Not every material-handling challenge can be solved with an off-the-shelf product.
Some applications involve unusual loads, limited space, specialized production processes, difficult lifting requirements, unique facility constraints or equipment that must work together in a very specific way.
Fredon Handling provides custom material handling solutions for manufacturers, warehouses and industrial facilities that need equipment configured around the actual application.
Rather than forcing a process to fit standard equipment, Fredon can help evaluate the load, movement, workflow, facility and operator requirements and identify a more appropriate solution.
When Is a Custom Material Handling Solution Needed?
A custom solution may be worth considering when standard equipment does not adequately address the application.
Common examples include:
- Unusual load shapes
- Oversized components
- Heavy or awkward materials
- Limited floor space
- Low ceiling height
- Difficult machine loading
- Special lifting or rotation requirements
- Multiple handling steps
- Existing equipment that must be integrated
- Unique production cells
- Specialized drum handling
- Nonstandard storage requirements
- Unusual dock conditions
- Processes requiring precise positioning
The goal is to solve the handling problem without creating unnecessary complexity.
Start With the Application
Custom material handling should begin with the work that needs to be accomplished.
Important questions include:
- What is being handled?
- How much does it weigh?
- What are its dimensions?
- How stable is the load?
- Where does it begin?
- Where does it need to go?
- How often is it moved?
- Does it need to be lifted, tilted, rotated or positioned?
- How do employees interact with it?
- What equipment is already involved?
- What facility constraints exist?
Understanding these details makes it easier to determine whether a standard product can be adapted or whether a more specialized solution is appropriate.
Custom Material Positioning
Some loads need more than simple vertical lifting.
A material may need to be:
- Raised
- Lowered
- Rotated
- Tilted
- Turned
- Held
- Positioned accurately
- Transferred between equipment
Custom material positioning solutions may combine equipment such as:
- Hydraulic lift tables
- Turntables
- Tilt tables
- Pallet positioners
- Cranes
- Hoists
- Workstations
The right combination depends on the process.
Custom Lifting Solutions
Heavy or awkward components may require specialized lifting equipment.
Possible applications include:
- Machine loading
- Component installation
- Assembly
- Maintenance
- Mold handling
- Tooling changes
- Equipment repair
- Production support
Custom lifting solutions may involve:
- Bridge cranes
- Jib cranes
- Gantry cranes
- Hoists
- Below-the-hook lifting devices
- Specialized load attachments
The complete lifting system should be selected around the load and required movement.
Custom Overhead Handling
Overhead systems can be especially useful when floor space is limited or loads need to move through a defined production area.
A custom overhead handling system may be designed around:
- Coverage area
- Building structure
- Headroom
- Load weight
- Travel path
- Workstations
- Machinery
- Operator access
The objective is to create a lifting path that supports the production process without interfering with surrounding equipment.
Custom Workstations
Some production processes require more than a standard industrial workbench.
A custom or highly configured workstation may need to accommodate:
- Specialized tools
- Large components
- Multiple operators
- Testing equipment
- Assembly fixtures
- Parts storage
- Lift tables
- Overhead handling
- Packaging equipment
Workstations should be designed around the sequence of work rather than simply filling an available space.
Custom Storage Solutions
Inventory does not always fit neatly into standard pallet rack or shelving.
Custom storage may be needed for:
- Long materials
- Irregular products
- Heavy components
- Specialized tooling
- Production fixtures
- Large assemblies
- Unique containers
Potential solutions may involve:
- Cantilever racking
- Heavy-duty shelving
- Custom rack configurations
- Mezzanine storage
- Parts storage systems
- Equipment platforms
Storage should be planned around the material and how it is accessed.
Custom Drum Handling
Industrial drums often create specialized handling challenges.
A drum may need to be:
- Lifted
- Transported
- Rotated
- Tilted
- Positioned
- Dispensed
- Palletized
- Suspended from a crane
Standard drum handling equipment may work for many applications, but unusual drum sizes, process requirements or facility conditions may require a more specialized approach.
Custom Loading Dock Solutions
Older or specialized facilities may have loading docks that do not fit typical equipment configurations.
Custom dock solutions may be considered when:
- Dock dimensions are unusual
- Trailer heights vary significantly
- Existing equipment no longer matches operations
- Space is restricted
- Loading volumes have changed
- Specialized vehicles use the dock
A dock assessment should examine both the physical opening and the way products move through the area.
Integrating Multiple Material Handling Systems
Many complex applications require several pieces of equipment to work together.
For example:
A pallet arrives by forklift.
A lift table raises it to working height.
A turntable rotates the load.
A workstation holds tools and components.
A jib crane positions heavier parts.
A custom handling solution should consider the entire sequence rather than treating each piece of equipment independently.
Custom Solutions for Manufacturing
Manufacturing environments often contain specialized processes that standard warehouse equipment was never designed to support.
Potential applications include:
- Machine tending
- Assembly
- Fabrication
- Welding
- Inspection
- Production feeding
- Tooling changes
- Heavy component handling
- Packaging
Custom material handling can help connect these processes more efficiently.
Custom Solutions for Warehouse Operations
Warehouse applications may also require nonstandard solutions.
Examples may include:
- Unusual pallet sizes
- Oversized inventory
- Specialized picking
- Unique staging requirements
- High-density storage
- Limited aisle space
- Multi-level storage
- Specialized containers
The best solution depends on inventory characteristics and material flow.
Solving Material Handling Bottlenecks
A custom solution is often most valuable when one difficult step is slowing down the entire process.
Possible bottlenecks include:
- Waiting for a forklift
- Manual repositioning
- Difficult machine loading
- Excessive travel
- Poor material access
- Slow pallet handling
- Limited staging space
- Inefficient part presentation
The key is to identify the actual bottleneck before selecting equipment.
Standard Equipment vs. Custom Equipment
Not every unusual application requires fully custom equipment.
In many cases, a standard product can be:
- Reconfigured
- Combined with other equipment
- Modified for the application
- Integrated into a custom layout
A good material handling review should first determine whether an existing solution can meet the need before adding unnecessary complexity.
How Fredon Approaches Custom Material Handling
A custom material handling project should generally follow a problem-solving process.
Understand the Load
Identify:
- Weight
- Dimensions
- Shape
- Stability
- Center of gravity
- Handling sensitivity
Understand the Movement
Determine whether the material must:
- Lift
- Lower
- Rotate
- Tilt
- Travel horizontally
- Follow a fixed path
- Move between workstations
Understand the Process
Document how the material moves through the operation.
Understand the Facility
Evaluate:
- Floor space
- Clear height
- Columns
- Machinery
- Aisles
- Utilities
- Workstations
- Existing equipment
Understand the Operator
Consider how employees interact with the load and equipment.
Identify the Simplest Effective Solution
The objective should be to solve the problem with the least unnecessary complexity.
Designing Around Future Growth
Custom equipment should not only solve today’s problem.
Where practical, it should also account for:
- Higher production volume
- Larger products
- New SKUs
- Additional shifts
- New machinery
- Layout changes
- Expansion
A solution that is too narrowly designed may become difficult to use as the operation changes.
Information to Gather Before Contacting Fredon Handling
The more information available, the easier it is to evaluate a custom application.
Helpful information includes:
- Maximum load weight
- Load dimensions
- Load photographs
- Starting position
- Final position
- Required movements
- Handling frequency
- Cycle time
- Facility dimensions
- Available headroom
- Existing equipment
- Current process
- Current problems
- Desired improvement
- Drawings
- Photos or video
Even a simple sketch can be useful for explaining a unique handling problem.
Frequently Asked Questions About Custom Material Handling
What is a custom material handling solution?
A custom material handling solution is equipment or a combination of systems configured around a specific load, facility, process or handling requirement that standard equipment does not fully address.
Does custom material handling always require custom-built equipment?
No. Many custom solutions use standard equipment configured or integrated in a unique way.
What types of equipment can be part of a custom solution?
Custom systems may include lift tables, cranes, hoists, workstations, pallet racking, shelving, mezzanines, drum handling equipment, turntables and other material handling devices.
When should I consider a custom solution?
A custom solution may make sense when the load, movement, facility or production process cannot be handled effectively with standard equipment.
What information does Fredon need to evaluate a custom application?
Useful information includes load weight, dimensions, required movement, operating frequency, available space, existing equipment and photos or drawings of the application.
Can multiple types of equipment be combined?
Yes. Many custom material handling applications involve several systems working together to lift, position, store or move material.
Solve the Material Handling Problem Around Your Process
Every facility has different products, equipment, people and workflows.
When standard equipment does not fully solve the problem, Fredon Handling can help evaluate the application and identify a custom or integrated material handling solution.
Tell us what you need to move, lift, store or position, where it needs to go and what is making the process difficult today.