Selecting the right vacuum lifter for your business, your processes and the materials you handle is crucial for ensuring safety, efficiency, productivity and ultimately a satisfactory return on your investment. Vacuum lifters are widely used in industries like manufacturing, logistics, engineering and construction to lift heavy, bulky, or delicate and fragile materials. But with so many options available, how do you make the best choice?
Understanding the Types of Vacuum Lifters
Before diving into the technical specifications, it’s important to understand the several types of vacuum lifters available on the market. The type of lifter you need depends on whether it will be stationary or portable and what power sources you have available.
- Manual Vacuum Lifters: Assist with the manual handling of light to medium loads, where a crane or fork hoist is not available. Manual vacuum lifters comprise of a vacuum cup and handle which can be attached to a load such as a sheet of glass or marble or steel. This allows the load to be picked up and carried manually with a safe grip and without marking the material surface. They are often used in construction for onsite installations of window glass, porcelain tiles or architectural cladding materials.
- Powered Vacuum lifters (Electric, Pneumatic:) Usually an “under-hook” lifting attachment on an overhead or jib arm crane, powered vacuum lifters use electricity or air (compressed or vacuum) to generate suction for attaching the vacuum cups to the surface to be lifted. There are options available to allow the secured product to be tilted or rotated too. Powered vacuum lifters have the widest range of cup configurations and lifting capacities available in any of the vacuum lifter types. Powered Vacuum lifters are used extensively in manufacturing and engineering, where there is good electricity supply or compressed air supply available that can be run to the vacuum lifter.
- Portable Powered Vacuum lifters (Battery) Where the load needs to be transported outside the range of an overhead crane, a self-contained battery powered electric vacuum lifter is the answer. Usually set up for use with a fork hoist but can also be used with a crane, or a combination of both. A wide range of vacuum cup configurations and lifting capacities is available, from lifting very thin sheet metal to slabs of pre-cast concrete.
- Tube Vacuum Lifters use the vacuum pump or blower to both create the suction for the vacuum cup to connect to the material surface and to lift the secured load, via a concertinaing vacuum tube. Vacuum tube lifters are good for loads up to 200kg and are often used in manufacturing, lifting bags, sacks, cartons and sheets, eliminating what was previously a manual handling lift. Tube vacuum lifters are commonly used with Jib Cranes and workstation cranes over a specific work zone.
Assessing Load Capacity and Weight Considerations
One of the most important factors in choosing the right vacuum lifter is its load capacity. You must select a lifter that can safely handle the maximum weight of the materials you work with.
- Understand the Weight of Your Materials: Make an inventory of the typical materials you handle and their corresponding weights. It’s always better to overestimate than to risk overloading a lifter, which could lead to accidents or equipment damage.
- Consider Variability: If your operation handles a range of materials with different weights and dimensions, opt for a versatile vacuum lifter that can accommodate varying loads.
- Account for Safety Margins: Always choose a lifter that offers a safety margin—usually, this means selecting a vacuum lifter with a capacity that exceeds your heaviest material by at least 10-20%.
Material and Surface Compatibility
Vacuum lifters rely on suction to lift materials, so achieving a complete seal between the material surface and the lifter’s suction cups is critical.
- Porous vs. Non-Porous Materials: For non-porous materials like glass, sheet metal, and plastic, most standard vacuum lifters work very effectively. However, for porous materials like wood or cardboard, you will need specialised advice on vacuum lifters that can handle air pressure loss.
- Surface Finish and Texture: Smooth surfaces provide the best seal for suction-based lifters. If you handle rough or uneven materials, ensure the lifter you choose has adjustable or flexible suction cups that can create a secure seal.
- Rigidity of material: The thinner the material to be lifted, i.e. thin sheets of steel or board, the more suction cups will be required to prevent the material sagging and peeling off the suction cups, The more rigid the material, the lesser number of suction points are needed to lift it safely.
Evaluate the Work Environment
Your work environment plays a significant role in determining the right vacuum lifter. Different environments present different challenges, and your lifter must be equipped to handle them.
- Indoor vs. Outdoor Use: If your operations take place outdoors, you need a vacuum lifter that can withstand harsh weather conditions. For example, lifters used in construction sites should be durable, water-resistant, and able to operate in dusty environments.
- Construction site: Where there is potential for people to be working around a suspended load on a vacuum lifter, a vacuum lifter with a dual circuit vacuum system will be required.
- Temperature Extremes: In industries where vacuum lifters are exposed to extreme temperatures—such as metal fabrication—choose a machine built to withstand high or low temperatures without compromising functionality.
- Space Constraints: If you work in a tight space, a compact and maneuverable vacuum lifter will be essential. Ensure that your lifter’s design allows for easy navigation and operation in confined areas.
Safety Features and Compliance Standards
Safety is non-negotiable when choosing a vacuum lifter. Ensure that the model you select adheres to relevant safety regulations and standards.
- Safety Mechanisms: Look for lifters with safety features such as back-up vacuum reservoirs in case of vacuum pump failure, emergency release systems, and audio-visual warning alarms. These features help prevent accidents and equipment failures.
- Dual Circuit: As a fail-safe feature when working around other people, such as on a busy construction site, the vacuum lifter should have a dual vacuum circuit set up, with each circuit capable of holding the full rated capacity of the vacuum lifter. This means that if one vacuum circuit fails, there is another one that can take the full load safely.
- Compliance with Industry Standards: Verify that your vacuum lifter complies with industry safety standards, such as those set by Worksafe New Zealand, Approved Code of Practice for Cranes, the relevant standards such as AS1418 Cranes Hoists and Winches, AS2359 Powered Industrial Trucks, AS 4991 Lifting Device standard.
Cost and Long-Term Value
While cost is an important consideration, it’s essential to think about the long-term value of the vacuum lifter. A 3-minute productivity improvement every 30 minutes can result in over 200 man-hours gained in a year. Return on investment is often a relatively short payback period. Once paid back, a vacuum lifter is sending earnings to your bottom line every day. More importantly than the financial aspect is the safety benefits a vacuum lifter will provide. The reduction in manual handling risk to a business is often undervalued until there is an accident or injury.
- Initial Investment vs. Lifetime Cost: Consider the initial cost alongside potential maintenance expenses, operational efficiency, and the lifter’s lifespan.
- Energy Efficiency: Opt for a vacuum lifter that is energy efficient, as this can reduce your operational costs over time.
Read our case study about Windsor Industries a supplier of premium caskets to the funeral industry, who not only increased staff safety but also their overall productivity.
Conclusion
Choosing the right vacuum lifter requires careful consideration of your materials, work environment, safety standards, and budget. By thoroughly assessing these factors, you can select a vacuum lifter that not only meets your current needs but also provides long-term value, enhancing productivity and ensuring the safety of your workforce. Prioritize quality, safety, and efficiency, and you’ll make a decision that benefits your business for years to come.
Helping New Zealand manufacturers safely solve their lifting challenges with the best local and global solutions
At Stratalign we’ve spent years helping New Zealand businesses identify and secure the lifting equipment they need. Our team has the knowledge and expertise to identify and install your ideal wall-mounted jib crane, to help you work more efficiently, productively and safely than ever before.
