Mobiler Hebelift ZH mit Reifen-Klemmgreifer in Logistik-Halle
Mobiler Hebelift ZH mit Reifen-Klemmgreifer in Logistik-Halle
CATEGORY 04 / LOGISTICS
LIFTING AIDS FOR LOGISTICS
Logistics is the area with the highest volumes, the most variable loads, and the strictest ergonomic requirements in industrial manufacturing. From small individual packages in shipping to 50-kilogram sacks in receiving, to filling 1,000-kilogram big bags: lifting aids relieve employees, accelerate processes, and reduce physical strain throughout the entire shift.
Zeilhofer HHT supplies logistics companies with manipulators up to 800 kg, mobile lifting devices with 48-volt batteries, vacuum lifters for cardboard boxes, and special equipment for sacks, drums, and containers. Engineering, manufacturing, and commissioning are all handled in-house from Holzkirchen, Germany: ISO 9001 certified, DIN EN 1005 compliant.
CHAPTER 1
WHAT IS LOGISTICS HANDLING?
Logistics handling encompasses all lifting, carrying, and positioning activities along the value chain between production and the end customer. It is characterized by high production volumes, frequent load changes, variable geometries, and increasing time pressure. In practice, this affects five main areas:
Goods receipt: Unloading of trucks and containers, buffering, quality inspection
Storage: Loading and unloading in high-bay racking, block storage and shelf storage
Order picking: Pick-by-Light, Pick-by-Voice, multi-stage batch orders
Packaging: Tray filling, carton closure, palletizing
Shipping: Loading of trucks and containers, parcel lines, courier sorting
Typical load ranges extend from 5 kg (single-item picking tray) to 1,200 kg (big bag of granules). Ergonomic requirements are derived from DIN EN 1005 (Safety of machinery: human physical performance) and the key indicator method (KIM) of the Federal Institute for Occupational Safety and Health. Those who fail to automate professionally risk sick leave, quality losses, and non-compliance with workplace safety regulations.
CHAPTER 2
REQUIREMENTS FOR LIFTING AIDS IN LOGISTICS
Five requirements determine the suitability of a lifting aid for logistics applications:
01 Mobility and flexibility
Logistics workplaces are changing daily. Mobile lifting aids with battery power and omniwheel chassis can be moved between stations, without a compressed air connection or power cables. The Zeilhofer Hebelift ZH with a 48-volt battery runs for over 8 hours, and a battery change takes less than 30 seconds.
02 Variable gripping devices
A picking station handles cartons, small load carriers (KLTs), bags, and trays daily. Vacuum lifters with interchangeable suction plates, pneumatic clamping grippers, and magnetic grippers for steel parts cover all requirements. Quick-change interfaces reduce setup times to under 30 seconds.
03 Clock accuracy for pick-and-pack lines
Modern shipping lines achieve cycle times of 8 to 12 seconds per carton. The lifting aid must not become a bottleneck here. Pneumatic manipulators with programmable motion profiles, defined end-position approach, and pick-by-light integration synchronize seamlessly with the line cycle.
04 Safety and DGUV compliance
Industrial lifting aids are subject to annual safety inspections according to DGUV Regulation 54. The German Ordinance on Industrial Safety and Health (BetrSichV) additionally requires risk assessment, instruction, and inspection documentation. Safety light curtains, emergency stop switches, and two-hand operation ensure workplace safety during shift work.
05 Robustness at high production volumes
Logistics facilities operate in two to three shifts, seven days a week, often for 10 to 15 years. Their design and materials must withstand millions of load cycles. Zeilhofer lifting aids from the early 2000s are still in daily use by customers with good maintenance practices.
CHAPTER 3
PRACTICE: CARTON AND KLT PICKING
Picking cartons, small load carriers (SLCs), and trays is the most common application of lifting aids in logistics. Loads range from 5 to 30 kg per unit; multiplied by 200 to 600 picks per employee per hour, this results in a volume of movement that cannot be managed manually on a sustained basis.
Typical applications
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Storage in high-bay racking up to 8 m high
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Outsourcing to picking trolleys or conveyor belts
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Transferring between KLT sizes (e.g. KLT 400×300 → KLT 600×400)
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Tray collection for multi-order picking
Zeilhofer solution
The Hebelift ZH with vacuum grip or the Acer mobile cable manipulator with vacuum traverse. The vacuum traverse lifts KLTs and cardboard boxes from the top, protecting the material and working quickly. For different sizes, the suction plate can be changed in under 30 seconds via a quick-change interface.
Advantages of this application
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High pick rate of up to 600 picks per hour
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Order picker workload decreases by 60 to 80 percent
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Gentle handling prevents damaged packaging.
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Integration with pick-by-light and pick-by-voice systems is possible.
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Wireless battery operation for up to 8 hours of shift
CHAPTER 4
PRACTICE: BAG GOODS AND BIG BAGS
Sacks containing 25 to 50 kg (flour, sugar, cement, chemicals) and big bags up to 1,200 kg are among the heaviest and most unstable loads in logistics. Manual handling regularly violates the LMM risk thresholds.
challenges
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Unstable, flexible geometry without fixed grip points
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Load range 25 kg (flour/sugar) to 50 kg (cement) for bags
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Big bags with loops, often weighing 800 to 1,200 kg, suspended load
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Dust sensitivity, often related to food or pharmaceutical hygiene
Zeilhofer solution
For sacks: Articulated manipulator with sack gripper (clamping jaws or suction plate with adapter). The operator guides the sack over the pallet or hopper with minimal effort. For big bags: Hubachse ZH90 with hook attachment or special big bag device with four-point attachment of the loops. Pendulum-free load guidance prevents vibrations during lifting.
Advantages of this application
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Worker no longer lifts himself: physical strain drops drastically
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Pendulum-free guidance protects components on the filling hopper.
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Highest load capacity up to 1,200 kg on the market
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Hygiene versions available for pharmaceuticals and food.
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DGUV-compliant safety control with emergency stop
CHAPTER 5
PRACTICE: GOODS RECEIPT AND PALLET LOADING
In the receiving area, 24-ton semi-trailer trucks arrive with mixed loads, from individual cardboard boxes to full pallets of 1,000 kg of steel. Here, lifting aids must be flexible, fast, and adjustable to changing geometries.
Requirements
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Variable loads from 5 to 1,200 kg per position
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Variable height from ground level to 1.8 m truck loading area
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Quick gripper changes between different components
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Safe loading of high-bay warehouses with block stacking
Zeilhofer solution
The articulated manipulator with vacuum quick-change system is the universal solution. The quick-change system allows for switching between carton vacuum lifters, clamping grippers, and magnetic grippers in seconds. For particularly heavy pallets, the Hubachse ZH90 serves as a stationary lifting aid: the pallet is picked up by a forklift, and the individual cartons are unloaded using the articulated manipulator.
Advantages of this application
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A lifting aid for 90 percent of all goods receiving tasks
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Quick-change grippers keep downtime under 30 seconds
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Large working radius up to 4 m covers truck loading area
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Pneumatic drive with standard compressed air connection 6 bar
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Preliminary inspection in the Holzkirchen showroom before delivery
CHAPTER 6
PRACTICE: WORKSHOP AND SPARE PARTS LOGISTICS
Workshop logistics and spare parts picking represent a growing market driven by the trend towards local repairs and the move away from a throwaway mentality. Typical tasks include lifting engines, transmissions, axles, and body parts for the workshop and spare parts warehouse.
Typical applications
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Engine installation and removal in workshops
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Gearbox replacement with loads of 60 to 120 kg
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Spare parts picking from high-bay racking
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Tire handling: 25 to 40 kg per tire
Zeilhofer solution
The ZH mobile lifting platform with a 48-volt battery is often the ideal solution here. It is moved between the lifting platform, workbench, and spare parts storage area. The component-specific device grips motors via eye bolts or lifting points, tires via clamping grippers, and body parts via vacuum lifters.
Advantages of this application
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Mobility without a compressed air connection
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Up to 100 kg load capacity: covers 95 percent of all workshop tasks
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Omniwheel chassis for tight workshop spaces
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Lifting height up to 2 m for work on lifting platforms
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Battery swap in under 30 seconds, 8+ hours runtime
CHAPTER 7
PRACTICE: SHIPPING AND CONTAINER LOADING
Shipping lines and container loading combine high volumes with precise stacking. Incorrect stacking leads to transport damage, and unstable containers to safety incidents at the port.
Requirements
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Daily output: 500 to 5,000 packages per line
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Variable carton sizes from KLT to overseas container carton
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Stacking heights up to 2.4 m when container loading
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Gentle handling of sensitive shipments
Zeilhofer solution
The Acer cable manipulator with vacuum traverse for carton loading combines high speed with a large working radius. For particularly heavy container packages up to 800 kg, the articulated manipulator with clamping gripper takes over. The stacking height is monitored by sensors, providing the operator with visual feedback on the optimal position.
Advantages of this application
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High loading speed for just-in-time shipping
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Lightweight aluminum construction on the cable manipulator for fast handling
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Large radius up to 4 m covers the container's internal depth
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Vacuum lifter protects delicate packaging
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Stack sensor warns of excessive lifting height and collision
CHAPTER 8
LARGE CONTAINER PICKING WITH INTERCHANGEABLE ATTACHMENT SYSTEM
Drums, canisters, grease buckets, bag-in-box containers, and cardboard boxes often converge at the same workstation in many logistics centers, especially in the chemical, lubricant, and consumer goods industries. Setting up a separate station for each container type results in a loss of space and flexibility. The more economical solution is a single workstation capable of handling all types of containers.
Typical applications
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Picking of barrels, canisters, grease buckets and bag-in-box containers at the same workstation
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Moving from the automatically provided source palette to a manually provided target palette
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Switching between gripping principles: drum grippers or clamping grippers for round containers, vacuum lifters for cardboard boxes
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Integration into automated goods-to-person order picking with conveyor technology connection from the high-bay warehouse
Zeilhofer solution
The articulated manipulator or Hubachse ZH90 is equipped with tool-free interchangeable attachments via a quick-change coupling. Each attachment is precisely designed for a specific container type, drum gripper, canister gripper, vacuum lifter for cartons, and can be changed during operation, without tools and without system downtime. A storage device for unused attachments directly at the workstation keeps changeover times short.
Advantages of this application
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One workstation covers all container types instead of several specialized stations.
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Tool-free attachment change in under 30 seconds
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Load capacity up to 1,200 kg for heavy barrels and large containers
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Reduced space requirement compared to separate devices at each workstation
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Seamless integration into automated goods-to-person order picking via PLC/WMS interfaces
CHAPTER 9
COMPLETE SOLUTIONS FOR LOGISTICS LINES
Zeilhofer HHT supplies logistics companies not only with individual lifting aids, but with complete solutions from a single source in Holzkirchen:
01 Process analysis and concept
Joint assessment of loads, cycle times, distances, and workstations. Concept including lifting aid selection, gripper design, setup plan, and binding price indication. Free of charge and without obligation.
02 Design and Manufacturing
Engineering and manufacturing in Holzkirchen, Germany. In-house designers for component-specific gripping devices. ISO 9001 certified. Made in Germany.
03 Factory pre-acceptance in the showroom
Preliminary inspection with the original workpiece in the showroom in Holzkirchen, Germany, or digitally via video transmission. Customer approval before delivery.
04 Commissioning worldwide
On-site assembly, operator training and commissioning by our own technicians: worldwide in over 50 countries.
05 Service and Maintenance
Maintenance contracts, UVV testing according to DGUV regulation 54, original spare parts, technical hotline with remote support, plant relocation during factory moves.
References
Zeilhofer HHT has been supplying logistics service providers, trading companies, distribution centers and production logistics for years. Their systems are in daily use in shipping centers, workshop logistics and picking lines of leading companies, among others.
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
Frequently asked questions about lifting aids in logistics
01 Which lifting aids are suitable for logistics companies?
Depending on the application: the battery-powered Zeilhofer Hebelift ZH (5-100 kg, flexible travel), articulated manipulators with vacuum quick-change system (5-800 kg, stationary), Hubachse ZH90 for heavy loads (up to 1,200 kg, pallets and big bags). The articulated manipulator with quick-change gripper is usually the universal choice for goods receiving and shipping.
02 What loads can be handled in order picking?
Typical load ranges: 5 to 30 kg (KLTs, cartons, trays), 25 to 50 kg (bagged goods), 50 to 200 kg (engines, gearboxes, large components), 200 to 1,200 kg (big bags, heavy pallets). Zeilhofer HHT covers the entire range from mobile lifting platforms to the high-performance Hubachse ZH90.
03 How quickly does a lifting aid pay for itself in logistics?
Typical amortization time is 12 to 24 months: through reduced sick leave, increased picking rate, prevention of transport damage, and extended employee working life. In multi-shift operations, it is often less than 12 months. Zeilhofer lifting aids reach 15 to 20 years of economic service life.
04 What compliance requirements must lifting aids in logistics meet?
Mandatory requirements include: CE conformity according to Machinery Directive 2006/42/EC, DGUV Regulation 54 (annual UVV inspection), Industrial Safety Ordinance with hazard assessment, ergonomic design according to DIN EN 1005, possibly ATEX for potentially explosive atmospheres or hygiene conformity for food and pharmaceuticals. Zeilhofer supplies all systems CE-compliant.
05 Are lifting aids possible without a compressed air connection?
Yes. The Zeilhofer Hebelift ZH with a 48-volt battery operates completely wirelessly and without compressed air. It offers over 8 hours of runtime per battery charge and can be changed in under 30 seconds. Ideal for mobile logistics applications without pneumatic infrastructure.
06 How does a lifting aid integrate into pick-by-light or pick-by-voice systems?
Via PLC interfaces (Profinet, EtherCAT, EtherNet/IP). The Zeilhofer manipulator receives the pick position from the warehouse management system (WMS) and positions itself semi-automatically. The operator then manually adjusts the gripper for final alignment.
07 Can existing order picking stations be retrofitted?
Yes. During the initial consultation, Zeilhofer HHT analyzes the existing infrastructure, pneumatics, electrical systems, IT connectivity, and adapts the lifting aid accordingly. For mobile lifting devices, infrastructure adjustments are usually not necessary. For stationary manipulators, adapters and customized setup are included.
08 Where are Zeilhofer systems for logistics companies manufactured?
Zeilhofer designs and manufactures them centrally in Holzkirchen, Germany. Commissioning is carried out worldwide at customer sites in over 50 countries. Made in Germany, ISO 9001 certified, with maintenance service and original spare parts throughout the entire lifespan of the system.
09 How do I handle multiple types of containers at one workplace?
Via an interchangeable attachment system: The Zeilhofer articulated arm manipulator or Hubachse ZH90 is equipped with tool-free interchangeable attachments, drum grippers, canister grippers, vacuum lifters for cartons, which can be swapped during operation using a quick-change coupling. This allows a single workstation to pick drums, canisters, grease buckets, bag-in-box containers, and cartons, instead of requiring a separate station for each container type. The changeover takes less than 30 seconds.
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FURTHER GUIDES ON THIS TOPIC
PRODUCT
Mobile Hebelift ZH without compressed air
48-volt battery, omniwheels, up to 100 kg. Ideal for flexible logistics applications.
APPLICATION
Lifting aids for cardboard boxes
Manipulators, vacuum lifters and surface suction cups specifically for cardboard production lines.
OVERVIEW
UVV inspection for lifting aids
Obligation, procedure and deadlines of the annual accident prevention inspection according to DGUV Regulation 54.