The Binar Handling System from Schmalz is the perfect solution for our challenges. The balance function is an absolute game changer.∼ Henk Zwartenkot, Director of Business Development, Saferoad Restraint Systems B.V.
50% Faster: Saferoad Lifts with Electrical Smart Hoists QLR from Binar Handling
At Saferoad Restraint Systems B.V., moving heavy steel components used to be done entirely by hand. Two employees lifted and positioned the unwieldy parts, weighing up to 100 kilograms, manually every day – a physically demanding task with a high risk of injury. Today, two Quick-Lift-Rail systems (QLR) from Binar Handling take over these tasks and raise production to a new level in terms of ergonomics, efficiency, and safety.
Characteristics of the success story
| Industry | Metal |
|---|---|
| Workpiece | Guard rails |
| Product group | Smart Hoists Quick-Lift Rail QLR |
| Type of handling | Manual Handling |
With Schmalz
100
kilograms
effortless handling
50
percent
more productivity
The Customer: Saferoad Restraint Systems B.V.
Saferoad Restraint Systems B.V. is a Dutch company belonging to the Saferoad Group, which operates throughout Europe. Its focus is on the development and manufacture of vehicle restraint systems such as steel guardrails, crash barriers, end terminals and crash cushions. These products protect millions of road users from serious accidents every day. Saferoad uses innovative manufacturing processes and attaches great importance to the safety and well-being of its employees. The company employs a dedicated team that is committed to the quality and reliability of its products. The Heerenveen location is part of the Saferoad Group's international production and service network and operates in accordance with internation quality, environmental, and occupational health and safety standards.
The Challenge
At Saferoad, the daily handling of heavy steel components was purely manual work for many years. Two employees lifted and moved the parts, which had a length of up to five meters and weighed up to 100 kilograms, from pallets into boxes – around 100 repetitions per day. This process was not only extremely physically demanding but also carried a permanently increased risk of injury. At the same time, the task always tied up two people, which limited the flow of materials and noticeably reduced efficiency. With increasing productivity and growing quality standards, it became clear that the previous process had reached its limits. Saferoad was looking for a solution that would significantly reduce the physical strain on employees, be intuitive to use, and could be integrated into production without a long start-up period. Above all, it should enable a single operator to achieve the work safely, quickly, and precisely – thus making the entire process future-proof.
Schmalz's Solution
To improve the physically demanding handling process, Saferoad installed two Quick-Lift-Rail (QLR) systems from Binar Handling, a Schmalz Group company. The devices are equipped with custom-made grippers that were specially developed for the long, galvanized steel components and ensure a safe hold without damage. The installed devices are two QLR 125s: electrically powered, rail-guided smart hoists for loads up to 125 kg. The QLR can be easily moved in X and Y directions; vertical lifting is continuous via a precise, buttonless control handle that enables movements accurate to the millimeter. The auto-balance function automatically compensates for the weight of the workpiece, so that even heavy parts can be guided and positioned with ease and precision. Another strength is the mechanical-electrical-pneumatic rotary feedthrough, which allows the load to rotate continuously without twisting cables or hoses. This means that even components with a length of five meters can be safely oriented and deposited in a controlled manner. The QLR systems can be easily integrated into existing rail and crane systems and, thanks to their servo-controlled drive, are particularly reliable and energy-efficient. The effect in practice is clear: where two employees were previously required, one person now operates the system – without heavy lifting and without the risk of back or muscle injuries. Handling time is reduced by around 50 percent, and one operator now moves the same 100 parts per day as two previously did. For Saferoad, the use of QLR systems represents a noticeable improvement: greater efficiency, safe processes, a more stable material flow, and a significant reduction in the workload for employees, an important step toward modern, ergonomically designed production.
Customer benefits through the Schmalz solution
More efficiencyOne person now does the work of two – with the same daily output of round 100 parts.
Healthier workplaceNo more manual lifting. Physical strain is significantly reduced, as is the risk of injury.
Easy operationThe QLR system is intuitive, quick to learn, and enables precise guidance on the workpiece.
Balance functionThe automatic weight compensation system makes heavy parts virtually weightless and safe to handle.
Products used in the application
Smart Hoists Quick-Lift Rail QLR
- Load capacity up to 600 kg
- Sensitive and precise positioning of different workpieces
- Integration into existing or new rail systems
Aluminum Bridge Cranes
- Modular crane system for flexible and cost-effective assembly of individual crane solutions
- Installation on ceiling or portal construction
- Particularly suitable for large workspaces
- Lift capacity up to 1,200 kg