• Apr 29, 2022
• Case Studies

15/10 ton Double Girder Overhead Crane for Bangladesh Paper Plant

Yuantai Crane offers 15/10 ton double girder overhead crane and 5 ton single girder overhead crane for paper scroll handling in drying workshop. Check the paper workstation overhead crane now.

The customer operates a large-scale paper manufacturing facility in Bangladesh. This paper mill produces a range of products, including rolls of tissue paper, paper towels, napkins, and other hygiene-related paper goods. As demand for consumer paper products grew, the facility expanded its capacity by constructing a new drying workshop. In this industry, careful handling of delicate paper rolls is essential to avoid damage and ensure consistent production quality.

Customer's Material Handling Needs

Within the new drying workshop, operators needed a reliable lifting solution to move freshly formed paper scrolls from the production conveyor to storage racks and drying frames. Key requirements included:

• Lifting Capacity: The crane needed to handle heavy paper rolls—up to 10 tons each—during stacking and transfer. In certain areas, lifting beams had to carry combined loads of 15 tons when moving multiple rolls.
• Wide Span Coverage: The workshop measured approximately 25 meters in width. The crane span had to cover the full clearance from wall to wall to allow unobstructed movement of paper rolls.
• Precise Load Control: Gentle handling was crucial. Paper rolls deform easily under uneven pressure, so the crane's hoist had to provide smooth starts, stops, and controlled lowering to avoid tearing or crushing the paper.
• High Duty Cycle: Three shifts operated daily. The crane needed to withstand continuous use—lifting, traveling, and lowering cycles—over an 18-hour production window without breakdowns.
• Limited Hook Approach: Space between the overhead beams and drying racks was constrained. The crane's hook approach and headroom had to be minimized to slide under low frames while still lifting large-diameter rolls.

Challenges with Previous Equipment

1. Inadequate Lifting Capacity

Before installing Yuantai's solution, the paper plant used a combination of smaller 5-ton hoists and manual gantries. These cranes could not handle the new, larger 10-ton paper rolls and frequently overloaded, causing safety hazards.

2. Frequent Downtime and Maintenance

The older hoists and gantry trolleys were not designed for continuous high-frequency operation. Bearings and motors overheated during peak shifts, leading to frequent service interruptions and unplanned maintenance costs.

3. Damage to Paper Rolls

Manual handling and unreliable hoists caused paper rolls to shift or tilt during lifting. This misalignment often led to torn edges or crushed sections, increasing material waste and rework.

4. Limited Operational Flexibility

Previous equipment required significant manual guidance. Operators had to reposition each roll by hand, slowing the production line. The lack of precise controls prevented safe handling in confined spaces around drying frames.

Yuantai's Double Girder Overhead Crane Solution

Yuantai recommended a 15/10T double girder overhead crane tailored to the paper plant's drying workshop layout. This solution combined two separate crane units sharing the same runway: one 10 ton hoist for routine paper roll handling and a 15 ton hoist for stacking multiple rolls or carrying maintenance equipment. Key design features included:

1. Custom Crane Configuration

This tailored crane setup combines dual-capacity hoists, extended spans, and precise control to meet the unique demands of a roll-drying workshop. Each element is designed for safe, smooth handling of paper rolls and maintenance equipment.

2. Dual-Capacity Hoists

The crane features two hoists to match different lifting tasks. A 10 t hoist handles single paper rolls and offers a low-speed, high-precision mode for delicate placement. When operators need to move two stacked 7.5 t rolls or heavy drying-rack assemblies, they switch to the 15 t hoist. This flexibility reduces changeover time and avoids overloading any single unit.

3. Span and Headroom

With a 25 m span, the crane covers the full width of the drying workshop. It travels from the loading docks to storage racks in one continuous reach. Engineers set the minimum hook approach at 300 mm below the girder to let the hoist clear low-hanging drying frames. This tight clearance ensures the crane can slide under racks without obstructing the drum or tipping the load.

4. Rigid Trolley Design

The double-girder end trucks deliver high lateral stiffness to keep long paper rolls from swaying. Precision-machined wheels and axles guarantee smooth, low-vibration travel across the 50 m runway. This stability is crucial during roll changes, when even slight sway could misalign the load and strain the hoist components.

5. Advanced Wire Rope Hoists

Each hoist uses a frequency-controlled drive that adjusts lifting speed from 0.2 m/min up to its maximum rate. The 15 t hoist runs on a 45 kW motor, while the 10 t hoist uses a 30 kW unit. Both use 8×19 high-strength steel rope with a 5:1 safety factor to resist fatigue under three-shift operations. This ensures consistent performance over tens of thousands of cycles.

6. Control System

Operators move loads safely using a wireless remote control. This lets them stand clear of the load path and maintain full visibility. If the wireless link fails, a pendant station provides backup control. Both systems feature start/stop buttons, speed selectors, and emergency-stop switches for reliable operation.

7. Safety Devices

An overload limiter prevents the hoists from lifting more than 102 % of their rated capacity. Upper and lower limit switches on each hoist stop travel before the hook hits the beam or floor. Emergency-stop buttons located on the trolley and control panels allow instant shutdown in case of any hazard. These measures protect both personnel and equipment during daily use.

Advantages of the Yuantai Double Girder Crane

The Yuantai double girder crane combines load capacity, precision, and reliability to meet both production and maintenance needs. Its dual-hoist setup, robust components, and compact footprint make it a practical choice for facilities handling heavy paper rolls and related equipment. Below are its key benefits:

1. Seamless Paper Roll Handling

High-precision, dual-speed hoists let operators lift a 10 t roll from the conveyor at low speed for precise placement. Once aligned, they switch to high speed to move the roll onto drying racks quickly. This method cuts tears and deformation, reducing waste by about 12 % compared to manual handling.

2. High Utilization and Low Downtime

The crane’s sealed bearings, heavy-duty gearboxes, and reinforced trolley wheels withstand three-shift operation. Preventive maintenance intervals stretch from monthly checks to quarterly service. As a result, maintenance labor drops by 40 %, and uptime improves across continuous production cycles.

3. Versatility in Production and Maintenance

The 10 t hoist handles most roll transfers, while the 15 t hoist takes on heavier tasks. It moves stacked rolls during peak output, lifts drying-rack frames for cleaning or repairs, and transports ancillary machinery—such as heat exchangers or electric motors—to elevated service platforms. This dual capacity adapts to changing workshop demands without extra equipment.

4. Space-Efficient Design

Mounting both hoists on a single double girder reduces the number of runway beams and columns. This layout frees up floor space for roll storage and forklift lanes. Optimized headroom and a close hook approach let the crane work within the existing workshop envelope. No major building modifications are needed.

5. Enhanced Safety and Worker Comfort

Operators use a high-visibility wireless remote to stay clear of the load path. Built-in overload protection and limit switches stop the crane before over-travel occurs. Ergonomic controls and a low-twist rope design reduce operator fatigue. Together, these features support safer, more comfortable work conditions.

Performance in Diverse and Challenging Tasks

After commissioning, the crane demonstrated its ability to adapt to several demanding tasks:

• Handling Large-Diameter Paper Rolls: 2.5-meter-diameter rolls were lifted smoothly at slow speed. The crane's hoist maintained tension in the wire rope, preventing sudden drops when nearing the limit switches.
• Stacked Roll Transfer: Combined two 7.5T rolls (15T total) during peak periods. The dual hoist synchronized lift ensured stability, avoiding roll shifting and ensuring safe transfer to high-level storage racks.
• Drying Rack Maintenance: Removed heavy steel frames (12T each) from the top tier of racks for routine cleaning. The 15T hoist handled these loads without requiring a secondary jib or gantry system.
• Motor and Gearbox Replacement: During a scheduled shutdown, the 15T hoist lifted a 9T gearbox assembly to the roof-mounted crane positioner for routine inspection, showcasing versatility beyond paper handling.
• Emergency Load Recovery: In a power surge incident, both hoists automatically braked when power dropped below 20%. This prevented inadvertent load descent and allowed operators to reestablish power without load damage.

Additional Applications for Yuantai's Overhead Cranes

Beyond the paper industry, this 15/10T double girder overhead crane configuration suits multiple heavy-duty tasks across various industries:

Steel Structure Workshops

In steel fabrication shops, cranes lift and position structural beams and plates. The dual-capacity hoists can move individual steel sections (10T) or stacked assemblies (15T) to welding stations, improving workflow.

Power Generation Facilities

Hydropower and thermal power plants use similar hoists to install turbines, generators, and heat exchangers. The 15T capacity handles large turbine components, while the 10T hoist assists with smaller auxiliary equipment.

Shipyards and Marine Engineering

For shipbuilding piers, cranes lift hull sections, engines, and propulsion systems. The crane's high headroom and dual-speed controls enable precise positioning of heavy marine parts in confined docking areas.

Cement and Bulk Material Plants

Overhead cranes here transport heavy hoppers, mixers, and raw material bins. Durable wire rope hoists and rigid double girder trolleys maintain performance in dusty, high-load environments.

Automotive Manufacturing Lines

In assembly lines, overhead cranes move car bodies and chassis frames. The 10T hoist can lift individual body shells, while the 15T hoist transfers assembly jigs and fixtures between stations.

Customer Feedback

After installing Yuantai's 15/10T double girder overhead crane, our paper drying workshop runs smoothly. We no longer worry about damaging rolls. The crane's precise controls and reliable performance cut our downtime and improved safety. Yuantai's team guided us through design, installation, and training—making the entire process straightforward.

Conclusion

This case illustrates how Yuantai's 15/10T double girder overhead crane met the specific lifting and handling challenges of a Bangladesh paper plant. The dual-capacity hoist design addressed high-frequency handling of delicate paper rolls and occasional heavy-load tasks during maintenance. By combining robust construction, precise control systems, and a space-saving double girder arrangement, the crane improved operational efficiency, safety, and uptime. Beyond this paper mill application, similar crane configurations serve steel fabrication shops, power plants, shipyards, cement factories, and automotive assembly lines—demonstrating wide adaptability across heavy industries.

Contact Yuantai for Your Lifting Needs

If your facility requires a high-capacity overhead crane for paper handling or other industrial applications, please visit our overhead crane solutions page or contact us for a customized consultation.