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

A commercial vehicle manufacturer faced a classic problem. Spare parts support for an existing telescopic fork unit in its small parts warehouse had been discontinued. One of the two units had already failed. What was needed was a 1 to 1 replacement that would fit seamlessly into the existing system and could be implemented at short notice.

From On-Site Measurement to a Precisely Fitted New Unit

Our team assessed the situation directly on site and carried out a measurement of the old unit within a very short time. Based on this, we designed the telescopic fork unit 40-122/150-825 specifically for this project. This allowed the defective old unit to be replaced without extensive modifications to the system. The customer now has a unit with secured spare parts supply and high availability in continuous operation.

Built for the Future and for Sustainability

With our new telescopic fork unit, the entire system is well positioned for the years ahead. Instead of renewing the complete warehouse technology, only the affected component was replaced in a targeted way. This conserves resources and supports the customer’s sustainability strategy, without compromising on performance or process reliability.

Are you facing a similar challenge with an old unit that no longer has spare parts available? Talk to our sales team. Together, we will find the right solution for your system.

Technical data:

• Load: 200 kg

• Stroke: 820 + 30 mm

• Length of the top fork: 675 mm

• Length of the unit: 825 mm

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

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

• Self weight of the complete unit: approx. 95 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

Reliable Transport of Special Racks in Automated High-Bay Warehouses

The manufacturing of components for high-voltage substations places demanding requirements on intralogistics in terms of weight, geometry, and process reliability. Our telescopic fork unit D3-90-220-2400 is installed on a stacker crane and handles the transport of special racks designed specifically to carry these high-voltage components. The unit is precisely matched to the available installation space of the stacker crane and integrates into the automated material flow without additional interfaces. Its targeted configuration for the respective load carriers ensures stable and repeatable handling even under demanding load profiles.

Safe Loading of Vacuum Furnaces Under Process-Critical Conditions

A key application of the telescopic fork unit is the loading of vacuum furnaces in which the high-voltage components undergo thermal treatment. With a stroke of 4,800 mm and a unit length of 2,400 mm, the telescopic fork unit reaches even deeply positioned furnace openings safely and enables the controlled transfer of loaded special racks without the need for manual intervention or additional conveyor technology. Positional accuracy and repeatability are critical in this process step, as deviations can disrupt furnace operation. The telescopic fork unit reliably meets these requirements and is designed for continuous use in industrial environments.

Customer-Specific Engineering for a Demanding Application

The solution was developed to precisely match the customers requirements. The result is a system that integrates seamlessly into the existing production process and supports high system availability. Like all AFB solutions, this telescopic fork unit was engineered for reliable 24/7 continuous operation.

Are you planning a similar project or do you have specific requirements for your load handling device? 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: 750 kg

• Stroke: 4,800 + 50 mm

• Length of the top fork: 2,400 mm

• Length of the unit: 2,400 mm

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

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

Self weight of the complete unit: approx. 1,925 kg

Reliable Pallet Transfer in a Timed Material Flow

At a leading automotive manufacturer, our eccentric lifting device with telescopic fork unit 70-166-HK-G-1300 handles the pick-up and transfer of various pallet types to provide load carriers for automated guided vehicles (AGVs). The system is designed for a payload of 1,000 kg and forms a central interface in the automated material flow. The combination of eccentric lifting device and telescopic fork unit enables precise and repeatable positioning of load carriers at a defined station, from which the AGV picks up the pallets independently.

Integrated Base Frame for Flexible Height Compensation

A key design feature of this solution is the integrated base frame, which provides height compensation beneath the eccentric lifting device. It creates the structural prerequisite for aligning the system exactly to the AGV transfer height, regardless of the local conditions of the installation. This constructive flexibility significantly simplifies integration into existing material flow structures and reduces commissioning effort.

High Availability for Demanding Production Environments

As part of the material flow in automotive production, the system is subject to particularly high demands in terms of availability and quality. Failures or inaccuracies in the transfer process would have a direct impact on the production cycle. The system was therefore designed for continuous 24/7 operation and meets the high quality standards required in the automotive industry.

Are you planning a similar project or do you have specific requirements for the provision of load carriers in your material flow? 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: 1,000 kg

• Stroke: 1,750 + 30 mm

• Length of the top fork: 1,250 mm

• Length of the unit: 1,300 mm

• Lifting height: 120 mm

• Lifting time: approx 3 s

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

• Acceleration telescopic fork (loaded / unloaded): 0,7 / 1,5 m/s²

• Self weight of the complete unit: approx. 1,106 kg

Reliable Connenction Between Production and High-Bay Warehouse

We developed a transfer car with eccentric lifting device and telescopic fork for an automotive supplier, serving as the central connection between production and the connected high-bay warehouse. The system’s task is to pick up just-in-sequence containers holding exhaust systems from various lift platforms and transport them operation safe to the conveyor system. From there, they are transferred to the high-bay warehouse for storage. The transfer to production follows the same principle, but in the reverse direction. The transfer car handles both individual and stacked containers with a maximum width of 3,800 mm, providing the flexibility required for ongoing series production.

Designed for Demanding Three-Shift Operation

Operating across three shifts places high demands on system reliability. A availability of 99 % was required, achieved through a robust design, low-maintenance components, and a targeted engineering of all drive elements. The eccentric lifting device enables precise height adjustment to the respective transfer points, while the telescopic fork ensures safe and position-accurate handover of the containers to the conveyor system. Combining both functions in a single mobile unit reduces the space required and eliminates additional interfaces in the material flow.

Custom Engineering for Large-Format Load Carriers

The dimensions of the load carriers, with a width of up to 3,800 mm, needed a design specifically tailored to this application. Both the pick-up geometry of the telescopic fork and the lifting kinematics of the eccentric lifting device were engineered to match the exact dimensions and weights of the JIS containers. The ability to handle stacked containers increases system flexibility and supports an efficient material flow in line with the pace of series production.

Are you planning a similar project or do you have specific requirements for transfer cars and load handling devices in your intralogistics? 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:

• Stroke of telescopic fork unit: 1,950 + 30 mm

• Eccentric lifting height: 120 mm

• Lifting time: 3,5 m/s

• load weight: 1,000 kg

• Travel speed: 160 m/min

• Lowest discharge level: 483 mm (from the floor)

Designed for the Demanding Conditions of a Steel Plant

We developed the telescopic fork unit 320-350-2000 for an international customer in the steel industry. The unit handles the storage and retrieval of steel coils weighing up to 15 t on a single prong in an automated high-bay warehouse. The operating conditions in a steel plant place exceptional demands on robustness and reliability. The top fork is fitted with a prism that securely holds the coil in position throughout the entire movement. both during storage and retrieval and while the stacker crane drives along the aisle.

Controlled Deceleration Protects the Load

To prevent the coils from shifting when the telescopic fork unit returns to its centre position, the unit is equipped with hydraulic dampers. These ensure that the profiles are decelerated smoothly and in a controlled manner at the end positions. Our telescopic fork unit 320-350-2000 replaces a unit delivered in 2014, succeeding a device with a long and proven track record.

More Than a Replacement: 20 Years of Experience Built In

The customer receives more than a simple copy of the original unit. The new design incorporates the experience gained from over 20 years of operation and continuous development. Among other improvements, the lubrication concept was revised to simplify maintenance and increase system availability during ongoing operation. In addition, the position of each individual profile is actively monitored before the stacker crane begins to travel. This ensures that the telescopic fork unit is fully retracted and that the automated process runs without interruption.

Are you planning a similar project or looking to replace an existing telescopic fork unit? 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: 15,000 kg

• Stroke: 1,900 + 50 mm

• Length of the top fork: 1,600 mm

• Length of the unit: 2,000 mm

• Speed (loaded / unloaded): 30 / 40 m/min

• Acceleration (loaded / unloaded): 0,3 / 0,6 m/s²

• Self weight of the complete unit: approx. 2,121 kg

We developed and delivered the telescopic fork unit 290-354-2850 for an end customer in the metal processing industry. The unit is designed for a payload of 13 tonnes and handles the precise loading and unloading of machine pallets. The top fork was equipped with additional drilled holes for the customer-specific mounts of the machine pallets, ensuring process-reliable pick-up and transfer of the machine pallets. The design is specifically customized to the requirements of automated production environments in metal processing.

Flexible Prong Adjustment for Different Load Carrier Formats

The telescopic fork unit features two prongs and is prepared for a prong adjustment system with an adjustment range of 800 mm. This construction allows different machine pallet formats to be handled without any retooling effort, enabling flexible use of the telescopic fork unit across varying production situations. The prong adjustment is therefore a key factor in the system’s adaptability to varying load carrier dimensions within the same installation.

24/7 Operation as the Foundation for the Smart Factory

The unit is designed for continuous 24/7 operation and forms a central element in the end customer’s journey towards a smart factory. The fully automated handling of large components eliminates the need for manual intervention in the material flow. The system supports continuous, cycle-accurate production and contributes to increased system availability. The robust design and consistent engineering for continuous operation ensure a stable production process even under high loads.

Are you planning a similar project or do you have specific requirements for a load handling device in your production? 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: 13,000 kg

• Stroke: 2,950 + 50 mm

• Prong adjustment range: 800 mm

• Length of the top fork: 2,300 mm

• Length of the unit: 2,850 mm

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

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

• Self weight of the complete unit: approx. 4,960 kg

In a temperature-controlled pre-zone, a compact transfer car supplies buffer positions located between the conveyor system and the adjacent high-bay warehouse. The transfer car is belt-driven along the aisle and handles the lateral  movement along the buffer row reliably and with precise positioning. The entire system is designed to meet the specific requirements of a refrigerated area, where stable operating conditions and high system availability are equally critical.

Customer-Specific Design with Integrated Lifting Unit

The transfer car is equipped with an eccentric lifting unit and a telescopic fork unit, which together handle the transfer of load units between the conveyor system and the buffer positions. Load units are feed-in and -out via roller conveyors. The design was tailored precisely to the customer’s spatial and logistical requirements, allowing the system to integrate into the existing material flow without additional interfaces.

Controlled Sequence Between Buffer and High-Bay Warehouse

Using the telescopic fork unit mounted on the transfer car, load units are picked up from the conveyor system and placed onto one of the stationary buffer positions. After a defined dwell time, the load units are returned to the high-bay warehouse. This process runs fully automated and ensures a continuous, cycle-reliable material flow between the refrigerated area and the warehouse.

Are you planning a similar project or do you have specific requirements for your material flow? 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:

• Stroke of telescopic fork unit: 1700 + 30 mm

• Eccentric lifting height: 100 mm

• Lifting time: 3 m/s

• load weight: 1,050 kg

• Travel speed: 60 m/min

• Lowest discharge level: 1.025 mm (from the floor)

Today we’re celebrating a very special anniversary: Simon from our small parts production team has been part of our team for 25 years—and what a journey it’s been.

Simon started out as an unskilled laborer. He didn’t have any formal training, but he did bring something you can’t learn: dedication, reliability, and a genuine desire to grow. We gave him the chance and he seized it. Today, he is a skilled worker. A textbook success story.

He still looks back fondly on his first day and the opportunity that was offered to him back then. That is exactly what defines us as a company: We see people—not just resumes.

Simon, we thank you from the bottom of our hearts for 25 years of dedication, reliability, and passion. We are proud to have you on our team and look forward to everything we will experience together in the future.

Congratulations on your anniversary!