Fully Automated Handling of Sensitive Insulators between Material Supply and Kiln

Cleanroom and firing processes place high demands on handling technology. For an application in which unfired insulators are transported fully automated between a material supply unit and several kilns, we developed the special telescopic fork unit 150-210-2450 with integrated top fork lift. The telescopic fork picks up the load carrier at the material supply station, lifts it carefully using the upper fork lift mechanism, and travels to the kiln position. There it positions the load carrier precisely in front of the open kiln, transfers it, and retracts. Once the firing process is complete, the telescopic fork unit retrieves the load carrier with the fully fired insulators and sets it down in a controlled manner at the material supply station.

Top Fork with Integrated Lift as a Key Design Decision

The telescopic fork unit is responsible for picking up and releasing the load carriers and is installed on a transfer car. The transfer car serves as the link between the material supply station and the kiln. The top fork is supported from below during extension, which significantly reduces deflection and allows the insulators to be transported securely in position on the load carrier. The integrated top fork lift takes over the lifting function directly at the telescopic fork unit, so the transfer car requires no lifting unit of its own. The load is raised entirely by the top fork lift of the special telescopic fork.

Cleanroom Suitability and Process Reliability in Continuous Operation

Use in a cleanroom places particular demands on material selection, surface treatment, and the emission behaviour of the system. Our special telescopic fork unit 150-210-2450 was designed for exactly these conditions and operates fully automatically during ongoing production. The transfer processes at the material supply station and at the kiln run reproducibly and in sync with the production cycle, ensuring consistently high process quality. The system integrates seamlessly into the existing automation structure and is designed for continuous operation.

Are you planning a similar project or do you have specific requirements for the use of telescopic fork units in cleanroom or thermal process environments? Contact our sales team. We will be happy to advise you and work with you to develop the right solution for your application.

Technical data:

• Load: 1,200 kg

• Stroke: 3,000 + 50 mm

• Length of the top fork: 1,550 mm

• Length of the unit: 2,450 mm

• Lifting height: 50 mm

• Lifting time: approx 4 s

• Speed telescopic fork (loaded / unloaded): 5 / 5 m/min

• Acceleration telescopic fork (loaded / unloaded): 0,25 / 0,25 m/s²

• Self weight of the complete unit: approx. 1,337 kg

For a customer in the  production automation, we designed, engineered and manufactured the 210-420-3400 telescopic fork unit precisely to meet the customer’s requirements. The core of the project is the fully automated connection of a tooling machine to a compact high-bay warehouse. Machine pallets with a load weight of up to 10 t are automatically retrieved from the high-bay warehouse, precisely loaded into the machine and, once processing is complete, removed again and returned to storage. Our telescopic fork unit takes on the central role in this material flow, ensuring a reliable, accurately positioned transfer of the machine pallets.

Decoupled Setup Increases Machine Utilization

A key benefit of this solution is decoupling the setup process from the machining process. Machine pallets can be prepared independently of the running machine operation. As a result, the machine is not interrupted by setup times, which noticeably increases machine runtime. Finished workpieces are automatically removed from the machine right after processing and returned to the high-bay warehouse. The entire process runs without manual intervention, which significantly improves process reliability and reduces the staffing required at the machine.

Designed for 24/7 Continuous Operation

Our 210-420-3400 telescopic fork unit is designed for continuous 24/7 operation. With a base length of 3,400 mm and a stroke of 3,550 mm, it reliably covers larger transfer areas and provides the reach needed for use with tooling machines that have deep working spaces. Robust construction, low maintenance requirements and high repeatability make it a dependable foundation for fully automated production environments. Precisely fitted to the customer’s requirements and seamlessly integrated into the existing plant structure, it delivers where precision and reliability matter most.

Are you planning a similar project or would you like to learn more about how our telescopic fork units are used in production automation? Talk to our sales team. We are happy to advise you and work with you to develop the right solution for your application.

Technical data:

• Load: 13,000 kg

• Stroke: 3,550 + 30 mm

• Length of the top fork: 3,000 mm

• Length of the unit: 3,400 mm

• Speed (loaded / unloaded): 30 / 30 m/min

• Acceleration (loaded / unloaded): 0,1 / 1 m/s²

• Self weight of the complete unit: approx. 4,270 kg

As part of a retrofit project at an established automotive manufacturer, a telescopic fork unit 100-174-HK-1240 with 4 prongs was successfully integrated into an existing conveyor system. The challenge was to adapt the load handling device precisely to the existing installation conditions on site. Dimensions, prong arrangement, and the mechanical interface were specifically tailored to the spatial and technical requirements of the system. This individual adaptation was a requirement for deploying the unit within the existing infrastructure without requiring extensive structural modifications.

Replacement of Third-Party Components on Transfer Car and Vertical Conveyor

Our telescopic fork unit replaced third-party components that had previously been in use on both a transfer car and a vertical conveyor as part of the modernisation process. The targeted replacement of these components enabled seamless integration into ongoing production operations. By using a uniform, coordinated system, interfaces were simplified and maintenance requirements were reduced.

Higher Throughput and Improved Availability

Following the replacement, both the throughput and the availability of the overall system were measurably increased. The flexible adaptation of the telescopic fork unit to the specific on-site requirements made a significant contribution to the modernisation of the conveyor system. The project demonstrates how a consistently solution-oriented approach can efficiently upgrade existing systems without requiring complete new installations.

Are you planning a similar project? Get in touch with our sales team. We will analyse your requirements and work with you to develop a suitable solution. Contact us today.

Technical data:

• Load weight: 3,000 kg

• Stroke: 1,400 + 30 mm

• Length of the top fork: 1,240 mm

• Length of the unit: 1,240 mm

• Speed (loaded / unloaded): 30 / 30 m/min

• Acceleration (loaded / unloaded): 0.5 / 0.5 m/s²

• Self weight of the complete unit approx ca. 837 kg

For a major automotive manufacturer, a telescopic fork unit V-95-5/8″-222-2500 with fork adjustment was designed for use in a high-bay warehouse to store racks of varying sizes.  The key challenge was to move frames with different dimensions efficiently, process-reliably, and without manual intervention or additional changeover times. The integrated prong adjustment with an operating range of 1,400 mm allows the prongs to be precisely adapted to the respective frame width. This enables different load carriers to be picked up flexibly and safely within the same system.

Designed for Heavy Loads and Continuous Operation

Our telescopic fork is designed for a payload of 1,000 kg, reliably handling even heavier frames. A main requirement  in this application is the  continuous operation: the system runs 24 hours a day, seven days a week, without interruption. The design was engineered accordingly for maximum availability, robustness, and ease of maintenance.

Seamless Integration into the Existing High-Bay Warehouse

The telescopic fork V-95-5/8″-222-2500 was structurally adapted to the available installation space of the stacker crane, allowing it to integrate optimally into the existing warehouse structure. The combination of a large adjustment range, high load capacity, and continuous duty strength makes this load handling attachment the right solution for high-bay warehouses with non-uniform load carriers in demanding industrial environments.

Are you planning a similar project or need a customized solution for your high-bay warehouse or production facility? Contact our sales team and we will be happy to advise you individually and develop the optimal solution for your application together with you.

Technical data:

• Load: 1,000 kg

• Stroke: 2,600 + 50 mm

• Prong adjustment range: 1,400 mm

• Length of the top fork: 2,000 mm

• Length of the unit: 2,500 mm

• Speed (loaded / unloaded): 42 / 72 m/min

• Acceleration (loaded / unloaded): 0,4 / 1 m/s²

• Self weight of the complete unit: approx. 1,045 kg

The telescopic forks unit are installed on a robust, stationary frame that takes load carriers from a vertical conveyor. Afterwards the telescopic fork unit transfers the load carriers in a controlled process to a stationary unit. From there, the load carriers are transported further or they are subsequently processed. With a stroke of 3,500 mm, the system covers a large working area. Due to the proven AFB quality, the system is designed for continuous, 24/7 industrial use — it is low-maintenance, precise, and durable.

Customization and Smart Sensor Technology

To ensure optimal integration into the existing production environment, the telescopic fork unit was fitted with a specially adapted top fork. It was prepared for the installation of individual mounts for customer-specific load carriers. Additionally, integrated position detection sensors for the skids ensure maximum process reliability and a smooth transfer between system components.

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Would you like to learn more about using telescopic forks in your production process, or would you like to develop a custom solution for your application?

Contact our sales team—we will be happy to advise you personally.

Technical data:

• Load: 2400 kg

• Stroke: 3500 + 200 mm

• Length of the top fork: 2000 mm

• Length of the unit: 3400 mm

• Speed (loaded / unloaded): 30 / 60 m/min

• Acceleration (loaded / unloaded): 0,5 / 1 m/s²

• Self weight of the complete unit: approx. 1620 kg

We developed a V-F-60-166-HK-1400 telescopic fork unit with four prongs for a system integrator, specially tailored to the requirements of an end customer in the woodworking industry. Designed for use in an automatic high-bay warehouse, the unit meets the highest standards of reliability, precision and continuous durability. Each prong can support a load of 550 kg, enabling the safe handling of stacked wood cuts.

Flexible Adaptation to Different Load Carriers

The telescopic fork unit is installed on a storage and retrieval machine to carry out the storage and retrieval of various load carriers containing stacked wood cuts. The unit is equipped with a prong adjustment system that allows it to adapt flexibly to the different dimensions of the load carriers. The two outer prongs can be moved precisely to adjust the position to the length of the load. Regardless of the selected setting, all four prongs always extend simultaneously. This ensures the load remains stable during movement, storage and retrieval, and prevents it from deflecting. This creates a smooth material flow in the high-bay warehouse.

Reliability for Continuous 24-Hour Operation

The entire structure was designed to operate continuously under the  intensive conditions of an automated high-bay warehouse. The telescopic fork unit was also customised to fit the storage and retrieval machine’s available installation space, allowing for optimal integration. Thanks to its bespoke design and high quality, the telescopic fork unit ensures high system availability and stable operating processes.

Are you looking for a high-performance solution for your intralogistics system?

Contact our sales team. We would be delighted to help you implement your specific requirements.

Technical data:

• Load: 2200 kg

• Stroke: 1500 + 30 mm

• Length of the top fork: 1200 mm

• Length of the unit: 1400 mm

• Speed (loaded / unloaded): 31,5 / 50 m/min

• Acceleration (loaded / unloaded): 0,5 / 1 m/s²

• Self weight of the complete unit: approx. 795 kg

We developed a telescopic fork unit 105-174-HK-G-2100, for a leading automobile manufacturer, which is precisely configured to fit the requirements of the production line. Designed for the safe handling of car bodies with a maximum payload of 900 kg, the system forms a central element in the material flow after the painting process. Permanently installed on a robust frame, the telescopic fork unit creates a completely autonomous transfer station that integrates seamlessly into the production process.

Efficient Transfer Processes for 24/7 Operation

The system’s main task is to pick up the painted car body precisely from one skid and transfer it to the next skid for further transport and processing. With a stroke of 2,850 mm, the telescopic fork unit ensures reliable and fast transfer , even in continuous operation. Like all AFB solutions, this system is optimized for a long service life, robustness, and ease of maintenance, ensuring maximum availability within the production line.

Customized Pickup Technology and Integrated Sensors

The specially developed top fork provides the ideal platform for customer-specific car body supports. Sensors have also been integrated to detect the exact position of the load and ensure safe transfer between the skids. This combination of mechanical stability, intelligent detection, and customer-specific design makes the transfer station a reliable solution for demanding automotive processes.

Would you like to learn more about the custom-made telescopic forks and transfer stations offered by AFB?

Contact our sales team. We will be happy to advise you!

Technical data:

• Load: 900 kg

• Stroke: 2850 + 30 mm

• Length of the top fork: 2100 mm

• Length of the unit: 2100 mm

• Speed (loaded / unloaded): 30 / 60 m/min

• Acceleration (loaded / unloaded): 0,5 / 1 m/s²

• Self weight of the complete unit: approx. 1050 kg

For the automated loading and unloading of an industrial oven, our customer uses the telescopic fork F-60-166-HK-1250 with an integrated belt conveyor. The system is mounted directly on a vertical conveyor and enables precise positioning of the load carriers at the correct working level. In each cycle, four mold carriers are simultaneously inserted into or removed from the oven – an optimal solution for applications with high quantities and tight cycle times.

Seamless Integration into the Production Process

After removal from the oven, the mold carriers are automatically transported to a transfer station. There, a robot picks up the individual molds directly from the load carrier. This seamless handover reduces manual intervention and ensures that parts can be further processed quickly and safely. Thanks to the robust design and precise conveyor technology, a continuous material flow is guaranteed – regardless of temperature or environmental conditions in the oven area.

Increased Productivity through Customized Technology

Thanks to the customized design and construction of our telescopic fork with belt conveyor, the customer was able to fully automate the loading and unloading process. The result: significantly reduced cycle times, a consistent material throughput, and a noticeable reduction in operator errors. This solution impresses not only with its efficiency but also with its durability and ease of maintenance.

Would you like to learn more about our customized load handling devices?

Contact our Sales team now and let us advise you on how we can optimize your production processes as well.

Technical data:

• Load: 280 kg

• Stroke: 1600 + 30 mm

• Length of the top fork: 1250 mm

• Length of the unit: 1800 mm

• Speed (loaded / unloaded): 30 / 87 m/min

• Acceleration (loaded / unloaded): 0,5 / 1 m/s²

• Self weight of the complete unit: approx. 375 kg

The modernisation of an automatic high-bay warehouse places high demands on performance and availability. A central component of this optimisation is the use of a telescopic fork including a rotating unit D-60-166-HK-1400. This combination enables smooth and efficient material handling by discharging the load at the front. Due to the most modern technology, the new system offers improved performance compared to older devices and significantly reduces downtime. The telescopic fork with rotating unit was designed as a single unit to ensure easy installation on the stacker crane.

Custom solution for global modernisation projects

The device has been specifically designed to meet the needs of an international furniture retailer that is modernising its warehouses in several locations. The integration of the telescopic fork and rotating unit has standardised the technology used. This has not only increased the efficiency of the warehouse operations, but has also simplified maintenance and optimised the stocking of spare parts. Both the end customer and the operator of the high-bay warehouse benefit from the standardisation, which has reduced the variety of parts and increased operational reliability.

State-of-the-art technologies for maximum availability

AFB has precisely aligned the device with the customer’s modernisation strategy. The improved performance, coupled with higher availability, ensures a sustainable increase in the efficiency of warehouse operations. By using the latest technologies, the company remains competitive and can optimally control its logistical processes.

Contact our sales team to find out more about custom solutions for your warehouse automation needs!

Technical data:

• Load carriers: Pallets

• Load: 750 kg

• Length of the top fork: 1,250 mm

• Stroke: 1,650 + 50 mm

• Length of the unit: 1,400 mm

• Width of the unit: 1,280 mm

• Speed telescopic fork (loaded / unloaded): 30 / 80 m/min

• Acceleration telescopic fork (loaded / unloaded): 0,5 / 1 m/s²

• Rotation angle: 90° / 180°

• Rotation time: 3 s / 4 s

• Self weight of the complete unit: 620 kg

For a manufacturer of saws and storage technology in the field of long metal products and sheet metal storage, efficient use of space is a critical factor. Our 124-81-780 telescopic fork has been specially designed to meet the requirements of a long products warehouse and offers the perfect solution for space-saving storage with a high load capacity. With a basic length of 780 mm, a width of 89 mm and a height of 207 mm, this telescopic fork meets even the most demanding customer requirements.

Compact and durable

The special feature of the 124-81-780 telescopic fork is its slim design and high load capacity. The fork has a particularly narrow width of just 49 mm so that it can be used even in the tightest drive-in spaces. Although the compact design, it can carry a load of 600 kg per prong. This makes it ideal for applications where space is a limited resource.

Customized for continuous operation

Our telescopic fork was manufactured with AFB’s well-known quality and is designed for 24-hour operation, 7 days a week. This product not only guarantees space savings, but also reliability and durability in any industrial application.

Contact our sales team to find out more about the 124-81-780 telescopic fork and how it can optimize your application. We are pleased to assist you with any questions you may have and provide you with a customized quote.

Technical data:

• Payload: 600 kg

• Stroke: 830 + 30 mm

• Length of the top fork: 780 mm

• Length of the unit: 780 mm

• Speed (loaded / unloaded): 24 / 48 m/min

• Acceleration (loaded / unloaded): 0,5 / 1 m/s²

• Self weight of the complete unit: approx. 80 kg per prong