A Twist Grip Instead of Brute Force

Concrete components impress builders with their durability, quick mounting, and minimal labor requirements on the construction site. Beton-Fertigteil-Union GmbH & Co. KG (BFU), headquartered in Schramberg-Waldmössingen, Baden-Württemberg, has been providing its customers with these solutions – including stairs, walls, balconies, and ceilings – since its founding in 1996. At three production sites, the company manufactures these building elements, which weigh several tons, with a workforce of about 80 employees.

The precast concrete elements are produced in formwork that the skilled workers in BFU’s carpentry shop have previously cut to exact dimensions. In the large production hall, the fresh concrete is then poured into the forms, reinforced with steel, subjected to compression, and smoothed. After curing, the employees demold the components, inspect them for quality and dimensional accuracy, and prepare them for transport to the construction site.

“We were looking for an ergonomically designed solution for handling the formwork panels at our CNC machining center,” reports Rasim Shabani, production manager at BFU. The carpentry shop processes coated particle board panels with a weight of up to 80 kilograms and an area of up to six square meters. “Our employees were complaining of back problems caused by the strenuous work,” says Rasim Shabani. “In addition, we always needed at least two people to move the oversized sheets.” About 14 of these sheets must be loaded into and removed from the milling machine every day.

The requirements: The lifting aid must have slewability and be capable of moving at least 100 kilograms. The suction cup should be adaptable to accommodate different panel dimensions. “And of course, it was important to us that the device has a dust filter, is easy to operate, and is soundproofed,” the production manager summarizes the considerations.

With the vacuum tube lifter JumboErgo 140 from Schmalz, BFU found the perfect solution. “The vacuum experts were recommended to us because the company stands for quality and user-oriented solutions,” explains Rasim Shabani. Furthermore, the company’s headquarters in Glatten is less than 30 kilometers from their own location. “We really appreciate working with partners from the region.”

Working hand in hand, the two companies determined which equipment options were both practical and necessary. “In every department at Schmalz, we encountered highly competent and friendly employees,” praises Rasim Shabani. “The customer comes first, and we feel very well consulted and in good hands.”

“Anyone who’s ever moved an 80-kilogram wooden board by hand knows it really takes a toll on your back,” says the production manager. “Instead of lifting and heaving, our skilled workers now use the vacuum tube lifter and control it simply via a twist grip.” This grip resembles a motorcycle handlebar, allowing them to operate the device intuitively and position the heavy sheets with millimeter precision on the CNC machining center.

The vacuum tube lifter JumboErgo is suspended from a column-mounted jib crane, which is very flexible with a 270-degree working angle. The load glides softly from the stack to the machine, even at full weight. The modular area gripper grips reliably and can be adapted to different panel formats. An important detail is the springer balancer FZG, which keeps the tube lifter in balance – an indispensable feature for operator handle lengths of 750 millimeters or more.

The tube lifter has been in use at BFU since spring 2024. “Our colleagues really enjoy working with it because they can now move the heavy sheets effortlessly,” emphasizes Shabani. And the company benefits as well. “Processes now run much more smoothly, and our employees can focus on the important steps that require a bit of brainpower. The device makes life easier and work more efficient.”

For the BFU carpentry shop, the vacuum tube lifter JumboErgo therefore pays off in three ways: employees stay healthy, throughput rates increase noticeably, and workpieces end up exactly where they belong. In short: fewer staff absences, higher output, better quality.