Vacuum Lifter Simplifies the Handling of Formwork Panels

Beton‑Fertigteil‑Union GmbH & Co. KG was looking for an ergonomic solution for the manual handling of large formwork panels. Today, the vacuum tube lifter JumboErgo from Schmalz makes the work easier, improves process speed and improves precision in the CNC center.

Products used in the application

Characteristics of the success story

Industry	Universal
Workpiece	Wooden boards
Product group	Vacuum Tube Lifter JumboErgo
Type of handling	Manual Handling

With Schmalz

percent

less manpower

kilogram

move ergonomically

The Customer: Beton-Fertigteil-Union GmbH & Co. KG

Beton‑Fertigteil‑Union GmbH & Co. KG (BFU), headquartered in Schramberg‑Waldmössingen, is a manufacturer of precast concrete components for structural and architectural applications. Since 1996, the company has supplied private builders, commercial customers, and public institutions with high‑quality elements such as staircases, walls, balconies, floor slabs, and custom components. With a workforce of around 80 employees, BFU produces precision‑engineered concrete components at three production sites. These elements are used in residential construction as well as in industrial and special‑purpose projects. BFU stands out for its high quality standards, flexibility, and a modern, vertically integrated manufacturing operation.

The Challenge

Cutting and handling the large formwork panels in the capentry shop placed a heavy physical strain on employees. The laminated particleboard panels weigh up to 80 kilograms and can reach sizes of up to six square meters. Manual handling typically required two people and regularly led to back complaints. In addition, around 14 panels had to be loaded and unloaded every day, which slowed down operations and further increased physical strain. For BFU, it was clear that an ergonomic and efficient solution was needed. The new system had to be able to swivel, move at least 100 kilograms, adapt to different panel sizes, offer intuitive operation and be equipped with a dust filter and sound insulation. The goal was a safe, fast process that would significantly reduce physical strain on employees.

Processes now run significantly faster and our colleagues can move the heavy panels effortlessly.

∼ Rasim Shabani, Production Manager

Schmalz's Solution

With the vacuum tube lifter JumboErgo 140, BFU found a solution that met all the requirements. The tube lifter is suspended from a column-mounted jib crane with a working angle of 270 degrees. It is operated using an ergonomically designed twist grip, resembling a motorcycle handlebar. This allows the employees to move the panels intuitively, sensitively and with millimeter-level precision onto the CNC machining center. The modular area gripper adapts flexibly to different panel formats. An integrated dust filter provides long-term protection for the system. The FZG springer balancer keeps the tube lifter constantly balanced, which is an essential feature, especially when using longer operating handles.Even at maximum load, the panels glide effortlessly from the stack to the machine. The JumboErgo has been in daily operation since spring 2024. Employees benefit from a noticeable reduction in physical strain, while process times have measurably improved. Panels can now be positioned precisely and without physical effort, enhancing process quality and significantly reducing the risk of strain injuries or damage.