Short answer: In Germany there is no fixed legal kilogram limit for adults when lifting. The decisive rule is the Load Handling Regulation (LasthandhabV): the employer must avoid hazardous manual lifting or assess the strain in a risk assessment, in practice usually with the Key Indicator Method of the BAuA. As a guideline, around 25 kg for men and 15 kg for women apply to occasional lifting, and around 20 kg and 10 kg to frequent lifting. Only the Maternity Protection Act sets fixed limits: without aids, pregnant workers may lift at most 5 kg regularly and at most 10 kg occasionally. Reference values at a glance Men, occasional lifting: around 25 kg Men, frequent lifting: around 20 kg Women, occasional lifting: around 15 kg Women, frequent lifting: around 10 kg Pregnant workers: at most 5 kg regularly, at most 10 kg occasionally without mechanical aids (Section 11 MuSchG, legally binding) Young people under 18: much lower values, assessed case by case (Section 22 JArbSchG) Important: apart from maternity protection, these are guideline values from practice and occupational safety recommendations, not limits. Frequency, posture and gripping conditions can lower the critical load considerably. The risk assessment of the specific workplace is always binding. The underlying EU Directive 90/269/EEC applies across the EU, while national rules in other countries may differ in detail. ZH90 lifting axis for drum motors up to 400 kg Is there a legal weight limit for lifting? A fixed legal upper limit in kilograms does not exist in Germany for adults. The BAuA also states that there are no legally binding limits for maximum acceptable load weights. The LasthandhabV implements EU Directive 90/269/EEC and obliges employers to avoid manual lifting that poses a risk, especially to the lower back, or to minimise that risk. The permissible load therefore always depends on the specific workplace. Nothing fundamental changes in 2027 either: the new EU Machinery Regulation addresses manufacturers of new machines, not operators. More in the article EU Machinery Regulation 2027: ergonomics duties. Why weight alone is not the deciding factor A single kilogram figure says little about the actual strain. The annex to the LasthandhabV lists four groups of characteristics that must be assessed together: Load: weight, shape and size, position of gripping points, centre of gravity and grip Task: posture, distance of the load from the body, lifting and carrying distance, frequency and duration Work environment: space, floor, climate and lighting Personal factors: physical suitability, work clothing, knowledge and instruction A medium load lifted many times a day in an awkward posture can be more strenuous than a single heavy lift. How to improve these factors at the assembly workstation is explained in the guide Ergonomics at the assembly workstation. The Key Indicator Method: how the risk is assessed The Key Indicator Method (KIM) of the German Federal Institute for Occupational Safety and Health is the recognised procedure for combining the characteristics from the annex into an overall assessment. Revised versions for six types of physical strain have been available since 2019. Lifting is covered by the module Lifting, Holding and Carrying (KIM-LHC). The assessment runs in four steps: Time rating: record the number of lifting and holding operations or the carrying distance per shift Load rating: assess the effective load weight, separately for women and men Posture rating: classify posture when picking up, holding and setting down Working conditions: factor in gripping conditions, space, floor and environment The ratings produce a score that is assigned to one of four risk ranges: Risk range 1, under 20 points: low strain, overload is unlikely Risk range 2, 20 to under 50 points: moderately increased strain, design measures are useful for less resilient persons Risk range 3, 50 to under 100 points: substantially increased strain, design measures are advisable Risk range 4, 100 points or more: high strain, design measures are required From risk range 3, the German occupational medicine rule AMR 13.2 considers the strain substantially increased. The employer must then offer occupational health checks and should consider technical measures such as a lifting aid. Avoid, minimise or ignore: three ways forward A business generally has three ways to deal with hazardous manual lifting, with very different consequences: Doing nothing: requires no investment up front, but breaches the duty to avoid under Section 2(1) LasthandhabV. The consequences show up in the medium term: more sick leave, musculoskeletal disorders as the leading cause of incapacity for work, declining takt reliability and, in the worst case, liability risks with the employers' liability insurance association. Organisational measures: job rotation, extra breaks or two-person lifting reduce the strain somewhat. They need no investment, but permanently tie up more staff per task and do not solve the underlying problem, because the load remains with every lift. Technical aids: Section 2(1) of the LasthandhabV explicitly names suitable equipment, in particular mechanical devices. A lifting aid takes the full weight, and the operator guides the load with almost no effort. Risk assessment under the LasthandhabV in 5 steps If manual lifting cannot be fully avoided, Section 2(2) of the LasthandhabV requires an assessment of the working conditions. In practice, this breaks down into five steps: Record the tasks: which lifting and carrying operations occur at the workplace, and how often per shift? Assess: classify load, posture, frequency and working conditions according to the annex and the Key Indicator Method Determine the risk range: calculate the score and assign risk range 1 to 4 Derive measures: technical before organisational and personal measures, taking physical suitability into account under Section 3 Document and instruct: record the result in writing and instruct employees under Section 4 The complete legal framework, load design and an ROI analysis are summarised in our Lifting Aids 2027 white paper. How many kg may women and men lift? Besides the LasthandhabV, the German Social Accident Insurance (DGUV), the employers' liability insurance associations and occupational safety authorities provide guidance. For occasional lifting, around 25 kg for men and around 15 kg for women are the threshold above which a closer assessment is advisable. For frequent, regular lifting, occupational safety bodies recommend avoiding loads over 20 kg for men and over 10 kg for women. Anyone lifting several times per minute or moving loads above shoulder height reaches the critical range at lower weights. Which aids help when lifting boxes is shown in the guide Lifting aids for boxes. How much may you lift during pregnancy? Pregnant workers are the only group with fixed legal values. Under Section 11(5) of the German Maternity Protection Act, they may not regularly lift, hold, move or carry more than 5 kg, or occasionally more than 10 kg, by hand without mechanical aids. With aids, no comparable physical strain may arise. The employer must assess the working conditions for this under Section 10 MuSchG. A lifting aid can redesign the workplace so that continued employment remains possible, instead of transferring or releasing the employee. Does this also apply to young people and apprentices? Additional restrictions apply to young people and apprentices under 18. The German Youth Employment Protection Act (JArbSchG) sets no fixed kilogram limit, but Section 22 prohibits young people from work that exceeds their physical capacity. In practice, employers' liability insurance associations use much lower reference values than for adults, as bones and intervertebral discs are not yet fully developed. Under the age of 15, employment is generally prohibited under Section 5 JArbSchG anyway, with exceptions such as school work placements. A case such as a 14-year-old repeatedly lifting 80 kg is therefore clearly outside any common reference value. At apprentice workstations with regular load handling, a lifting aid often pays off at much lower weights. When the load is too heavy: handling technology from Zeilhofer Once components exceed the limit of safe manual lifting, handling technology fulfils the duty to avoid under Section 2(1) LasthandhabV. Depending on weight and movement, a different system fits: Hebelift ZH: mobile and moved by hand, 48 V battery, up to 100 kg, ideal for frequent lifts at changing workstations Rope manipulator: light and fast, up to 150 kg, for high cycle rates ZH90 Flex-Arm: combines a Z-axis with an articulated arm, up to 200 kg Articulated manipulator: sway-free load guidance up to 800 kg, for positioning, rotating and tilting ZH90 lifting axis: linear Z-axis, sway-free up to 1,200 kg, for heavy vertical lifts Lift-rotate device ZH: lifting and turning assemblies, electric up to 4,000 kg Every solution is designed individually for load, motion sequence and environment. An overview of all types is available in the guide Lifting aids for production and industry, the basics are explained in What is a manipulator? and What is a lifting axis? Find the right system for your component in a few clicks with the product finder. A simple rope manipulator starts at approx. EUR 10,000 without installation, complex lifting axis solutions reach up to approx. EUR 150,000. Details in the guide What does a manipulator cost? Instead of a one-off payment, leasing and hire purchase are available, see Leasing and financing lifting aids. Ergonomics and cost-effectiveness If the critical load is regularly exceeded, musculoskeletal disorders become a risk, one of the leading causes of lost working days in production. What these absences really cost is calculated in the article Musculoskeletal disorders in production. Technical lifting aids measurably reduce physical strain, reduce awkward postures and at the same time improve takt reliability and throughput. Ergonomic workplaces are also an argument in the competition for skilled workers. More under Function and benefits. Further practical examples How an assembly workstation is relieved in practice is shown in the article Lifting aid for assembly. More examples can be found in the blog, and all topics in the guides overview. Individually engineered, all from one source Every workplace has its own requirements. That is why every solution is developed individually: engineering, design, manufacturing, commissioning and service all come from one source in Holzkirchen, Germany. Zeilhofer Handhabungstechnik has been certified to ISO 9001 since 2008 and works to TISAX Level 2 with prototype protection. With more than 2,500 systems delivered since 1999, solutions for 18 industries and customers in over 50 countries, we understand the requirements of heavy and sensitive components. Frequently asked questions (FAQ) How many kg may you lift at work? Germany has no fixed legal limit for adults. What counts is a risk assessment under the Load Handling Regulation, usually with the Key Indicator Method. As a guideline for occasional lifting, around 25 kg for men and 15 kg for women apply. How many kg may a woman lift? As a guideline, around 15 kg apply to women for occasional lifting and around 10 kg for frequent lifting. These are reference values, not legal limits. Binding values only exist during pregnancy: at most 5 kg regularly and at most 10 kg occasionally. What is the Key Indicator Method? The Key Indicator Method of the German Federal Institute for Occupational Safety and Health (BAuA) rates the risk of lifting, holding and carrying based on frequency and duration, load weight, posture and working conditions. The score assigns the task to one of four risk ranges, from low to high. What does the Load Handling Regulation require from employers? Under Section 2(1), the employer must avoid hazardous manual lifting through organisational measures or suitable equipment, in particular mechanical devices. If that is not possible, Section 2(2) requires an assessment of the working conditions, Section 3 the consideration of physical suitability and Section 4 instruction of employees. From what weight does a lifting aid make sense? As soon as the Key Indicator Method results in risk range 3 or 4, design measures are advisable or required. With frequent lifting or awkward posture, this is often the case well below 25 kg. How much may you lift during pregnancy? Under Section 11(5) of the German Maternity Protection Act, pregnant workers may not regularly lift, hold, move or carry more than 5 kg, or occasionally more than 10 kg, without mechanical aids. A lifting aid can redesign the workplace so that continued employment remains possible. Are there separate lifting limits for young people? The German Youth Employment Protection Act sets no fixed kilogram figure, but Section 22 prohibits work that exceeds young people's physical capacity. In practice, much lower reference values apply than for adults. A 14-year-old repeatedly lifting 80 kg is far outside any common reference value. Is verbal instruction of employees enough? Instruction under Section 4 of the LasthandhabV must take into account the characteristics listed in the regulation's annex and the physical suitability of employees. It should be documented and repeated at reasonable intervals. Does buying a lifting aid automatically make you compliant? No. The lifting aid fulfils the duty to avoid manual handling under Section 2(1). Risk assessment, documentation and instruction remain separate employer obligations. What is the difference to the UVV inspection? The Load Handling Regulation governs the physical strain on people during manual lifting. The UVV inspection under DGUV Regulation 54 concerns the technical safety of the lifting aid itself and is carried out annually. Which loads can a Zeilhofer lifting aid move? The Hebelift ZH lifts up to 100 kg on the move, the rope manipulator up to 150 kg, the ZH90 Flex-Arm up to 200 kg, the articulated manipulator up to 800 kg and the ZH90 lifting axis up to 1,200 kg. The lift-rotate device ZH turns assemblies up to 4,000 kg. Have your workplace analysed Want to know from what weight a lifting aid pays off at your workplace? We analyse your process and develop a suitable solution. We reply to enquiries within 24 hours on working days. Request a free consultation. Sources: German Load Handling Regulation (LasthandhabV), Section 11 Maternity Protection Act, Section 22 Youth Employment Protection Act, BAuA: limits for lifting, holding and carrying. As of October 2026. This article does not replace legal advice or a risk assessment. Stay up to date: with our newsletter you receive new guides, application examples and news on lifting aids directly in your inbox. #OccupationalSafety #Ergonomics #LoadHandling #HandlingTechnology #LiftingAid #Manipulator #KeyIndicatorMethod #WorkplaceSafety #Production #ZeilhoferHHT

The internal components of a fire door are heavy, large, and must be precisely fitted into the door frame. Previously, this often required two people. In our explanatory video, we demonstrate step by step how a manipulator from Zeilhofer Handhabungstechnik performs this exact task: ergonomically, precisely, and with virtually any component size. The solution originated from a specific customer request in the door manufacturing industry. We explain which manipulator is used and for whom it is suitable in the product article "Manipulator for Fire Doors". This article explains how it works: how the internal components are picked up, moved, and precisely fitted into the frame. What are the inner workings of fire doors? A fire door consists of more than just the visible door leaf. Inside, a special insert, the so-called core, provides the fire-resistant properties. Depending on the fire protection class, such as T30, T60, or T90, this core has a different construction, and is correspondingly heavier and more susceptible to damage. During assembly, the internal components must be precisely fitted into the surrounding frame. This step is physically demanding and crucial for the quality of the finished door. Inaccuracies or damage during insertion directly affect the fire door's functionality. The challenge: heavy slabs, previously handled by hand The video clearly illustrates the initial problem: Two people had to lift the massive plate together and place it into the frame. Manually handling such components is physically demanding, ties up personnel, and is neither ergonomic nor efficient in the long run. The customer, a door manufacturer, therefore needed a solution that would significantly simplify the insertion of the internal components and simultaneously reduce the strain on employees. We explain in detail on our benefits page why ergonomic handling technology is becoming increasingly important, especially in production. Here's how the solution works step by step The process shown in the explanatory video demonstrates how easy it is to handle the manipulator: 1. Pickup: The manipulator is guided over the interior. The gripper closes until it has securely grasped the component. 2. Lifting: The heavy plate is lifted almost weightlessly. Instead of two people, one person now operates the system. 3. Moving and positioning: The component is guided to the frame in a controlled and pendulum-free manner and aligned precisely. 4. Insertion: The inner components slide perfectly into the prepared frame. 5. Placement: Once the position is reached, the gripper releases. The process is complete. The crucial point: The entire process can be repeated as often as desired and delivers the same precise result for every component. The adaptive gripper: flexible for any size A key feature of the solution is the gripping device. It automatically adapts to the component: the gripper simply closes until it has securely grasped the internal parts. This ensures reliable handling even with small formats. This allows for the handling of different door sizes and variants without complex retooling. Various manipulator designs and individually developed grippers make the system a perfectly tailored solution for each production task. We explain what a manipulator is in our guide: What is a manipulator? The result: ergonomics, speed, and repeatability The manipulator transforms a physically demanding two-person task into an ergonomic one-person process. Employees experience a noticeable reduction in strain, lowering the risk of injury and fatigue. Simultaneously, speed increases because the internal components slide directly into the frame in a controlled manner, without any pendulum motion. For the customer, this means consistently high quality, a safer workplace, and a more efficient production process. Or, as the video puts it: handling technology can be something truly beautiful. Do you have a similar handling task? Whether it's the internal components of fire doors, other large-format building elements, or delicate workpieces: Together, we analyze your process and develop a suitable manipulator with a customized gripper solution. From our base in Holzkirchen, we serve customers in over 50 countries. #ZeilhoferHHT #FireDoors #InteriorDesign #DoorManufacturing #HandlingTechnology #Manipulator #GripperSolution #Ergonomics #ExplainerVideo #IndustrialAutomation #LoadHandling #AssemblyTechnology #MadeInGermany

Electric lifting aid works entirely without compressed air. Battery-powered systems are mobile and flexible, usable where no compressed-air network is available. Fully electric lift axes also lift the heaviest loads with precision. Zeilhofer Handhabungstechnik from Holzkirchen, Germany, engineers every electric lifting aid individually. For the full comparison of drive concepts, see our guide Pneumatic or electric lifting. This article focuses on the electric solution. ZH lift with suction device for stainless steel inner boxes How an electric lifting aid works Instead of compressed air, the electric lifting aid uses an electric drive or battery. The operator guides the load with little effort, the system carries the weight and holds the position safely, even during a power failure thanks to load-holding brakes. Advantages of the electric lifting aid no air network needed, usable anywhere. battery-powered lifts are movable and flexible. ideal for cleanroom, food and pharma. fully electric lift axes achieve high repeatability. Electric or pneumatic: in brief With existing compressed air and sensitive balancing, pneumatic is often preferable. Without compressed air, at changing locations or in hygienic areas, electric wins. The detailed comparison is in the guide Pneumatic or electric lifting. Applications and load ranges Mobile, battery-powered lift up to 100 kg for changing workplaces. Fully electric lift axis up to 1,200 kg for heavy vertical lifts without compressed air. Cleanroom, food and pharma, where compressed air should be avoided. More on the strongest solution: ZH90 lift axis. How pendulum-free guidance works is explained in function and benefit. Ergonomics and cost-effectiveness Every lifting aid lowers the risk of musculoskeletal disorders. Whether the investment pays off is shown in amortisation and ROI of a lifting aid. Zeilhofer is certified to ISO 9001 and TISAX Level 2 with prototype protection. Individual engineering Whether mobile and battery-powered or fully electric and stationary: Zeilhofer plans every electric lifting aid from process analysis through design and manufacturing to commissioning and service, all from a single source. Frequently asked questions about electric lifting aids What is an electric lifting aid? A lifting aid with an electric or battery drive that lifts loads without compressed air. It ranges from the mobile lift up to 100 kg to the fully electric lift axis up to 1,200 kg. Does an electric lifting aid need compressed air? No. Electric and battery-powered lifting aids work without a compressed-air network and are therefore usable independently of location. How heavy may the load be? The mobile, battery-powered lift handles up to 100 kg. Fully electric lift axes reach up to 1,200 kg. The right size depends on load, cycle time and installation space. Electric or pneumatic: which is better? There is no universally best drive. Without compressed air or for mobile, hygienic applications, electric is preferable; with compressed air and sensitive balancing, often pneumatic. Your electric lifting aid Talk to our engineers about your application. We check whether electric, pneumatic or electropneumatic fits best and develop the solution from A to Z. #ElectricLiftingAid #LiftingAid #Battery #Manipulator #LiftAxis #Ergonomics #HandlingTechnology #NoCompressedAir #Cleanroom #ZeilhoferHHT

In window production, Zeilhofer Handhabungstechnik moves heavy glass panes and window elements ergonomically and without damage. Vacuum suction devices pick up the smooth, sensitive surfaces gently. The ZH90 lifting axis combined with a suction device guides large panes pendulum-free. #GlassHandling #VacuumLifter #LiftingAxis #zhht

A mobile lifting aid for panels is a wheeled lifting device that uses a suction cup to pick up panels, lifts them, and transports them on wheels precisely to where they are needed. The solution from Zeilhofer Handhabungstechnik is based on the battery-powered Hebelift ZH. It lifts loads up to 100 kg and operates without a crane, rail system, or compressed air. This article presents a current practical example with two suction cups and explains its function, design, and safety. It will also help you decide whether a mobile solution is suitable for your panel handling needs. Explainer video: Mobile lifting aid for panels The most important points in brief What: Mobile lifting aid with suction device for moving panels, also known as a mobile panel lifter or floor trolley with suction device. Mounting: two suction cups that can securely grip almost any flat component with a smooth, dense surface. Load capacity: Basic unit up to 100 kg. The device is designed for the actual component; the system shown is designed for 15 kg. Power: 48-volt lithium-ion battery for a full shift. Charging is done at any standard wall socket; the battery is quickly replaceable. Movement: Lifting via electric spindle drive, movement and alignment via omniwheels, the carriage turns on the spot and moves sideways. Safety: Vacuum pumps with pressure gauge, overload protection and crush protection sensors. Infrastructure: no compressed air, no crane, no rails, no foundation. Manufacturer: Development and production in Holzkirchen, over 2,500 systems delivered since 1999, certified according to ISO 9001 and TISAX Level 2 with prototype protection. What is a mobile lifting aid for panels? A mobile lifting aid for panels combines three functions in one device: a chassis, a lifting column, and a holding device that grips the panel using negative pressure. Unlike a vacuum lifter on a crane, it is not tied to a crane track. Unlike a stationary manipulator, it does not require a fixed location. The operator drives the device to the panel, picks it up, and moves it to the next work step. Several terms are used in common parlance for this device: mobile panel lifter, wheeled panel lifter, panel lifting device, or floor trolley with suction device. These should be distinguished from two types of equipment with similar names: Panel lifts used in drywall construction lift plasterboard panels to the ceiling using a hand crank and are not intended for mass production. Hand suction lifters with one or two suction cups are carried and therefore do not relieve the back. Practical example: Moving panels using two suction cups The system shown on the cover solves a problem found in almost every manufacturing process: A plate is picked up at one point, moved a few meters, and precisely placed at another. The device uses two suction cups for this purpose. These cups make contact with the plate, the vacuum pump creates a vacuum, and the plate is securely attached to the device without any jamming or pressure marks. The system shown is designed for 15 kg because the customer's workpiece weighs no more than that. The Hebelift ZH, as the basic unit, can lift up to 100 kg. However, we always design the device specifically for the actual component, not for the maximum technically possible load. This keeps the system lightweight, maneuverable, and economical. Two suction cups, many components Two suction cups at a fixed distance are sufficient for most flat components. They hold the part securely and prevent it from twisting around the suction axis. This means that the same device can be used to pick up anything with a smooth and sufficiently dense surface. Sheets made of metal, plastic, glass or coated wood-based material Sheet metal and cut-to-size pieces Panels, cladding and side walls Lids, doors and housing parts Mounting plates Only with large or flexible formats do we use additional suction cups to prevent the panel from bending when lifted. How does the mobile lifting aid for panels work? The process is divided into five steps: Approach: The operator pushes the device against the stack of plates, the rack, or the machine. Thanks to omniwheels, this is also possible sideways and in narrow aisles without the need for maneuvering. Suction: The two suction cups are placed on the plate. The vacuum pump creates a vacuum, and the pressure gauge shows the operator that the plate is held securely. Lifting: An electric spindle drive lifts the platform smoothly and without oscillation. Working heights can be programmed via the joystick, allowing for quick access to frequently used positions. Alignment: The plate is not rotated at the device itself, but with the entire carriage. The carriage rotates on the spot and moves sideways, so the plate is quickly in the correct position. Travel and placement: The operator guides the plate to the destination, places it precisely, and releases the vacuum. Technology at a glance Basic unit: Hebelift ZH made of extruded, patented aluminum profiles, with three or four chassis. Drive: 48-volt lithium-ion battery, quickly interchangeable. The Hebelift ZH was the first lift in the world with this battery. Chassis: specially developed Omniwheels for movement in all directions, significantly smoother than conventional fixed casters. Operation: Joystick with programmable working heights, one-handed operation possible. Device: two suction cups with vacuum pump and pressure gauge. Rotating or tilting units are available as options if required by the application. All variants can be found on our page Devices, Grippers, Suction Cups and Magnets. Safety: Overload protection and sensors to prevent crushing. Extension: optionally with articulated arm for greater reach. Our guide to the Hebelift ZH without compressed air explains why battery operation opens up so many applications. The basics of vacuum technology can be found in the article "What is a suction device?" Which panels can be lifted with a suction device? The material is not the deciding factor, but rather the surface. A suction cup will only adhere reliably if the surface is as airtight, flat, and load-bearing as possible. Sheets made of steel, stainless steel, and aluminum are very well suited. For oiled sheets, we select the appropriate suction cup material and profile to prevent the sheet from slipping. Mounting plates: very suitable, also galvanized or coated. Coated wood-based materials (melamine-coated chipboard, lacquered MDF, furniture fronts): well suited. Raw chipboard or OSB panels are permeable to air and require higher suction power or a different mounting solution. Plastic and composite panels (acrylic glass, polycarbonate, aluminum composite panels): well suited, sensitive surfaces remain scratch-free. Glass plates: well suited. A prerequisite is a suction cup distribution adapted to the size and weight. Highly structured, perforated, or porous panels: only with a special design. Here we check whether a suction device, gripper, or magnet is the better choice. Our article "Handling Plates Safely: Which Attachment Fits Your Plate?" explains in more detail which mounting device is best for which panel type. How heavy is my panel? Calculation examples You can calculate the weight of a panel using a simple formula: length × width × thickness × density. The following examples show how quickly common formats reach the limits of what is manually manageable: Steel sheet 2,000 × 1,000 × 3 mm: approximately 47 kg Stainless steel sheet 2,000 × 1,000 × 2 mm: approximately 32 kg Aluminum plate 3,000 × 1,500 × 4 mm: approximately 49 kg Mounting plate made of galvanized steel 1,700 × 1,100 × 3 mm: approx. 44 kg Float glass 2,000 × 1,000 × 8 mm: approximately 40 kg Chipboard 2,800 × 2,070 × 19 mm: approximately 72 kg MDF board 2,800 × 2,070 × 19 mm: approximately 83 kg Acrylic glass 3,050 × 2,050 × 8 mm: approximately 60 kg Even lightweight panels like the 15 kg ones from our practical example quickly become unwieldy due to their size, because the center of gravity is far from the body and the movement is repeated many times per shift. Our article "How many kg can you lift?" explains how the permissible load is assessed when lifting manually. How much suction power does a plate need? The theoretical holding force of a suction cup is calculated by multiplying the vacuum pressure by the suction area. A round suction cup with a 100 mm diameter achieves a theoretical holding force of approximately 470 Newtons, or about 48 kg, at a vacuum pressure of 0.6 bar. In practice, this force is never fully utilized for three reasons: Safety factor: In vacuum technology, a safety factor of at least 2 is common for horizontally mounted plates. Vertical plates: If the plate is vertical, it is no longer the suction force that holds it in place, but rather the friction between the suction cup and the surface. This significantly increases the required suction area. Dynamics: Additional forces act on the plate when the car starts, brakes and turns. Therefore, we always determine the number, size, and position of the suction cups for the specific plate and movement. The calculation above is for guidance only and does not replace a proper design. Where is the mobile lifting aid for panels used? Control cabinet construction: Pick up mounting plates from the storage trolley and bring them to the enclosure. More information can be found in the guide "Lifting aids in control cabinet construction". Sheet metal and metal processing: Moving blanks between storage, press brake, welding station, and assembly. For loading laser cutting systems with heavy sheets, we recommend stationary solutions; see Loading sheets into laser cutting systems. Wood and furniture industry: transporting coated panels and furniture fronts from the stack to the machine without scratching. See also manipulator for the wood industry. Equipment and plant construction: Moving cladding, side walls, covers and doors in assembly. Glass and window construction: Move panes and fillings ergonomically, see Handling of glass panes. Plastics processing and facade construction: Handling acrylic glass, polycarbonate and composite panels without damaging the surface. Prototype construction, testing and maintenance: one device for changing tasks, without installation and without being tied to a specific workplace. Mobile lifting aid, crane or manipulator: which is the right fit? Not every task on a flat surface requires a mobile solution. The following classification will help you decide. The mobile lifting aid for panels is the right choice if the panels weigh up to 100 kg, the work locations change or multiple workplaces are served no crane track and no compressed air are available The aisles are narrow and a lateral approach is needed. A stationary manipulator or lifting axis is better if the plates are heavier: articulated manipulator up to 800 kg, lifting axis ZH90 up to 1,200 kg, work is carried out at a fixed workstation at a high pace the plate must be swivelled over large radii. A vacuum lifter on the crane is useful if a crane track is already in place, very large formats can be moved over longer distances. Why a device with rigid load guidance is often more precise than a vacuum tube lifter is explained in the guide "Tube Lifter or Device?". When a lifting platform is generally the right choice is explained in the guide "Lifting Platform: When is it the right choice?". If you are still unsure, our product finder will guide you to the right lifting aid in just a few steps. Safety: what you should pay attention to when handling plates with a vacuum A panel detaching from the suction cup and pinch points between the device, panel, and surroundings are the greatest risks in mobile panel handling. The DIN EN 13155 standard for loose lifting devices provides guidance on safety requirements for vacuum lifters. The following points should be checked for each solution: Vacuum indicator: A pressure indicator on the vacuum pump shows the operator at all times whether the plate is held securely. Warning device: If the negative pressure drops into the danger zone or the power supply fails, a warning must be issued. Vacuum reserve and check valve: They hold the plate in place during brief pressure drops. Overload protection: It detects when the load exceeds the design specifications and protects the device and operator. Crushing protection: Sensors stop the movement before hands or body parts are trapped. Annual inspection: Like any lifting aid, the mobile lifting aid for panels is also subject to the annual UVV inspection, which Zeilhofer offers as a service. The system in our practical example is equipped with vacuum pumps with pressure gauges, overload protection, and crush sensors. We will determine together during the project planning phase what additional safety features your application requires. Ergonomics: why plate handling without muscle power is worthwhile Musculoskeletal disorders are the leading cause of sick days in Germany. According to the AOK Absenteeism Report, 19.8 percent of all sick days in 2024 were attributable to this group of illnesses, often resulting in extended absences. According to the BIBB/BAuA survey of the working population, approximately one in four employed individuals reports frequently lifting and carrying heavy loads (BAuA). When handling large sheets, there's an additional factor that weight specifications alone underestimate: the size. A large sheet is moved with outstretched arms, a twisted torso, and often by two people. The key indicator method identifies precisely these postures as particularly strenuous, even with lighter weights, if the movement is repeated frequently. Employers are obligated under occupational health and safety legislation and manual handling regulations to assess such hazards and reduce them through the use of appropriate equipment. Learn more in the guide "Ergonomics at the Assembly Workplace" and in our white paper "Lifting Aids 2027". With the mobile lifting aid, the device carries the weight; the operator only needs to guide it. A two-person task often becomes a one-person task, and expensive surfaces remain free of scratches and edge damage. Cost-effectiveness: what the mobile solution saves No infrastructure: crane track, rail system and compressed air connection are not required. Retrofitting a compressed air system quickly costs five figures. Low energy costs: Depending on the electricity price, a battery charge costs approximately 0.50 to 1.00 euros and is sufficient for one shift. Multiple use: One device serves several workplaces, halls or departments. Less waste: Controlled picking up and putting down protects sensitive surfaces. Less personnel required: Plates that previously required two people to carry are now moved by one person. Financing: In addition to purchasing, leasing with a term of 24, 36 or 48 months and hire purchase through our financing partner are possible. Our guide "What does a manipulator cost?" explains which factors determine the price of a lifting aid. From inquiry to finished system Process analysis: We clarify plates, movements, cycle times and environment, preferably directly at your location. Design: Our engineers design the basic unit, suction device and safety equipment. Manufacturing: The system is being built in our 2,500 m² hall in Holzkirchen. Acceptance: You accept the system at our premises, optionally also as a digital pre-acceptance. Commissioning and training: We will put the system into operation and train your employees. Service: Maintenance, spare parts and the annual UVV inspection from a single source. Checklist for your request To enable us to quickly provide you with a reliable offer, the following information will be helpful: Panel material and surface (for example, oiled, coated, textured) Formats, thicknesses and weights, ideally the smallest and the largest sheet Pick-up position (stack, rack, machine) and storage position Number of lifting operations per shift Environment and pathways (aisle widths, floor conditions, use in multiple halls) Photos or a short video of your process today would be especially helpful. We respond to inquiries within 24 hours on weekdays. Why Zeilhofer Handhabungstechnik Zeilhofer Handhabungstechnik, based in Holzkirchen, has been developing, designing, and manufacturing lifting aids, manipulators for loads up to 800 kg and lifting axes for loads up to 1,200 kg since 1999. Around 250 custom-built systems leave our factory each year, totaling over 2,500 systems across 18 industries, from major automotive manufacturers to medium-sized production companies. The basic unit, fixture, and control system all come from a single source, certified according to ISO 9001 and TISAX Level 2 with prototype protection. Do you want to move panels in your production without effort? Send us your application, and we will get back to you within 24 hours. Frequently asked questions about the mobile lifting aid for panels What is a mobile lifting aid for panels? A mobile lifting device that picks up panels via a suction mechanism, lifts them, moves them, and precisely places them at a different location. Zeilhofer's solution is based on the battery-powered Hebelift ZH, lifts up to 100 kg, and requires neither a crane nor rails nor compressed air. Are two suction cups enough to safely lift a plate? Yes, for sheets and flat components with a smooth, dense surface. Two suction cups at a fixed distance hold the part securely and prevent it from twisting around the suction axis. Only with large or flexible formats are additional suction cups necessary to prevent the sheet from warping. Which panels can be lifted using a suction device? Panels with the densest possible, flat surface: sheet metal, mounting panels, coated wood-based materials, plastic, composite, and glass panels. Raw, porous, or perforated panels require a special design or a different mounting method. How heavy can the panel be? The Hebelift ZH is designed for loads up to 100 kg. The device is adjusted to the actual component: The system shown in the article is designed for 15 kg because the workpiece weighs no more than that. Heavier plates are handled by the articulated manipulator (up to 800 kg) or the ZH90 lifting axis (up to 1,200 kg). How do I calculate the weight of a plate? Length times width times thickness times density. A steel sheet measuring 2,000 × 1,000 × 3 mm weighs approximately 47 kg, an MDF board measuring 2,800 × 2,070 × 19 mm weighs approximately 83 kg. How is the plate aligned? In the version shown, it's not the device itself that rotates, but the entire carriage. Thanks to omniwheels, it turns on the spot and moves sideways, allowing for precise alignment of the plate. Rotating or tilting units on the device are available as options if the application requires them. Does the mobile lifting aid require compressed air or a crane? No. The lifting drive, vacuum, and control unit run on a 48-volt battery that lasts one shift and can be charged at any standard household outlet. When is a stationary manipulator the better choice? For panels weighing over 100 kg, high cycle rates at a fixed workstation, or large swivel radii. The mobile solution demonstrates its strengths at changing locations and without hall infrastructure. What safety features does the mobile lifting aid have? The system shown uses vacuum pumps with pressure gauges, overload protection, and sensors to prevent crushing. DIN EN 13155 provides guidelines for vacuum lifters. In addition, an annual safety inspection is mandatory. What information does Zeilhofer need to prepare a quote? Sheet material and surface, formats and weights, picking and putting positions, lifting operations per shift, and the routes within the plant. We answer inquiries within 24 hours on weekdays.

We developed the #collaborative lifting axis ZH90 so that it can work safely and efficiently with people in a shared work environment. In contrast to conventional industrial robots, which often work in closed cells and operate separately from people, our lifting axis is designed to #interact directly with human employees and work together on tasks. Here are some features and #characteristics of our collaborative lifting axis ZH90📯: ▶️ #Safety: The lifting axis is equipped with advanced safety systems, including sensors and software that detect and avoid obstacles. This helps prevent collisions with people and makes the work environment safe. ✔️ ▶️ #Flexibility: The lifting axis is easily programmable and adjustable to perform different tasks in different industries. It can be quickly reprogrammed to learn and accomplish new tasks. ✔️ ▶️ #Working mode: The lifting axis can be moved or operated manually, collaboratively or automatically. ✔️ ▶️ Proximity to work: The lifting axis is designed to work in close proximity to human employees. This facilitates collaboration between humans and machines. ✔️ ▶️ #User-friendliness: Operating the lifting axis is easy and does not require extensive programming knowledge. For example, it is possible to program this using the teach-in procedure, in which the employee guides the lifting axis through the desired movements. ✔️ ▶️ #Versatility: The possible uses are extremely versatile. ✔️ The ZH90 lifting axis thus helps to advance #automation in many areas by supporting and complementing human #workforce instead of replacing it. This enables more efficient #production, better #quality and a safer working environment. 🧑‍🏭 #zhht #automation #robots #manufacturing #cobots #workforce #innovation #technology #assembly #automotiveindustry #eMobility

High-voltage storage units are the heart of modern e-mobility. At the same time, they place enormous demands on handling: With a weight of up to 800 kg, they are not only heavy, but also sensitive and safety-relevant. This is precisely where our ZH90 lifting axis comes in. It enables the precise, safe, and ergonomic handling of these components, from picking up and precise positioning to assembly. 🛡️ Maximum safety: Stable guidance and sensitive positioning protect components, machines and people. 🍃 Ergonomic working: No manual lifting or use of force: the health of employees remains protected. 🎯 Highest precision: Even with sensitive components such as HV storage devices, the ZH90 ensures millimeter-precise handling. 🚀 Increased efficiency: Faster, controlled movement of the heaviest components saves time and money. This makes handling high-voltage storage systems not a challenge, but a safe, efficient and predictable process 📈 #zhht #LiftingAxisZH90 #HighVoltageStorage #Electromobility #AutomotiveIndustry #HandlingSolutions #Industry40 #ErgonomicsAtWork #SafeHandling #IncreasedEfficiency #Precision #EnergyFuture #SmartProduction #HeavyLoadHandling #MadeInGermany

The ZH90 lifting axis moves what drives electromobility: high-voltage batteries with up to 800 kg 💪 Well-designed, sensitive & easy to operate, quick to use: this makes handling heavy high-voltage batteries child's play 🚀 #zhht #LiftingAxisZH90 #HighVoltageStorage #Electromobility #AutomotiveIndustry #HandlingSolutions #Industry40 #ErgonomicsAtWork #SafeHandling #IncreasedEfficiency #Precision #EnergyFuture #SmartProduction #HeavyLoadHandling #MadeInGermany

Sand core handling is gentlest when the core is picked up from the inside through its bores. A pendulum-free articulated arm manipulator with two picking pins holds the sand core securely without clamping the delicate outer contour, completely relieving the operator of the weight. Zeilhofer Handhabungstechnik has developed such a solution for the core-making department of a foundry. There, nine different sand cores, weighing between 1.1 and 68.9 kg, are picked up, rotated, and inserted within a working radius of 3 m. This article shows how the picking process works, which data determines the design, and what foundries should consider when choosing a lifting aid for sand cores. What is sand core handling? Sand cores create cavities, channels, and undercuts in the casting. Before casting, they must be removed from the core shooting machine or the core supply, assembled into a core pack, or placed directly into the mold. All these steps together are referred to as sand core handling. The larger and heavier the cores, the more important a handling technique becomes that combines precision, component protection, and ergonomics. Why sand cores require special handling Sand cores consist of bonded molding sand. They are dimensionally stable, but sensitive at edges and surfaces. Even slight impact or excessive clamping pressure can cause chipping, which later reappears as defects in the casting. The result is rework, scrap, or in the worst case, a completely discarded core package. A gripping solution for sand cores must therefore fulfill two requirements simultaneously: it must hold the core securely without stressing its outer contour. Conventional external grippers quickly reach their limits in this regard. The starting point in the practical example: nine cores up to 68.9 kg In our customer's core shop, several sand cores with very different weights are produced for each casting: Top core: 68.9 kg, must be turned 180 degrees before insertion. Base core: 37.0 kg Inner core 01: 37.0 kg Side core 01 and 02: approximately 24.0 kg each Frontal core: 22.0 kg Sprue core: 14.0 kg Inner core 02: 11.0 kg Locking cores: 1.1 kg The cores measure between 480 x 410 mm and 670 x 620 mm. Some are picked up from the side, others from above. Handling the fully assembled core package is not strictly necessary; the focus is on the individual cores. From manual hole gripper to lifting aid Previously, the cores were installed using a manual hole gripper. While this principle already engages gently in the core hole, the entire weight is borne by the operator. With cores weighing over 20 kg, numerous repetitions per shift, and the precise insertion into tight core holders, this is neither ergonomic nor reliable in the long run. The task was therefore: to retain the proven gripping principle via the bore, but to transfer the weight completely to a lifting aid and additionally to enable the turning of heavy cores. The solution: a receiving device with an internal grip via the core hole The core component is a specially designed receiving device. Two receiving mandrels engage with the existing bushing holes in the core, either Ø 20 mm conical at a depth of 50 mm or Ø 40 mm at a depth of 65 mm, depending on the core. Rubber elements on the mandrels expand upon engagement and hold the core from the inside. High clamping forces from the outside are completely eliminated. Depending on the geometry, the core is picked up from the side or from above. The article "Manipulator with Internal and External Grips" explains when an internal and external grip is suitable. A related spreading principle for roller cores is shown in the article "Manipulator with Interchangeable Spreading Mandrel". This is how inserting a sand core works. Guide the manipulator over the provided core and align the receiving mandrels with the socket holes. Insert the prongs; the rubber elements expand and hold the core from the inside. Lift the core; the manipulator bears the entire weight. Swivel the core towards the installation point and, if necessary, rotate it up to 180 degrees using a joystick. Lower the core into the core bearing or core pack without it swinging. Relax the rubber elements, pull out the prongs and pick up the next core. Four axes of rotation: Turn cores without repositioning To ensure that each core arrives in the correct position without repositioning, the manipulator has four axes of rotation: Main axis: manually rotatable 360 degrees continuously Boom arm: manually rotatable by 300 degrees Mounting device: manually rotatable through 360 degrees Gripper: pneumatically rotatable by 180 degrees, infinitely variable via joystick control This also allows the 68.9 kg top core to be turned over in a controlled manner and placed down precisely, without the employee having to hold or support it. Technical specifications at a glance Core weights: 1.1 to 68.9 kg Working radius in relation to the component: 3,000 mm Stroke range: 260 to 1,200 mm lower edge of component Interference contour: 3,100 mm lower edge of crane hook Mounting: two prongs with expanding rubber elements, from the side or from above Installation: on a stable base plate, without ground anchoring Movement: pendulum-free, gripper rotation pneumatically controlled via joystick External gripper, hole gripper or manipulator with internal grip: a comparison In practice, three approaches are possible for sand cores, which differ significantly in component protection and load-bearing capacity: External gripper or tongs: quick to implement, but high clamping pressure on the core surface and therefore an increased risk of chipping. Manual hole gripper: protects the outer contour, but the full core weight rests on the employee; heavy cores are difficult to turn. Manipulator with internal grip: protects the outer contour, bears the entire weight, enables rotation and millimeter-precise insertion Why an articulated arm manipulator and not a crane? Sand cores are often picked up laterally, and therefore off-center. A crane or chain hoist swings, and this swinging motion causes them to hit edges during insertion. An articulated arm manipulator absorbs the moments from the off-center load and remains stationary in any position. The differences are explained in the guide "Manipulator, Crane or Chain Hoist: What for What?", and the choice of the appropriate system is explained in the guide "Articulated or Cable Manipulator". For purely vertical lifting tasks with heavy loads, the ZH90 lifting axis is an alternative; it lifts up to 1,200 kg. An example of this is the lifting axis with a clamping device for sand cores. Ergonomics and occupational safety in core making Lifting weights between 20 and 70 kg, many repetitions per shift, plus twisting and precise positioning in a stooped position: This is a classic workload situation according to the German Manual Handling Regulations. The article "How many kg can you lift?" shows where the limits lie. The article "Musculoskeletal Disorders in Production" calculates what sick days due to back problems actually cost a company. The employee only guides the core using the manipulator. Experience and dexterity in core placement remain with the human; the technology takes care of the weight. What matters when designing sand cores Every core-making facility works with different cores and processes. For a reliable design, we primarily need: Core list with weight and dimensions per core Location, diameter and depth of the receiving bores Pick-up direction (side or top) and required rotations Working radius, lifting range and interfering contours such as crane runways or hall columns Cycle time and number of cores per layer Installation location: Base plate, floor anchoring or ceiling mounting From the core list to the first inserted core Analysis: We evaluate the core list, bore pattern and installation location and determine which cores can be accessed with a common device. Design: You will receive a concept for the manipulator, mounting mandrels and rotary axes with an initial price indication. Construction: Design and manufacturing in Holzkirchen, certified according to ISO 9001 and TISAX Level 2 with prototype protection Handover: Setup, employee training and commissioning directly at your foundry, with regular safety inspections upon request. Since 1999, Zeilhofer Handhabungstechnik has delivered over 2,500 systems for 18 industries. Further solutions for foundries include the manipulator for molding boxes and the ZH90 lifting axis in foundry operations. All industries can be found in the application overview. Frequently asked questions about sand core handling What is meant by sand core handling? Sand core handling refers to the picking up, transporting, rotating, and inserting of sand cores in the foundry, for example, when assembling a core package or placing it into the mold. The aim is to move the delicate cores without damage and without physically overexerting the employees. How do you handle sand cores without damaging them? The gentlest method is through existing core holes from the inside. Receiving mandrels with expanding rubber elements hold the core without clamping the delicate outer contour. A pendulum-free manipulator further prevents impact and chipping during insertion. What is the difference between a hole gripper and a manipulator with an internal grip? A manual core gripper also engages the core hole, but the operator bears the weight. With a manipulator featuring an internal grip, the lifting aid takes over the entire weight; the operator only guides the core. From what core weight does a lifting aid become worthwhile? Even cores weighing around 15 to 25 kg put considerable strain on the back when lifted frequently; heavier cores are almost impossible to insert precisely without aids. The assessment is carried out according to the Manual Handling Regulations and the key indicator method. Can a manipulator rotate or turn sand cores? Yes. In practical use, the gripper rotates pneumatically and continuously by 180 degrees via joystick, while the holding device can also be manually rotated by 360 degrees. This allows, for example, a 68.9 kg top core to be turned safely. Which manipulator is suitable for sand core handling? For lateral lifting and precise placement, a pendulum-free articulated arm manipulator is suitable. For purely vertical lifting tasks with heavy loads, the ZH90 lifting axis is an alternative. Can one device accommodate different sand cores? Yes, if the cores have comparable bore sizes. In this practical example, the device accommodates two bore sizes, Ø 20 mm conical and Ø 40 mm, and accepts the cores from the side or from above. Does the manipulator need to be anchored in the hall floor? Not necessarily. In the practical example, the manipulator stands on a stable base plate and can be set up without ground anchoring and moved if necessary. How much does a sand core manipulator cost? It depends on the load, working radius, axes of rotation, and device. Simple cable manipulators start at around €10,000, while complex solutions cost significantly more. The guide "What does a manipulator cost?" provides an overview. Further topics from the blog and guide Guide: What is a manipulator? Guide: Lifting aids for production and industry Guide: How much does a manipulator cost? Manipulator with internal and external grips: One system for different component geometries Custom grippers and fixtures: Special construction for every geometry Customized solutions in the field of foundries Articulated manipulator up to 800 kg Devices, grippers, suction cups and magnets How to handle sand cores more safely and ergonomically? Send us your core list with weights and pickup points. We will check which cores can be covered by a device and get back to you within 24 hours on weekdays. Zeilhofer Handhabungstechnik, Holzkirchen: Manipulators up to 800 kg and lifting axes up to 1,200 kg, developed and manufactured in Germany.

A lifting aid pays for itself as soon as the cost savings exceed the investment. The formula is simple: Payback period = Investment ÷ (annual savings minus annual operating costs). The only difficulty lies in accurately quantifying the savings. This article shows step by step which items should be included in the calculation, works through a complete example with clearly stated assumptions, and provides a worksheet for your own calculations. The most important points in brief Two key figures are sufficient for the investment decision: Static payback period (years) = Investment ÷ (annual savings minus annual running costs) ROI over the useful life (%) = (Net savings per year × useful life minus investment) ÷ investment × 100 The static calculation ignores interest rates and price increases. For most lifting aids, it is still meaningful because the amortization period is short compared to the service life. Those who finance through leasing compare the annual lease payment with the annual savings instead of the investment. The five areas for savings and how to quantify them 1. Freed-up staff time When heavy or bulky components are lifted by two people today, the second person is tied up during every lifting operation. With a lifting aid, one person can work alone. Calculate: Lifting operations per day × time tied up by the second person × working days × hourly rate. This item is usually the largest in practice. 2. Sick days avoided Musculoskeletal disorders are one of the most frequent causes of work incapacity. According to the AOK Absenteeism Report, 19.8 percent of all sick days in 2024 were attributable to this group of illnesses. The Federal Institute for Occupational Safety and Health (BAuA) estimates the resulting economic losses in production in 2024 at €134 billion, based on 881.5 million sick days. This translates to approximately €152 in wage costs and around €258 in lost gross value added per day. Within your own company, the costs are often higher due to additional factors such as replacement staff, overtime, and delivery delays. Assess your own value. Our article "Musculoskeletal Disorders in Production" provides further details on the overall cost of lost production days. 3. Shorter cycle times A lifting aid guides the load without swinging and positions it precisely. This saves time during lifting, alignment, and assembly. Measure the current time per operation and estimate the time with a lifting aid conservatively. 4. Less scrap and component damage Edges, scratches, and dropped parts cause rework and scrap. Calculate: damaged parts per year × cost per damage. 5. Lower employee turnover Physically demanding jobs are difficult to fill due to the skilled labor shortage. Each replacement requires recruitment and training. This cost is difficult to quantify and is therefore deliberately omitted from the calculation example. The cost side: what belongs in the investment Investment: Basic system, project-specific equipment, and, if applicable, control system. The price range is from approximately €10,000 to approximately €150,000; details can be found in the guide "What does a manipulator cost?" Assembly, commissioning and training: included in the offer or shown separately, depending on the project. Ongoing costs: maintenance, spare parts, energy and the annual safety inspection. Service life: 15 to 20 years with good maintenance, see service life of manipulators. Calculation example: Assembly workstation in two-shift operation A 35 kg component is currently lifted by two employees working together, 120 times per shift, across two shifts. All figures are assumptions and serve for illustrative purposes. Investment including installation: 40,000 euros Ongoing costs (maintenance, safety inspection): 1,500 euros per year Freed-up personnel time: 240 lifting operations per day × 30 seconds of time tied up by the second person × 220 working days × 45 euros per hour = 19,800 euros per year Averted sick days: 8 days × 400 euros in operational downtime costs = 3,200 euros per year Fewer component failures: 6 failures × 250 euros = 1,500 euros per year Result: The savings amount to €24,500 per year; after deducting operating costs, €23,000 remains. The amortization period is 40,000 ÷ 23,000 = approximately 1.7 years, or about 21 months. Over a 15-year service life, this results in a return on investment (ROI) of approximately 760 percent. This calculation does not yet include cycle time savings or employee turnover. Control test: without freed-up staff time If only one person is currently using the system, the largest expense is eliminated. This leaves €3,200 plus €1,500 in savings minus €1,500 in operating costs, totaling €3,200 per year. The payback period is approximately 12.5 years. Even with a usage period of 15 to 20 years, the system still pays for itself, but at a significantly slower rate. This comparison demonstrates why a fair calculation considers each item individually. (Illustrative calculation example. Your actual values depend on the workplace, component and process and are specifically determined in the process analysis.) Worksheet: Your own amortization calculation You can use this information to calculate the amortization for your workplace yourself: Component weight and dimensions Lifting operations per shift and number of shifts Are two people lifting today? If so: time allocated to the second person per lift? Hourly rate including additional wage costs Sick days per year at this workplace related to lifting, and your cost per day of absence Damaged components per year and cost per incident Current time per lifting operation and estimated time with lifting assistance Investment as per offer and ongoing costs per year Add up the savings per year, subtract the ongoing costs, and divide the investment by the result. That's your payback period in years. Four typical mistakes in ROI calculation Only count sick days: Health is the most important argument, but rarely the biggest cost factor. Personnel time and cycle time are always included. Don't forget assembly and commissioning: Always compare the complete scope of delivery, not just the system price. Setting too short a service life: Anyone who calculates with five years underestimates the ROI of a system that runs for 20 years. Ignore ongoing costs: Maintenance and safety inspections are predictable and should be included in the calculation from the start. Economic efficiency is not the only criterion. Employers are obligated under occupational health and safety laws and manual handling regulations to assess and reduce hazards associated with manual lifting. There are no fixed kilogram limits; the decisive factor is the risk assessment, for example, using the key indicator method. If the assessment reveals a need for action, a technical solution is required, regardless of the payback period. Our article "How many kilograms can you lift?" explains how the assessment works. Financing and funding Those wishing to avoid a one-time investment can choose from leasing options with terms of 24, 36, or 48 months, or hire purchase with terms of 12 to 48 months, both through our financing partner Würth Leasing. If the monthly payment is less than the monthly savings, the lifting aid pays for itself from the very first month. Some employers' liability insurance associations (Berufsgenossenschaften) offer subsidies for occupational safety measures, but the conditions vary depending on the association. Check your eligibility for funding with your association before purchasing. Read more about buying, leasing and hire purchase in our article on financing options. This is how Zeilhofer supports you In the process analysis, we assess the values of your workplace and calculate the amortization together with you. Afterwards, you will receive an indicative price and subsequently a fixed-price offer. Zeilhofer Handhabungstechnik has been developing and manufacturing lifting aids, manipulators for loads up to 800 kg and lifting axes for loads up to 1,200 kg in Holzkirchen since 1999, with over 2,500 systems delivered to 18 industries. We are certified according to ISO 9001 and TISAX Level 2 with prototype protection. Our product finder will show you which system is right for your needs. Would you like to know when a lifting aid will pay for itself at your workplace? Send us your key details, and we will get back to you within 24 hours on weekdays. Frequently asked questions about the amortization of lifting aids How do you calculate the amortization of a lifting aid? Payback period in years = Investment ÷ (annual savings minus annual operating costs). Savings include avoided sick days, freed-up employee time, shorter cycle times, less waste, and lower employee turnover. How quickly does a lifting aid pay for itself? This depends primarily on whether a second person becomes available for lifting. In the example calculation presented in this article, an investment of €40,000 pays for itself in approximately 21 months. Without freed-up employee time, it takes around 12.5 years; however, with a usage period of 15 to 20 years, the system still becomes profitable. How much does a sick day cost? According to the Federal Institute for Occupational Safety and Health (BAuA), the economic losses in production in 2024 amounted to €134 billion for 881.5 million days of sick leave. This corresponds to approximately €152 in wage costs and around €258 in lost gross value added per day. Within individual companies, the costs due to replacements, overtime, and lost production are often higher. Which savings should be included in the ROI calculation? Avoided sick days, freed-up personnel time when lifting in pairs, shorter cycle times, fewer damaged components and lower costs for fluctuation and replacement. Which costs should be included in the calculation? The investment for the basic system and equipment, assembly and commissioning, as well as the ongoing costs for maintenance, spare parts, energy and the annual safety inspection. What is the expected lifespan? Well-maintained manipulators and lifting aids achieve 15 to 20 years of economical operation. Anyone expecting shorter timeframes significantly underestimates the ROI. Is a lifting aid worthwhile even without a quick return on investment? Yes, if the risk assessment indicates a need for action. Employers must reduce hazards associated with manual lifting in accordance with occupational health and safety legislation and the manual handling regulations, regardless of the amortization period. How much does a lifting aid cost? Simple cable manipulators with hook attachments start at around €10,000, while complex lifting axis solutions can cost up to €150,000. Details are explained in the Zeilhofer guide "What does a manipulator cost?".

A manipulator with internal and external grips picks up components from either the outside or the inside, depending on which gripping direction the component geometry allows. Zeilhofer Handhabungstechnik develops these manipulators individually for components with a wide variety of geometries, from aerospace and mechanical engineering to general industrial manufacturing. Explainer video: Manipulator with internal and external grips What looks similar at first glance often differs considerably in practice, especially in whether a component offers a stable outer contour for clamping or whether access is only possible from the inside. If each access direction requires a separate fixture, unnecessary setup times, additional investments, and more storage space for interchangeable fixtures result. The answer is a manipulator with interchangeable gripping jaws for internal and external gripping. A comparable approach for components with particularly complex geometries is described in the article "Individual Grippers and Fixtures: Custom Construction for Every Geometry". Why the choice of gripping direction often fails in practice Components differ in weight, shape, and surface finish, but above all in how securely they can be gripped. This is precisely where the real challenge often lies in practice: some components lack a stable, undamaged gripping point on their outer edge, for example, because the surface is delicate or the contour too irregular. Others, on the other hand, can only be gripped from the outside because there is no access to the interior. Maintaining a separate holder for each access direction is time-consuming, ties up storage space, and increases investment costs. A related problem with frequently changing components is also described in the article Manipulator with interchangeable gripper system for flexible production processes. One system, two gripping directions: Interchangeable jaws instead of two devices The core of the solution consists of interchangeable jaws on the articulated arm manipulator. Depending on the component, the appropriate jaw variant is used, either for external or internal gripping, for example via a bore, a recess, or an inner rim. Instead of maintaining two separate handling devices or undertaking complex modifications, simply changing the gripping jaws is sufficient. This saves setup time and increases flexibility in daily production, especially for components with significantly different accessibility. The gripping jaws are among the fixtures that we individually design as part of the overall system; you can find more information on the page Fixtures, Grippers, Suction Cups & Magnets. This is how switching between the inside and outside grips works. Changing the jaws follows a fixed procedure and usually requires no additional tools: Place the component and move the manipulator into the changeover position. Release the locking mechanism of the current jaws Remove the jaws and attach suitable jaws for the new gripping direction. Close the lock and perform a function test. Pick up the next component and continue working. This reduces a setup process, which would traditionally have meant several minutes of downtime, to a quick adjustment during operation. Secure gripping for a wide variety of components Whether gripping from the inside or outside doesn't change the fundamental requirement: the component must be securely fixed and guided in a controlled manner. The manipulator supports virtually the entire weight of the component, allowing even bulky or heavy parts to be positioned precisely with minimal effort. This reduces physical strain on workers and noticeably lowers the risk of accidents. Our articulated manipulators can handle loads up to 800 kg, and the ZH90 lifting axis even up to 1,200 kg, both with pendulum-free guidance. The article "Manipulator, Crane, or Chain Hoist: Which is for What?" describes the general advantages of a manipulator over a crane or chain hoist. Interchangeable jaws compared to other solutions When accessing different components, three basic approaches can be distinguished, with noticeable differences in effort and flexibility: One fixed device per gripping direction: very quick changeover, but high investment and storage costs, as a separate system is required for both inside and outside gripping. Modification of the existing equipment: lower investment, but long setup times, tool usage and system downtime with each change Interchangeable jaws: one basic device for both gripping directions, changeover in minutes without special tools, low investment with high flexibility Custom-designed for your components Each component has its own requirements regarding weight, shape, and accessibility. Therefore, we design each mounting individually. The planning process takes into account, among other things: Component weight Dimensions and geometry Gripping options from inside and/or outside Surface finish Centre of gravity required freedom of movement Requirements of the production process Based on this, a customized fixture is created that can be optimally integrated into the existing production process. Less downtime, more process reliability Because internal and external gripping can be performed on the same manipulator, switching to a second device and the associated downtime are eliminated. This directly impacts system availability: less downtime, a more consistent material flow, and noticeably shorter setup times, especially when the order sequence changes frequently. A similar principle for components with particularly complex geometries is also described in the article "Manipulator with Interchangeable Spreading Mandrel". Typical areas of application aviation automotive industry Mechanical engineering Medical technology Precision engineering general industrial manufacturing with a high variety of components Interchangeable jaws ensure maximum flexibility wherever components need to be gripped from both the inside and the outside. From consultation to commissioning Consultation: We review your component range and clarify which components can be accessed from the outside and which can only be accessed from the inside. Concept: You will receive a design proposal for the manipulator, clamping jaws and control system, including an initial price indication. Manufacturing: Design and construction in our plant in Holzkirchen, with our own technicians, certified according to ISO 9001 and TISAX Level 2 with prototype protection Commissioning: Assembly, training and commissioning directly at your site, worldwide, with optional maintenance contract One solution, many access directions No two components are alike, and often accessibility is the deciding factor in whether gripping must be done from the inside or the outside. Instead of maintaining a separate system for each variant, interchangeable gripping jaws combine both gripping directions in a single manipulator. This creates a solution that adapts to the component, not the other way around. Frequently asked questions about the manipulator with internal and external grip What is a manipulator with an internal and external grip? A manipulator with internal and external grips has interchangeable gripping jaws, allowing components to be securely gripped either from the inside or the outside, depending on their geometry. For which components is an inside or outside grip suitable? An external grip is suitable for components with a stable, undamaged outer contour. An internal grip is used when the outer surface is delicate, does not offer a secure clamping point, or the component has a hole, recess, or inner edge. How quickly can you switch between the inside and outside grips? In most cases, a single movement is sufficient, without any special tools. The exact time required for the change depends on the chosen locking mechanism and the individual design of the mount. What advantages do interchangeable jaws offer compared to two separate devices? Changing the jaws costs significantly less than operating two separate systems. You save on double the investment, require less floor space, and can get through your daily production without lengthy setup times. Is it possible to retrofit an existing manipulator with an internal and external grip? Often yes, provided the existing mounting interface allows it. The best approach is for us to take a close look at your existing system and tell you what is technically possible. Up to what weight can components be handled? Our articulated manipulators can handle components up to 800 kg, while the ZH90 lifting axis can handle up to 1,200 kg. Both guide the load without pendulum movement; the specific design depends on the weight, geometry, and gripping direction of the respective component. For which industries is this solution suitable? Industries that benefit the most are those with a high diversity of components and different access requirements, such as aviation, automotive, mechanical engineering, medical technology and other industrial manufacturing. Further topics from the blog and guide Guide: What is a manipulator? Guide: Manipulator, crane or chain hoist: Which one is for what? Guide: Lifting aids for production & industry Manipulator with interchangeable gripper system for flexible production processes Custom grippers and fixtures: Special construction for every geometry Manipulator with interchangeable spreading mandrel: One system for all roller diameters Pick-up fixture for truck bumpers: one fixture for three component types Devices, grippers, suction cups & magnets How do you want to handle your components flexibly and safely? Do you have components with varying gripping requirements and are looking for a fixture that covers both internal and external gripping? Our engineers will be happy to advise you and design a customized solution for you, Made in Germany, from a single source. Our guide, "What is a manipulator?", offers more in-depth information on manipulators, their variations, and selection criteria. #zhht #HandlingTechnology #InnerGrip #OuterGrip #HoldingJaws #ComponentHandling #AerospaceEngineering #MechanicalEngineering

When a task is repeated hundreds of times a day, a small movement quickly becomes a considerable physical strain. This was precisely the challenge faced by the Spitzingsee Alpine Railways when loading their mountain carts at the Stümpflingbahn chairlift. On a typical operating day, employees have to pick up a cart and attach it to the chairlift up to 400 times; on peak days, this number can reach 600 times. Each cart weighs between 20 and 30 kilograms, depending on its size. Explainer video: How to handle mountain carts In Germany, the Manual Handling Ordinance regulates how much weight is generally considered acceptable for manual lifting; more information can be found in the article "How many kg can you lift? Limit values and the key indicator method". Our guide "Industrial Lifting Aids" provides an overview of all types of lifting aids. The existing homemade solution was no longer sufficient for summer operations at the mountain station. A task that many mountain railways are familiar with. Mountain carts offer guests a summer experience on two wheels. For the staff behind them, however, operating them primarily means one thing: the carts must be constantly prepared, moved to the lift station, and attached to the chairlift so they can be transported back uphill. At the Spitzingsee Alpine cable cars, this task was initially eased with a custom-built solution, which halved the perceived weight of the carts. However, with up to 600 handling operations on a peak day, this was no longer sufficient to provide lasting relief for employees. From the initial measurement to the perfectly fitting lifting aid A lifting aid for mountain carts cannot be an off-the-shelf product. Every mountain station has its own geometry, and every loading zone on the chairlift has its own installation space. At the Spitzingsee Alpine lifts, the loading zone is located beneath the lift station in a clearly defined corridor approximately three meters high and three meters wide. Within this space, the entire process, from picking up the cart on the ground to inserting it into the receiver on the chairlift, had to be carried out safely without disrupting the existing loading process. Together with the on-site operations management team, the actual distances were measured directly at the system: the hook position on the cart, the required lifting height for transfer to the chairlift, and the available space in the loading zone. Only on this basis was the precisely fitting receiving device, including the hook, created, which fits perfectly into the existing workflow at the mountain station. Simply hook it up, the manipulator does the rest. The process for employees is deliberately kept simple. The cart, which is standing on the ground, is hooked into the lifting device. From this moment on, the manipulator takes over the entire weight and lifts the cart, suspended in mid-air, to the height of the handover position at the chair. The operator now only guides the movement; they no longer carry it. The cart is precisely aligned and transferred to the chair, after which the manipulator returns to its starting position for the next operation. A physically demanding lifting process thus becomes a controlled, repeatable movement sequence that can be reliably performed even with several hundred repetitions per day. Less effort, more safety: the advantages at a glance significantly less physical effort required when hooking up Lower risk of overuse injuries with high repetition rates Consistently safe and precise positioning on the chair Shorter cycle times per cart, especially on peak days simple, intuitive operation without lengthy training. A more predictable, ergonomic workday for employees A task that extends far beyond Spitzingsee Mountain carts are no longer a niche product. Many stations worldwide operate their own mountain cart fleets, from the Alps to Scandinavia and Japan. The core task is the same everywhere: carts must be provided, transported, and transferred to chairlifts or conveyor belts, often several hundred times a day. What was developed as a customized solution for the Stümpflingbahn cable car at Alpenbahnen Spitzingsee can, in principle, be applied to this task: to other mountain stations, other cart models, and other loading situations. Crucially, as with all our projects, the manipulator and loading device must be precisely tailored to the specific system. Handling technology that fits into everyday work life A good handling solution is not characterized by the use of as much technology as possible. What is crucial is that it noticeably supports employees in their daily work. At Zeilhofer Handhabungstechnik, we develop manipulators and lifting devices for a wide variety of industries: from the automotive sector and food production to, as in this project, the cable car and leisure industry. Our focus is never on a standard product, but rather on the specific task within each work process. This project also demonstrates how our rope manipulator moves loads smoothly and without pendulum swing: the lifting device was custom-designed for attaching the mountain carts. Because modern handling technology doesn't just move loads. It relieves the people behind it of some of the daily strain. Rope manipulator with fixture for mountain carts Frequently asked questions about the lifting aid for mountain carts How does a lifting aid work when attaching mountain carts to the chairlift? The employee hooks the mountain cart into the mounting device; the manipulator takes over the weight and guides the cart, suspended in mid-air, to the transfer position at the chair. The operator only controls the movement, not the weight. How much do mountain carts weigh and how often do they need to be lifted daily? Depending on their size, mountain carts weigh between 20 and 30 kilograms. At the Spitzingsee Alpine cable cars, up to 400 handling operations occur on a normal operating day, and up to 600 on peak days. What role does the available construction space at the lift station play? The loading zone under the lift station is often very limited. At the Spitzingsee Alpine lifts, a corridor approximately three meters high and three meters wide was available, within which the entire process, from picking up the carts to transferring them to the chairlift, had to take place. Can a lifting aid for mountain carts also be adapted for other cable car or leisure facilities? Yes. Since each mountain station, loading zone, and cart type is structured slightly differently, the loading device is individually designed. What distinguishes the new lifting aid from the previous in-house solution of the Spitzingsee Alpine Railways? The previous in-house solution reduced the perceived weight of the carts by about half, but was no longer sufficient for up to 600 handling operations on peak days. The new lifting aid completely takes over the weight of the cart, so that employees only have to control the movement and no longer have to carry it themselves. Who develops and builds the lifting aid for mountain carts? The lifting aid is individually designed and manufactured by Zeilhofer Handhabungstechnik in Holzkirchen, from the initial on-site measurements to the fully operational system. Does a lifting aid for mountain carts need to be inspected regularly? Yes. Like any lifting aid, a system for mountain carts is subject to annual accident prevention inspections according to DGUV Regulation 54. More information can be found in the guide: Accident Prevention Inspection for Lifting Aids. Want to make your mountain cart or chairlift loading more ergonomic? Do you operate a mountain railway or amusement park with mountain carts or similar vehicles that are manually attached to a lift or transport point every day? Our engineers will develop a customized lifting aid for you, from the initial on-site measurements to the finished system. Made in Germany, all from a single source. Our guide offers more background information on ergonomic handling technology.