Gabage Crane-7.5 Ton Grab Overhead Crane Kit, Economical Solution

Case Study: 7.5 Ton Grab Bucket Overhead Crane Kit

Supplied three grab bucket crane kits to Indonesia, enhancing garbage handling efficiency with high load capacity and reliable performance.

Project Overview of Grab Overhead Crane Kit

In 2024, we delivered 3 sets of 7.5 Ton Grab Bucket Overhead Crane Kits for garbage handling in Indonesia. The cranes are specially designed for waste management operations, featuring a 7.5-ton capacity and a grab bucket to lift and move bulk garbage materials effectively. This project aims to support the customer’s need for heavy-duty equipment to improve waste handling efficiency.

Customer and Industry Context

• Target Industry:
  Garbage handling in Indonesia, where waste management is critical for the environment and public health.
• Customer’s Needs:
  The customer sought efficient, heavy-duty cranes capable of handling large volumes of waste. They required cranes that could operate in tough conditions while maintaining high reliability.
  The cranes needed to fit within the operational space available at the waste management site.
  The grab bucket mechanism was essential for managing bulk material handling with ease and speed.

The customer’s primary goal was to improve waste collection and disposal efficiency, ensuring smoother and quicker operations at the site.

QZ Grab Bucket Overhead Crane Kit without Main Girder (6.3T-24M H17M, 3 Units)

The QZ Grab Bucket Overhead Crane Kit without a Main Girder is a specialized crane designed for efficient handling of bulk materials, specifically tailored for waste management or other industries dealing with heavy, irregular loads. This crane features an innovative design with no main girder, which helps maximize space and improve maneuverability in tight or restricted areas. It is capable of handling loads up to 6.3 tons.

Key Specifications

• Capacity: 6.3 tons. The crane is designed to handle loads of up to 6.3 tons, making it suitable for medium-heavy applications where large volumes of materials need to be moved efficiently, such as handling waste or scrap metal.
• Span: 24 meters. With a 24-meter span, the crane is able to cover a significant area within the workshop or site, making it ideal for large-scale operations where the movement of heavy loads across a wide area is required.
• Height: 17 meters. The 17-meter lifting height ensures the crane can handle lifting and lowering tasks that involve substantial height, making it suitable for operations that require clearance over tall containers or for reaching higher storage bins.

Design without Main Girder

The no main girder design refers to the crane’s structure, which eliminates the need for a traditional girder system. This design offers several advantages:

• Space Optimization: Without the main girder, the crane requires less headroom and takes up less space, making it ideal for workshops or sites with low ceilings.
• Improved Flexibility: The reduced structural components make the crane more adaptable to smaller workspaces, allowing for smoother operation in confined environments.
• Reduced Weight: The absence of the main girder can reduce the overall weight of the crane, leading to a more lightweight and maneuverable system.

Grab Bucket Mechanism

This crane is equipped with a grab bucket, which is designed to efficiently collect and lift bulk materials. The grab bucket allows for precise material handling, especially when dealing with irregularly shaped or loose materials like waste, garbage, and scrap. The bucket can be controlled to open and close, ensuring materials can be lifted and moved without spillage or damage.

Applications

The QZ Grab Bucket Overhead Crane without a main girder is specifically suited for industries that require heavy-duty material handling but have spatial constraints. It is widely used in:

• Garbage Handling: Moving large quantities of waste and garbage efficiently within the facility.
• Scrap Metal Handling: Transporting heavy scrap materials in recycling plants.
• General Bulk Material Handling: Suitable for moving irregularly shaped or large bulk materials.

Advantages of the QZ Model

• Compact Design: The absence of the main girder allows for a more compact crane, ideal for operations in limited spaces.
• Efficient Material Handling: The grab bucket mechanism provides a highly efficient way to handle and move bulk materials.
• Cost-effective: Reduced structural complexity and material requirements can result in lower initial costs and maintenance expenses.

The QZ Grab Bucket Overhead Crane  and Overhead Bridge Crane Kit is a versatile, efficient, and space-saving solution for handling bulk materials in industries such as waste management and scrap recycling, providing customers with a reliable tool for heavy-duty material transport.

Manufacturing and Production Process

Production Timeline and Key Milestones

• 7.1: Factory Order Placed
  The production journey for the Grab Bucket Overhead Crane Kit began on July 1st. The order was officially placed, and preparations were made to source the necessary materials for manufacturing the crane kits.
• 7.29: End Beam Manufacturing Begins
  On July 29th, the fabrication of the end beams for the overhead crane kit started. These components are vital for the crane’s overall structure and play a critical role in the stability and operation of the crane system.
• 8.7: Completion of End Beams, SEW Hoists Ready for Shipment
  By August 7th, the end beams were fully completed. Additionally, the SEW hoists, essential for the crane’s lifting mechanism, were prepared for shipment, marking an important milestone in the production timeline.
• 8.20: Single Girder Crane Nearing Completion
  On August 20th, the single girder crane was almost ready for final assembly. At this point, end beam installation and motor fittings were in progress, bringing the crane kit closer to completion.
• 9.9: Scheduled Completion by End of the Month
  With September 9th approaching, the crane kits were on schedule to be completed by the end of the month. All parts were expected to be assembled, and the crane would undergo final adjustments and inspections for quality control.

Challenges and Solutions

Slow Production of Small Crane and Brake Components
During the production process, small crane parts and brakes faced delays in manufacturing, which slowed down the assembly of the overhead crane kit. These components were essential for the crane's performance, but their late production created a slight bottleneck.

Solution: To resolve this, we coordinated closely with suppliers to expedite production. Adjustments were made in other areas of the assembly line to ensure the project kept moving forward without further delays.

Timely Shipment of Critical Components (SEW Hoists and Motors)
The SEW hoists and motors were crucial for the functionality of the grab bucket crane kits, and there were concerns about their timely arrival. Any delay in receiving these key components could have impacted the entire production timeline.

Solution: To mitigate this risk, the logistics team ensured that the hoists and motors were shipped ahead of schedule. Close communication with suppliers allowed for the timely arrival of these critical parts, ensuring the crane kit assembly continued as planned.

The production of the Grab Bucket Overhead Crane Kits involved overcoming some challenges, but through effective planning and communication, the team was able to stay on track. Despite delays in smaller components, the project remained on schedule, and all critical parts were delivered and assembled on time.

Installation and Delivery Process

Shipment and Final Preparations

Before shipment, careful preparation was made to ensure that all necessary components, including after-sales parts, were included. This included:

• Pulley Pieces for the 10-ton and 20-ton hoists, which are essential for smooth and efficient crane operation.
• Slide Lines for both the 10-ton and 20-ton hoists, ensuring reliable power transfer and operation of the cranes.

These parts were carefully packed and included in the shipment to ensure that the customer had everything needed for both immediate use and future maintenance.

Delivery and Installation in Indonesia

Expected Delivery Date: The cranes were scheduled for delivery to Indonesia on October 11, 2024. This date was set to ensure that the customer would receive the overhead crane kits in a timely manner, allowing for efficient installation and commissioning.

Coordination with the Client for Installation and Final Commissioning: After the delivery, our team worked closely with the client to coordinate the installation and final commissioning of the Grab Bucket Overhead Crane Kits. This included:

• Ensuring the cranes were installed correctly and met all operational specifications.
• Providing training and guidance to the customer on how to use the cranes for garbage handling efficiently.
• Testing the cranes to ensure everything was functioning as expected and making any necessary adjustments.

The final step of the installation process was to perform a full inspection and handover, ensuring the cranes were ready to start operating and meet the demands of the customer's waste management facility. Through careful coordination, we made sure the cranes were up and running as planned.

Performance and Benefits

Efficiency in Garbage Handling

The 7.5 Ton Grab Bucket Overhead Crane is specifically designed to enhance the efficiency of garbage handling. The key features that contribute to its effectiveness include:

• Grab Bucket Mechanism: The grab bucket allows for easy collection and lifting of bulk waste, even in challenging or irregular conditions. Its precise control ensures that waste is moved without spillage, making the process faster and cleaner.
• High Load Capacity: With a 7.5-ton capacity, the crane can handle large volumes of waste, significantly reducing the need for manual labor and boosting the overall speed of operations.
• Wide Span and Height: The 24-meter span and 17-meter height provide extensive coverage, allowing the crane to access large areas within the waste management site, handling multiple waste collection points efficiently.

These factors combine to create a more productive waste management system, reducing downtime and improving the overall workflow at the facility.

Reliability and Durability

The Grab Bucket Overhead Crane is built to withstand the heavy-duty demands of continuous use in a waste management environment. The crane's construction and components are designed for:

• Durability in Harsh Conditions: The crane is made with high-quality materials that are resistant to wear and tear, ensuring it can operate in tough environments, such as those found in waste handling facilities where dust, moisture, and debris are common.
• Long-term Reliability: The robust design of the crane, combined with the use of reliable components like SEW hoists and high-grade motors, guarantees that the crane can perform efficiently over an extended period without frequent breakdowns.
• Low Maintenance Needs: Due to the crane's durable design, maintenance requirements are minimized, allowing for continuous operations with reduced downtime for repairs.

This durability ensures the crane provides consistent performance, even in demanding, high-volume waste handling operations.

Operational Benefits

The 7.5 Ton Grab Bucket Overhead Crane offers several operational benefits, making waste management more efficient:

• Increased Handling Capacity: With its 7.5-ton lifting capacity, the crane can handle larger amounts of waste at once, increasing the overall efficiency of the waste collection and disposal process.
• Smoother Operation: The grab bucket mechanism allows for seamless and controlled movement of waste, minimizing operational disruptions and ensuring that the waste is safely and efficiently transported from one point to another.
• Reduced Labor Costs: By automating much of the waste handling process, the crane reduces the need for manual labor, freeing up workers for other important tasks while increasing overall productivity.

These operational benefits not only improve the efficiency of waste handling but also enhance the overall effectiveness of the waste management process, reducing costs and improving throughput. The crane's design and capabilities allow for a smoother, more reliable waste collection and disposal system.

After-Sales Support

After-Sales Parts

To ensure the long-term performance and reliability of the Grab Bucket Overhead Crane, several after-sales parts were included as part of the delivery. These parts are essential for maintenance and continued efficient operation:

• 10-Ton and 20-Ton Hoist Pulley Pieces: These pulleys are integral to the lifting mechanism of the crane. They help in the smooth operation of the hoist, ensuring that the crane can lift and move heavy loads effectively. Regular maintenance or replacement of these pulleys ensures the crane continues to operate at peak performance.
• Single-Pole Slide Lines: These slide lines provide a stable and consistent power supply to the crane. They help prevent electrical issues, ensuring that the crane’s lifting mechanism remains powered and operational without interruptions.

These after-sales parts are essential to maintaining the crane's longevity and efficiency, providing the customer with everything needed for routine upkeep and repairs.

Customer Support and Warranty

Ongoing Support and Maintenance: After installation, our team continues to provide ongoing support to ensure the crane operates smoothly. We offer:

• Training sessions for operators to help them get the most out of the crane’s capabilities.
• Technical support for troubleshooting and quick problem resolution.
• Maintenance guidance to help customers extend the lifespan of their crane by following best practices for upkeep.

Our customer support is always available to assist with any issues or questions that arise after installation, ensuring the crane continues to meet operational needs effectively.

Warranty Terms: The cranes and components come with a comprehensive warranty, covering both parts and labor for a specified period. This warranty ensures that any defects in materials or workmanship are addressed promptly without additional cost to the customer. It provides peace of mind, knowing that if any issues arise during the warranty period, they will be resolved quickly and efficiently.

The combination of quality after-sales parts and responsive customer support ensures that the Grab Bucket Overhead Crane continues to deliver reliable performance long after installation. The warranty further adds to the assurance that the customer is backed by a professional team ready to address any concerns promptly.

Conclusion: Contact us to Get Cost-effectic Grab Bucket Kit for Your Needs

The supply and installation of the 7.5 Ton Grab Bucket Overhead Crane Kits in Indonesia was a resounding success. The cranes were delivered on time and installed with precision, meeting the client’s needs for efficient and heavy-duty waste handling. The cranes, with their robust design and specialized features, have proven to be effective in streamlining the waste management process, demonstrating their value in real-world operations.

The client has expressed positive feedback regarding the performance and efficiency of the Grab Bucket Overhead Cranes. They highlighted the cranes’ ability to handle large volumes of waste quickly and efficiently, significantly improving their operations. The cranes' reliable performance and user-friendly features have ensured a smooth integration into the customer's waste management system. The client is satisfied with the overall quality, performance, and after-sales support provided.

Given the success of this project, there is a strong potential for future orders. The client’s satisfaction with the current installation positions us well for additional business opportunities, whether it’s for more Grab Bucket Overhead Crane Kits or other related equipment for their expanding waste management needs. Based on the success of this project, we look forward to continuing our partnership with the client and exploring opportunities for further collaboration in the future.

Article by Bella ，who has been in the hoist and crane field since 2016. Bella provides overhead crane & gantry crane consultation services for clients who need a customized overhead travelling crane solution.Contact her to get free consultation.