After several years of testing, Eisenwerk Martinlamitz now
exclusively relies on the robust materials handling equipment from Hyster,
which is designed specifically for use in iron and steel works. The specially-equipped forklift trucks can
withstand the heat of the furnace in the plant and can be used where space is
outside Schwarzenbach, on the Saale River near the Czech border, ironworks
operation Martinlamitz (EWM) sells more than 50,000 tonnes of cast metal
annually. This metal is used for axles
on agricultural and construction equipment, commercial vehicles and railways,
transmission housings and parts for wind turbines, crane and maritime
engineering on to feet, arms and joints for robots. The foundry delivered the
axles used for the high-speed trains deployed for the Winter Olympics in Sochi,
documents reveal that one of Europe's oldest hammer forges existed in Martinlamitz
in 1200AD, and today's foundry derives from this. Today, EWM supplies grey cast
iron and modular cast iron parts to more than 21 countries around the world,
including Korea, India and China.
Hyster forklift trucks receive special equipment
EWM company site is steeped in tradition and places special demands on
logistics. In particular, the company requires powerful and manoeuvrable
forklift trucks that are capable of transporting cargo containing hot molten
mass, with temperatures of up to 1,400 degrees in the 1.8 tonne ladles around
its narrow factory halls.
EWM uses Hyster Fortens H4.0-5.5FT series forklift trucks with a 5.5 tonne
lifting capacity and a 600 millimetre load centre of gravity.
Hyster forklift trucks are especially manoeuvrable and robust, so they can also
withstand the tough operating conditions", EWM Managing Director, Barry
Thomas Irvin, explains.
forklift trucks' DuraMatchTM transmission prevents sudden braking,
for example, and controls the direction of travel to ease the load placed on
the brakes and tyres. The forklift trucks drive with super-elastic tyres, which
are robust enough to also compensate for uneven ground and floor surfaces.
Hyster also improved the stability mechanism (HSM) for lateral stability,
without compromising the ride on uneven surfaces.
Additional oil cooler and temperature-resistant hydraulics
order to withstand the high temperatures of the melting furnace, the forklift
trucks required to operate in that area are equipped with an additional oil
cooler and temperature-resistant hydraulic hoses. Additional filter systems
reduce dust accumulation, prolonging the service life. Reduced maintenance and oil-immersed
multi-disc brakes also increase the reliability of the Hyster material handling
equipment. Special attachments, such as a rotating fork clamp that can handle
loads of up to four tonnes, ensure reliable operation. With these special
adaptions to the forklift trucks, the hot, molten mass can be transported
directly from the oven to the mould casting facility where it is processed. EWM
has two ovens, each with a capacity of 16 tonnes that alternately produce 280
tonnes of cast metal daily. This production requires 50 million kilowatt hours
of electricity, which is the equivalent of a small town.
EWM: punctuality and quality count
recent years we have invested several million euros in the expansion of our
foundry", says Barry Thomas Irvin.
EWM has a fully-automated HWS Seiatsu mould casting facility for mould
dimensions of 1200 mm x 800 mm x 320/320 mm. This enables a casting output of
120 mould castings per hour at peak time. Additionally, an investment was made
in a new paint shop that works with water-soluble paints.
strengths are our punctuality and especially our quality. That is why we also
focus on reliable logistics solutions", says Barry Thomas Irvin.
has a fleet of 52 Hyster material handling vehicles. The entire logistics chain
– from the delivery of goods and materials to the transport of the molten mass
and castings within the plant, on to the loading of the finished parts – is all
handled by Hyster forklift trucks. The fleet includes high-lift trucks with and
without a platform, Hyster J1.5 -2.0XNT energy-efficient 3 wheel electric
counterbalanced trucks with 1.5 to 1.6 tonnes of lifting capacity, Hyster J2.2
-3.5XN compact 4 wheel counterbalanced trucks with 3 to 3.5 tonnes of lifting
capacity, and Hyster ICE forklift trucks with 1.6 to 5.5 tonnes of lifting
capacity. All the forklift trucks feature a robust and compact chassis design,
especially durable and reliable components, as well as low operating costs.
Reliable solutions for outdoor use
Martinlamitz ironworks now primarily deploys Hyster electric forklift trucks
for outside use.
is rather atypical," says Hyster dealer Jochen Kotschenreuther, who has
supported the foundry for many years. "Usually electric forklift trucks
are used for emission-free operation indoors."
took a different approach and first tested the use of the electric forklift
trucks outdoors. The results showed that the Hyster electric forklift trucks
are robust and meet EWM's tough demands even when used in outdoor areas for
loading and unloading. In addition to this, the use of electric forklift trucks
is financially viable despite the higher purchase costs. This is due to the
electric forklift trucks having significantly lower operating costs and
requiring less maintenance.
forklift trucks perform just as well as trucks equipped with internal
combustion engines. That is why it makes sense to use them in many areas today
that formerly were the domain of diesel trucks," explains Jochen
The robust Hyster
forklift trucks are in service for approximately 18,000 operating hours in
their 'first life' at EWM. Afterwards, they are refurbished and deployed in
less demanding operating areas. To ensure that they are always ready for use
during this period, Jochen Kotschenreuther has a technician permanently on-site
to maintain the machines. For the Martinlamitz ironworks, reliability and
punctuality have highest priority in the entire process chain.