Manufacturing
Compressor Manufacturer — Three Movers in a Cast-Iron Production Line
Integrating internal transport into the production flow itself.
A compressor manufacturer running an integrated production line for cast-iron components needed a way to move heavy castings — around 25 tonnes per unit — between processing stations without breaking the flow of production. Forklift handling was slow and demanded clearing aisles for every move. Crane hand-offs were limited to single zones and created queues. In practice, the line was paced by handling rather than by production capacity.
What complicated the choice further: the hall layout left little room to manoeuvre. Standard transfer carts simply did not fit the available footprint between stations.
The brief
Integrate internal transport into the production flow itself. Cast-iron components, around 25 tonnes per unit, moving repeatedly between processing stations on a predictable schedule. No interruption of the production rhythm. No operator handling of the load during transfer. And — critically — a Mover small enough to fit the available space between stations.
The configuration
Three HULCK Movers, identically configured to support a station-to-station production rhythm:
- Compact footprint. Each Mover is 2 metres by 2.2 metres — small enough to fit the space between stations, large enough to support the load.
- Differential steering. With turning radius zero, the Movers rotate around their own footprint. Critical in a tight hall where conventional steering would not have fit.
- Flat platform with hardwood deck. The platform is finished in hardwood specifically to protect the cast-iron components during transfer. No metal-on-metal contact, no surface damage.
- 25-tonne load capacity per Mover. Configured for the typical component weight, with a safety margin for the heaviest production runs.
- Wireless remote control. The operator stays at a safe distance and maintains full visual control of the transfer. No tethering, no cable management.
The result
Three Movers running between processing stations instead of forklifts shuttling and cranes queuing. The line paces production, not the handling equipment. The Movers fit the hall, the loads land where they need to land, and the production rhythm is set by the manufacturing process — not by the way components are moved between steps.
Cast-iron, integrated line, tight hall?
Tell us about your operation — load weight, station spacing, throughput — and we’ll configure Movers that fit into your production flow.