The challenge: manual handling bottlenecks on a moving line
Enviro-Tech Powder Coating in Winkler, Manitoba, hit a hard limit in their operations. The facility needed to load heavy grain bin foundations onto a moving powder coating line. The physical constraints made this difficult. The parts were massive, measuring up to 8 feet in length and weighing approximately 170.5 lbs.
The process required two operators and a forklift to wrestle these awkward loads onto the moving line hooks. It was a slow, labor-intensive grind. The forklift crowded the loading zone, creating a congested, unsafe work environment and forcing the paint line to run at slower speeds. This manual choke point hurt profitability and increased the risk of injury for the staff.
The solution: Gorbel G-Force intelligent lifting device
To clear the bottleneck and get the forklift out of the way, Enviro-Tech partnered with Acculift to install a Gorbel G-Force Intelligent Lifting Device (ILD). Unlike pneumatic balancers or chain hoists, the G-Force uses servo-drive technology with a processor-controlled drive system. This allows the device to match the operator's speed in real-time, making the 170-lb load feel weightless.
The system functions as a servo-powered Intelligent Assist Device (IAD) installed on an overhead bridge crane to save floor space. It utilizes a custom mechanical clamping tool designed to grip the structural tubing of the bin foundations securely.
The execution: synchronized precision
The G-Force changed the loading dynamic immediately. Video analysis shows a smooth workflow where a single operator handles the lifting device. One operator uses the handle to lower the clamp onto the stacked bin foundation. He then lifts the 170-lb part with almost no effort.
The device's "Float Mode" helps with final vertical positioning without requiring button presses, allowing the operator to use both hands to guide the part. The main technical success is the synchronization with the moving paint line. The operator tracks the moving hook and hangs the part exactly where it needs to go without the lag associated with traditional hoists.
The result: 50% labor reduction and better safety
The integration produced immediate improvements. The task now requires only one operator instead of two, cutting labor requirements for this station by 50%. Loading is no longer the bottleneck. The operator easily keeps pace with the line, allowing for consistent production speeds.
Safety improved as well. Removing the forklift from the work area reduced congestion and collision risks. Physical strain on the operator is virtually gone.
"It's a good system, it's something we couldn't be without on this line." — Tim Klassen, Owner, Enviro-Tech Powder Coating.