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FullSharp · since 1991

FullSharp installed a 5T overhead rail rated 200 kg from the line to the staging area of a packaging plant, with a KITO hoist and a vacuum lifting pad for carton boxes. The pad grips the flat top of the carton, the hoist lifts it and the operator pushes it along the rail, so corners stay intact and no forklift is needed in the narrow aisles.

Cartons in a packaging plant aren't huge, but they need loading and unloading continuously through the shift. Carrying them by hand dents the corners easily, and workers' backs tire fast. Narrow aisles between racks also leave no room for a forklift to turn.

FullSharp installed a 5T overhead rail, rated at 200 kg, running from the line to the staging area. A KITO hoist rides the rail, with a vacuum lifting pad mounted below it, pressing onto the flat top of the carton. The carton is held by suction, lifted, and pushed along the rail — no manual carrying required.

5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes

5T overhead rail with KITO hoist and vacuum lifting pad holding a carton box at the packing station.

Equipment Installed

  • 5T steel rail: FullSharp's rail profile, rated at 200 kg, mounted to the ceiling with threaded rods along the work line.
  • KITO hoist: stable lifting, brake holds securely when stopped mid-cycle.
  • Vacuum lifting pad: presses onto the flat surface of the carton, distributing suction evenly so the walls don't get squeezed out of shape.
  • Vacuum pump and control valve: builds vacuum with a low-pressure alert so the operator knows when the grip isn't strong enough.
  • Trolley running on the rail: a hand push moves it along the line, carrying the carton from the line to the pallet.

Key Specifications

  • Rail code5T steel rail
  • Rated load200 kg
  • HoistKITO
  • End effectorVacuum lifting pad

Benefits for Your Facility

No dented cartons

The pad grips the flat surface evenly, so corners aren't squeezed and walls don't tear.

Faster loading

Suction, lift, and push are three seamless steps, letting one person keep the whole line moving.

Makes use of ceiling space

The whole system hangs overhead, leaving the aisle between racks wide enough for carts to pass.

Real Installation Photos

5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 1 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 2 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 3 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 4 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 5 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 6 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 7 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 8 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 9 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 10 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 11 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 12 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 13 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 14 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 15 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 16 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 17 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 18 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 19 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 20 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 21 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 22 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 23 5T Overhead Rail, KITO Hoist, and Vacuum Lifting Pad for Carton Boxes - photo 24

Click a photo to enlarge. Album of 24 photos taken on site.

Suitable Applications

  • Carton and corrugated packaging plants
  • End-of-line packing for finished goods
  • Distribution warehouses and sorting centers
  • Pallet-stacking areas
  • Truck loading stations

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Frequently asked questions

How do you move cartons in aisles too narrow for a forklift?

An overhead rail carries the lifter above the aisle, so cartons are lifted and pushed along the route without any vehicle on the floor.

Will a vacuum pad dent carton corners?

The pad grips the flat surface evenly, so corners are not squeezed and walls do not tear the way they can when boxes are carried by hand.

What is the load rating of this rail system?

The 5T steel rail in this project is rated at 200 kg. FullSharp sizes rail and hoist to the heaviest carton and the route length.

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Installation Consultation for Your Facility

FullSharp visits the plant to measure the rail run, mounting height, and roof structure to finalize the anchor points. Our technicians weigh actual cartons and check the suction surface and seal quality of the carton material to select the right pad size. We then finalize the rail, hoist, and vacuum pump plan along with the installation timeline.

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