Automatic and
process cranes
process cranes
Automatic cranes for industry and production
When heavy components, tight production schedules, and the need for automation come together, standard cranes are no longer sufficient. Whether it’s a girder crane, gantry or semi-gantry system, a process crane for the steel and aluminum industries, or a special-purpose crane for paint lines and explosion-protected areas: For over 50 years, Vollert has been developing heavy-duty automated crane systems that are not intended as isolated lifting devices, but as an integral part of the production and logistics process. The result is systems that not only lift, but also position, buffer, transfer, and control.
You won’t find any crane hook
Configurators? We don’t use those. We develop customized crane systems using a proven modular system in close collaboration with our customers. This applies in particular to load-handling attachments, where - instead of conventional load hooks - we use lifting grippers, clamps, and crossbeams that are precisely tailored to the workpiece.
Girder cranes are the traditional choice when loads need to be moved across the entire floor area of a building and it is possible to install a crane runway on the building structure. They offer a high degree of flexibility in space utilization, integrate well into existing building structures, and can be designed for long spans and high load capacities.
Gantry and semi-gantry cranes are used when there is no suitable building structure for suspending a crane runway, when loads need to be moved outdoors, or when floor-mounted guides are advantageous for process-related reasons. Semi-gantry cranes offer a cost-effective interim solution when one side can be guided along the building wall.
The real strength lies in system integration
The choice between a girder crane and a gantry or semi-gantry system is not a matter of preference, but rather a matter of hall geometry, load distribution, floor conditions, and process logic. Vollert develops both system types from a common modular platform and combines them where it makes sense.
In many projects, the crane design is only part of the solution. What matters most is how the crane system interacts with material handling equipment, AMRs, storage systems, production control, and higher-level IT systems. This is precisely where the added value of a well-designed crane system architecture comes into play: when lifting, positioning, buffering, and transfer functions work together as a cohesive system.
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crane systems around the world
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tons and more
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years of know-how
Where automatic cranes are used
For more than 50 years, crane systems with Vollert's technology and know-how have been world leaders. Each crane system is individually planned and built. With our great expertise, we know and understand the special, industry-specific requirements.
Process cranes network and integrate all material, machining and processing operations - whether in the aluminium and steel industry, in automobile production, energy and recycling or in paint shops.
Automatic cranes work differently
Automated crane systems for heavy-duty applications differ fundamentally from standard overhead cranes. When loads of 5, 20, or 50 metric tons must be moved fully automatically, positioned precisely, and integrated into ongoing production processes, the system architecture, control logic, and load-handling attachments determine success or failure. A C-hook is not sufficient for this.
In practice, it is rarely just a matter of transporting a component from A to B. Crane systems often have to perform buffering functions, coordinate handoffs to conveyor systems or machining stations, maintain positioning accuracy down to the millimeter, or operate reliably over the long term under extreme conditions in a production environment.
This is precisely why an automated crane system is not a product decision, but a system decision. Those who base their selection solely on load capacity and span are underestimating the actual requirements. The decisive factors are process integration, availability, maintainability, and the ability to further develop the system as requirements grow.
Load-bearing devices
A crane system is only as good as its load-handling device. In heavy-duty processes where components must be precisely positioned, securely held, and transferred in sync with the process, the traditional load hook is not a practical solution. Vollert develops the right load-handling device for every application—as an integral part of the overall system.
Lifting grippers, load clamps, and crossbeams are precisely designed for the respective workpiece, load geometry, and process requirements. Many grippers are adjustable and offer the necessary flexibility for a changing product range. At the same time, the grippers and crossbeams are designed to be extremely slim so that as little surface area as possible is wasted when the workpiece is immersed in the surface coating bath.
In every case, however, Vollert load-handling devices ensure: safe force transmission, reproducible positioning, minimal setup times, and maximum process reliability. Especially when dealing with sensitive surfaces, hot materials, or irregular component geometries, the load-handling device is often the decisive factor for process quality.
Smart Features
For more than 50 years, crane systems featuring Vollert’s technology and expertise have been world leaders. Every crane system is individually designed and built. With our extensive expertise, we know and understand the specific, industry-specific requirements. Process cranes connect and integrate all material handling, loading, and processing operations—whether in the aluminum and steel industries, in automotive production, in the energy and recycling sectors, or in paint shops.
Our 4-rope hoist was specifically designed for the safe and precise handling of heavy loads. The symmetrical load distribution across four ropes ensures that the load is optimally stabilized and guided evenly—even when handling large, delicate, or asymmetrical components.
The even distribution of force reduces mechanical stress on lifting equipment and structures and minimizes unwanted movements during the lifting and travel process. This allows heavy loads to be transported particularly smoothly, precisely, and safely.
The 4-rope hoist offers decisive advantages, particularly in automated processes: higher positioning accuracy, improved process reliability, and reliable load control even with high load capacities and large lifting heights. At the same time, the robust design increases the availability and longevity of the entire system. Combined with intelligent control and automation functions, this results in a heavy-duty crane system that combines maximum efficiency with the highest level of operational safety.
During the automated transport of heavy loads, acceleration and braking cause natural oscillations in the load. Our intelligent oscillation damping actively reduces these vibrations and ensures smooth, controlled crane movement—even with heavy loads and long spans.
The automatic stabilization of the load significantly increases positioning accuracy, process reliability, and handling capacity. At the same time, mechanical stress on the crane, lifting equipment, and cargo is reduced. This enables shorter cycle times, smoother travel movements, and a safe material flow even in demanding heavy-load applications.
The pendulum damping operates fully automatically in the background and is optimally tailored to our automatic crane systems—for maximum efficiency when handling loads of 2 tons or more.
Our adjustable gripper systems, which are individually tailored to the loads being lifted, enable the safe and precise handling of a wide variety of loads, formats, and geometries—fully automatically and without manual retooling. The grippers adapt flexibly to changing component sizes and production requirements, ensuring maximum process reliability and efficiency.
Thanks to the variable adjustment, a wide variety of products can be transported using just a single gripping system. This reduces setup times, increases system availability, and provides maximum flexibility for modern production and logistics processes.
The precisely tuned gripping technology ensures gentle load handling and stable guidance throughout the entire transport process. Even heavy or sensitive components can be safely positioned and reliably moved.
In combination with our automatic crane systems, this creates intelligent material flow solutions for heavy loads starting at 2 tons—efficient, flexible, and optimally tailored to individual requirements.
Our automated crane systems can optionally measure the weight of transported loads continuously and in real time throughout the entire material flow. Continuous weight measurement ensures maximum transparency in the process and enables the safe, controlled handling of heavy loads. Continuous monitoring allows overload situations to be detected early on and critical operating conditions to be reliably avoided. At the same time, precise weight measurement improves process reliability, protects the crane system and lifting equipment, and enhances operational safety in daily use.
The recorded weight data can also be integrated directly into higher-level control and production systems. This provides additional benefits for material tracking, quality control, process documentation, and automated logistics processes.
Especially in automated heavy-duty applications, continuous weight measurement enables an optimal combination of safety, efficiency, and intelligent process control.
For applications with particularly high dynamic and performance requirements, our automatic crane systems rely on a powerful all-wheel-drive system. By distributing power to multiple driven wheels, this system enables high acceleration, precise travel movements, and optimal traction—even during extreme acceleration.
The even distribution of drive forces ensures smooth handling and improves crane control, particularly during fast transport cycles and on challenging terrain. At the same time, wheel slip and uneven loads are reduced, which increases running smoothness and extends the service life of the components.
All-wheel drive offers decisive advantages wherever high handling capacities, short cycle times, and maximum availability are required. Even with heavy loads starting at 2 tons, acceleration and travel processes can be executed efficiently, safely, and with high precision.
Combined with intelligent control and automation functions, this creates a powerful heavy-duty crane system for dynamic and highly productive material flow processes.
Our in-house manufactured rope drums, featuring precisely machined guide grooves, ensure optimal rope guidance and exceptionally reliable operation during daily heavy-duty use. The precisely calibrated grooves guarantee smooth winding and unwinding of the ropes and significantly reduce mechanical stress and wear.
The defined rope guidance reliably prevents overlapping, uneven winding, and damage to the ropes. This not only increases operational safety but also improves the smoothness of operation and positioning accuracy of the entire hoisting system. In general comparison, our rope drums have a significantly larger diameter than those of comparable standard cranes—resulting in significantly lower rope wear.
Since the rope drums are manufactured in-house, they can be precisely designed for the specific application, load capacity, and operational requirements. As a result, our customers benefit from a particularly robust, durable, and low-maintenance solution—even under high loads, intensive travel cycles, and demanding operating conditions. In combination with our automatic crane systems, this creates a high-performance and durable heavy-duty solution for the most demanding requirements in industrial material handling.
