Forklift equipment defies the ‘gates of hell’ at German foundry
Above: A German foundry that melts metal at 2,700 degrees Fahrenheit requires equipment that can remain durable in such a difficult environment.
July 2023- Forklift equipment defies the ‘gates of hell’ at German foundry
Hundhausen was established in 1914 by Walter Hundhausen and, over the past 109 years, has developed into one of Germany’s leading foundries. The company specializes in producing iron castings with nodular graphite. It makes standard and custom components for name-brand customers in the automotive and heavy vehicle industries, mechanical engineering, railroad technology, hydraulics, and wind energy. Hundhausen produces both small and large series and complex castings weighing from 15 kilograms to 220 kilograms. It meets quality standards for a wide variety of applications, such as automotive parts and railroad equipment.
Located in Schwerte, Germany, the Hundhausen factory supplies clients such as BMW, MAN (which builds trucks and buses), Mercedes and SAF (which makes chassis for trucks, trailers and buses).
To capitalize on high demand for its castings, the foundry implemented new production technology, including a new oven with a melting capacity of more than 76,000 pounds per hour. Parts of the operation are described as the “gates of hell,” with iron shards reaching 2,700 degrees Fahrenheit and bombarding lift trucks at speed.
In order to keep production on pace, Hundhausen operates three shift s per day, six days a week. The duty cycle is so intense that the operation routinely retires lift trucks after only 18 months.
Castings production and handling continuously evolve, requiring the flexibility to adjust existing solutions or implement new ones as needs change. Because of this unique, demanding duty cycle and extreme conditions, Hundhausen sought out strong, reliable trucks that could be customized to minimize maintenance downtime and help support operator safety and performance. To optimize productivity in these extreme conditions, Hundhausen turned to its longstanding partner, Hyster, with which it has worked for about 30 years. Although Hundhausen, a subsidiary of Beinbauer Group, had used a few competitive truck models in the past, the foundry chose to make Hyster its exclusive materials handling supplier and standardize its entire fleet to ease management and maintenance.
MULTI-USE FLEET
Working with Hundhausen, the team at Hyster evaluated the foundry’s requirements and narrowed in on a fleet of big trucks, standard lift trucks and pallet trucks. The trucks were reinforced for extra durability to withstand the heat from the melting ovens, minimizing downtime for maintenance and repairs that are otherwise required by the specialized application. Hundhausen put the customized Hyster big trucks to work optimizing productivity in the “gates of hell.” The steel roof and heat resistant front screen of the cab on the big trucks help protect operators and equipment from sparks and hot, flying debris. The advanced ergonomics of the custom cab also offer all around visibility to support high operator performance all shift long, even within the foundry’s harsh conditions. For the rest of the factory’s day-to-day material handling needs, Hundhausen deployed a fleet of nearly 30 Hyster lift trucks and platform pallet trucks.
ENHANCEMENTS
With the new trucks in place, Hundhausen experienced minimal downtime and enhanced operator productivity, thanks to the durability and ergonomics of the trucks, along with their applicationspecific enhancements.
A steel roof and heat-resistant screens protect truck operators from sparks and flying debris.
Extended fenders, for instance, help protect the tires from sparks and debris, minimizing tire wear and necessary repairs and replacement. On the lift trucks, the proprietary Hyster DuraMatch transmission system provides a smoother ride for operators while helping reduce wear to tires and brakes during aggressive direction changes. Hundhausen found the solution it needed for the long term. The Hyster equipment is capable of handling an intense duty cycle of more than 6,900 hours per year in harsh conditions. Standardizing the fleet across the facility also helped enable more efficient fleet management and streamlined maintenance when service is required.
Hundhausen, http://beinbauer-group.de/
Hyster, 800/497-8371, http://hyster.com/
