Yuantai Cranes Mexico project: 5T and 10T HD single-girder cranes improve mold handling with custom design, VFD control, low headroom structure, and installation support.
From Workshop Survey to Final Operation: A Customized Mold Handling Solution
A Mexican injection molding factory needed two overhead cranes to improve its mold handling process.After expanding production capacity, the factory faced more frequent mold changes and heavier mold handling tasks. Moving molds manually became slower and created safety concerns.
The customer needed a safer and more efficient way to handle:
- Heavy mold lifting
- Mold replacement
- Mold transfer between production stations
However, the customer had limited experience with crane systems. They needed support with crane selection, workshop measurement, installation planning, and final commissioning.Yuantai Cranes provided a complete project solution, starting from the first workshop survey:
- Checked the existing building structure and installation conditions
- Selected the suitable crane type based on the application
- Designed a customized crane system
- Manufactured and delivered the equipment
- Supported installation and commissioning
Based on the actual workshop layout and lifting requirements, Yuantai Cranes supplied two HD single-girder overhead cranes for the Mexican injection molding workshop. The cranes are now operating reliably for daily mold handling operations.
Project Background
The customer is a Mexican injection molding manufacturer with multiple production lines.After expanding production capacity, the factory faced a new challenge.The number of mold changes increased.The mold weight also increased.Workers needed to frequently move molds between production stations.Manual handling became inefficient and created safety concerns.
The customer needed overhead cranes for:
- Heavy mold lifting
- Mold replacement
- Mold flipping
- Material transfer between production areas
However, the customer did not have crane engineering experience.They needed support with:
- Workshop measurement
- Crane structure selection
- Installation planning
- Operation requirements
Our engineers first studied the actual working conditions before designing the solution.
Site Survey: Problems Found Before Crane Design
Challenge 1: Existing Workshop Structure Was Not Ready for Crane Installation
During the workshop inspection, our engineers found that the existing building was not originally designed for overhead cranes.
Problem: No Reserved Crane Installation Structure
The concrete corbels had several limitations:
- No embedded steel plates on the corbels
- No embedded components on column sides
- Uneven installation surfaces
- Missing corner support structures
The corbel dimensions were:
- Width: 300 mm
- Length: 420 mm
However, the actual conditions were different.
One side had an embedded steel plate extending about 400 mm.
The other side extended about 410 mm, but 20–30 mm of remaining concrete reduced the usable installation area.
These conditions required additional structural preparation before installing the crane runway system.
Can an overhead crane be installed in an existing factory without reserved supports?
Answer: Yes.
But the crane system must be designed according to the existing building.
How was this challenge solved?
For this Mexico project:
- Wall-side runway beams used chemical anchor connections.
- Column-side supports required embedded plate preparation.
- Additional steel structures were designed where corner supports were missing.
Project Result
The crane was adjusted to the factory, instead of forcing the factory to fit a standard crane.
Challenge 2: Inclined Columns Reduced the Crane Working Area
During measurement, engineers found that the middle columns leaned inward. The available space in the center area was smaller than both ends.
Problem: Standard Crane Span Could Not Match the Workshop
A normal crane span design could create several problems:
- Crane collision with columns
- Reduced travel distance
- Limited working coverage
Why cannot we simply use the workshop width as the crane span?
Answer: Because the maximum building width is not always the usable crane operating width.
What factors did the engineers consider?
Engineers need to consider:
- Column position
- End clearance
- Wheel position
- Trolley movement area
Project Result
For this project, the crane span was calculated based on the real working space.
Challenge 3: Uneven Support Heights Affected Rail Installation
In another workshop area, engineers found uneven concrete corbels.
Problem: Different Elevations on Crane Supports
Measured elevations:
- Left corbel: 6.707 m
- Right corbel: 6.753 m
The height difference was nearly 50 mm. Although this difference may seem small in normal construction, it can affect crane operation.
Uneven rail levels may cause:
- Crane drifting during travel
- Uneven wheel loading
- Increased mechanical wear
The engineers recorded each support point and provided adjustment requirements before installation.
Why does rail level accuracy matter for overhead cranes?
Answer: Because overhead cranes travel on fixed rails.
What problems can uneven rails cause?
If the rails are not level:
- The crane may not move smoothly.
- Wheels may carry different loads.
- Long-term operation becomes unstable.
Project Result
The engineers recorded every support point and provided adjustment requirements before installation.
Customized Crane Design Solution
After the site survey, we did not directly choose a standard crane model.
The engineers reviewed the actual working conditions first:Workshop structure, Mold weight, Lifting frequency, Required lifting height, Operator working habits,
Because every workshop is different, the crane design also needed to be different.For example, the available space limited the crane layout. The mold handling process required stable positioning. The building structure also affected the crane load design.
Based on these factors, we designed two HD single-girder overhead cranes for the customer.
| Equipment | Quantity | Main Application |
|---|---|---|
| HD Single-Girder Overhead Crane | 1 Set | Heavy mold lifting and replacement |
| HD Single-Girder Overhead Crane | 1 Set | Mold positioning and transfer |
The final solution matched the customer's production process, workshop conditions, and daily operation needs.
Solution 1: 10 Ton HD Single-Girder Overhead Crane
After checking the workshop structure and production requirements, we selected a 10 ton HD single-girder overhead crane for the heavy-duty handling area.
The crane needed to handle large molds while reducing the load on the existing building structure. It also needed enough lifting height and smooth movement for daily mold replacement operations.
Solution 2: 5 Ton HD Single-Girder Overhead Crane
After reviewing the workshop layout, we found that this working area had stricter space limitations.
The customer needed a crane for daily mold handling, but the workshop had limited headroom. The crane also needed to move smoothly and position molds accurately during production operations.
Based on these requirements, we selected a 5 ton HD single-girder overhead crane with a compact structure and better lifting height utilization.
Mold Handling Requirement: Precision Control
During the workshop survey, we found that the customer frequently needed to flip molds during production.
The heaviest mold: Up to 7 tons
The mold needed to move between:
- Horizontal position
- Vertical position
This operation was not only about lifting capacity.
The crane also needed to provide:
- Stable lifting
- Smooth movement
- Accurate positioning
For mold handling, precise control is important. A crane that only runs at one fixed speed may make the mold swing during movement and increase positioning time.
Electrical System Optimization
During the site inspection, we also checked the customer's existing crane electrical system.
We found that the existing crane used an integrated control design, where the crane travel and trolley travel controls were combined.
This design created several problems:
- More cable movement during operation
- More difficult maintenance
- Higher risk of electrical failure
For a production workshop, unstable electrical control can affect daily operation and increase downtime.
Project Result
After installation, commissioning, and acceptance testing, the two HD single-girder overhead cranes were put into operation in the customer's injection molding workshop in Mexico.
The cranes now support daily mold handling, mold replacement, and material transfer between production stations.
Since the system was commissioned, the customer has achieved:
- Faster mold replacement
- Safer handling of heavy molds
- Less manual lifting and handling
- Higher production efficiency
- More stable and reliable daily operation
More importantly, we did not simply supply a standard crane.
We designed the crane system around the customer's workshop, production process, and lifting requirements.Our engineers selected the right crane structure, added variable-speed control, and provided on-site technical support from survey to commissioning.The final solution fits the factory's actual working conditions. It supports today's production and leaves room for future expansion.
Why Choose Yuantai Cranes for Injection Molding Applications?
Most customers are not crane experts, and they don't need to be.
Simply tell us:
- What you need to lift
- Load weight
- Lifting height
- Workshop layout
- Working frequency
Our engineers will take care of the rest, including crane selection, structural analysis, customized design, installation support, and testing.We provide complete overhead crane solutions for injection molding factories and other manufacturing workshops.Send us your workshop layout or lifting requirements, and our engineering team will provide a customized crane solution based on your actual working conditions.
