CATEGORY 05
HANDLING TECHNOLOGY FOR CONTRACT HARDENING PLANTS: INCREASING THROUGHOUT WITHOUT MORE STAFF
Contract heat treatment companies are under double pressure: increasing batch sizes coupled with a shortage of skilled workers. Those who want to accept more orders but can't find additional staff must address the bottleneck at the furnaces.
The limiting factor in many hardening shops is not the furnace capacity, but the loading and unloading process. Heavy charging racks, hot workpieces, and physically demanding manual tasks slow down the production cycle and tie up two people where one would suffice. This is precisely where handling technology comes into play.
A lifting aid decouples throughput from personnel: batches are moved smoothly, quickly, and safely, regardless of the operator's physical effort. Zeilhofer Handling Technology from Holzkirchen has been developing customized solutions for 25 years that make hardening plants more productive and ergonomic.
CHAPTER 1
The bottleneck: Why handling limits throughput
A modern hardening furnace operates largely automatically. The bottlenecks lie before and after the process: during charging, transferring to the quenching bath, and unloading. Each of these steps is manual, heavy, and time-critical. When two employees lift and align a 400 kg rack, it costs time and effort, and it limits the number of batches that can be processed per shift.
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up to 50% = shorter loading time with guided lifting aid
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2 → 1 = Operator per heavy load
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1,200 kg = swing-free with ZH90 lifting axis
CHAPTER 2
Four levers for increased throughput
Four indicators reveal when manual charging reaches its limits and a technical lifting aid becomes economically viable.
01 Accelerate feeding
Positioning the load in front of the oven without pendulum movement, without setting it down or readjusting, shortens each loading process.
02 Decouple personnel
One person operates the line instead of two. Freed-up capacity goes into testing, equipment, or a second line.
03 Operating multiple ovens
A manipulator with a large radius or a movable lifting axis covers several stations.
04 Avoiding failures
Less physical strain reduces musculoskeletal disorders and stabilizes shift staffing.
CHAPTER 3
Profitability: When the investment pays off
The bill:
The payback period results from three factors: saved personnel time per batch, avoided downtime due to improved ergonomics, and increased revenue from higher throughput. In many hardening plants, the payback period is between 12 and 30 months.
Calculation example (illustrative)
Time saved on staff: 1 fewer person on the furnace line per shift
Reduced sick days due to lower physical strain
Higher throughput: more batches per shift without new hires
Funding: Employers' liability insurance associations often support ergonomics investments.
Zeilhofer prepares an individual economic analysis for every request, including your batch numbers and labor costs, free of charge.
CHAPTER 4
Manipulator, lifting axis, or crane? A comparison
Overhead crane
It lifts heavy loads, but it wobbles and is slow at precise positioning. Unsuitable for repetitive furnace loading because every cycle requires readjustment.
Hub axle ZH90
Linear, pendulum-free lifting up to 1,200 kg. Ideal for fast, precise loading on a fixed furnace line.
Joint or cable manipulator
Large working radius, serves multiple furnaces and stations. Ideal when a lifting aid needs to cover several process steps.
CHAPTER 5
Skills shortage: Making jobs accessible
The most demanding job in a hardening shop is often the one at the furnace. It's hot, physically strenuous, and difficult to staff. A lifting aid relieves the physical strain of this job, so it can no longer be staffed by just a few strong employees. This expands the available workforce and makes the hardening shop less dependent on individual high performers.
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Strenuous jobs are being made age-appropriate and inclusive.
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Learning time decreases because strength is no longer the limiting factor.
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Increased employee retention through improved ergonomics
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Less dependence on hard-to-find skilled workers
CHAPTER 6
From request to solution
01 On-site analysis
Recording batches, cycle times, furnace layout and bottlenecks in your hardening shop.
03 Engineering
3D-CAD, FEM, safety according to EN ISO 13849, heat-resistant design, manufacturing in Germany.
02 Concept and specifications
Individual analysis using your figures. Binding price indication, free of charge.
04 Commissioning
Integration into your production line, training, worldwide service by our own technicians.
CHAPTER 7
Why Zeilhofer?
25 years of special solutions for the metal industry
ISO 9001 and TISAX Level 2 with prototype protection
Heat-resistant components for oven removal as standard
Swing-free lifting axles up to 1,200 kg
Engineering and service from Holzkirchen, no outsourcing chains
FAQ / Q&A
FREQUENTLY ASKED QUESTIONS
01 How does a lifting aid increase throughput in the hardening shop?
It shortens loading and unloading times because charging racks are positioned without swinging or setting down. One person is sufficient instead of two, thus decoupling the bottleneck of furnace loading from personnel.
02 Is a lifting aid worthwhile in case of staff shortages?
Yes. It relieves the burden on existing staff, makes demanding jobs more widely available, and reduces absences due to musculoskeletal disorders.
03 When does a lifting aid pay for itself?
Usually between 12 and 30 months, depending on the number of batches, shift pattern, and labor costs. Zeilhofer prepares an individual assessment.
04 Manipulator or crane for furnace loading?
The crane oscillates and is slow in positioning. A manipulator or lifting axis guides the load smoothly, quickly and precisely, clearly superior for repetitive loading.
05 Can one lifting aid operate multiple ovens?
Yes. A large-radius articulated or cable manipulator or a movable lifting axis covers several furnaces and stations.
06 How quickly can a special lifting aid be delivered?
Designed according to specifications and manufactured in Germany, typically taking a few months. Initial consultation and price indication are free of charge.
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FURTHER GUIDES ON THIS TOPIC
In-depth guides on related topics in handling technology.