to-day production operations at SCHEUERMANN + HEILIG, employees previously handled plastic spools with a diameter of 1,200 millimeters and a weight of 30 kilograms manually. The spools had to be lifted by hand, rotated 90 degrees, and then placed onto pallets. This workflow was an integral part of daily operations and was repeated regularly throughout the production process. Each handling step required significant physical effort. In particular, lifting and controlled rotation of the spools placed considerable strain on employees’ backs, shoulders, and arms. Given the physical demands involved, it became clear that the manual process was reaching its limits over the long term. Against this backdrop, the company began looking for a solution to support the handling process. The goal was to reduce the physical workload associated with daily handling of the plastic spools, meet ergonomic requirements, and ensure a high level of workplace safety. At the same time, the handling process needed to become not only easier, but also more reliable, sustainable, and practical for long-term use in production.

Schmalz solutions are easy to operate, ergonomic and reliable.

∼ Klaus Ballweg, Head of Technical Purchasing, SCHEUERMANN + HEILIG GmbH

Schmalz's Solution

SCHEUERMANN + HEILIG chose an ergonomic handling solution featuring the vacuum tube lifter JumboErgo from Schmalz. Designed for repetitive lifting and transfer tasks, the tube lifter enables smooth, precise, and virtually effortless handling of plastic spools with smooth surfaces. Operation is controlled via an ergonomic control handle that allows operators to accurately lift, lower, and release the load. The vacuum tube lifter JumboErgo is equipped with a swivel function that allows workpieces weighing up to 120 kilograms to be safely and ergonomically rotated by 90 degrees. This feature simplifies the positioning of the plastic spools while reducing physically demanding compensatory movements. Load handling is performed by a double suction gripper. Two suction plates ensure even load distribution and provide secure holding of the plastic spools throughout the entire handling process. The vacuum tube lifter JumboErgo is mounted on a KBG-C jib crane. This freestanding crane structure enables the handling system to be moved flexibly throughout the work area, particularly where ceiling-mounted systems are not feasible or desired. The supporting structure is an integrated SRA aluminum overhead crane system, which guides the tube lifter across the entire workstation. Its lightweight aluminum design allows exceptionally smooth system movement. As a result, employees can move and position the vacuum-gripped plastic spools safely, steadily, and with great precision. The combination of the vacuum tube lifter JumboErgo and crane system creates a perfectly coordinated handling solution. It helps eliminate physically demanding movements and significantly reduces work-related musculoskeletal strain in daily operations. Klaus Ballweg, Head of Technical Purchasing at SCHEUERMANN + HEILIG GmbH, summarizes: "Manually lifting and placing the spools was physically demanding for our employees. The vacuum tube lifter JumboErgo provides significant relief in our day-to-day operations."