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FullSharp · since 1991

This warehouse stacks cartons high on pallets, and every day workers carried each box down to the packing benches and carried the packed ones back up. The boxes are full and heavy, and constant bending and reaching left everyone with sore backs by the end of the shift.

FullSharp installed a 5T overhead rail along the aisle, with a FullSharp electric hoist and a pneumatic carton clamp tool. The tool grips the outer sides and picks up two cartons side by side at once; the operator steers by the handles and uses the controls on the tool to lift and lower, with no box carried by hand.

Pneumatic carton clamp tool on an electric hoist, gripping two cartons on a pallet

Pneumatic carton clamp tool on an electric hoist, gripping two cartons on a pallet

A 5T ceiling rail running along the warehouse aisle

The rail hangs from the ceiling beams on brackets and runs the full length of the aisle between racks and packing benches. The hoist travels along it, so the tool reaches every pallet on the way, while the floor stays clear for trolleys and people.

A coiled air hose hanging along the rail feeds compressed air to the tool, and the hoist cable hangs from hooks on the rail, so both extend as the tool moves and nothing drags on the floor.

Installing the FullSharp electric hoist on the 5T rail Electric hoist on the rail with the coiled air hose Rail running along the warehouse aisle Ceiling rail along the building

How the pneumatic carton clamp works

The tool has a yellow steel frame with a pneumatic cylinder in the middle driving the clamp arms at both ends. Lower it onto the two cartons and press clamp: the pads press against the outer sides of both boxes. Rubber-covered handles let the operator steer, and the hoist control is mounted on the frame, so one hand holds and the other presses.

The clamp and release buttons each work together with a confirm button, so a box cannot be released by a single mistaken press while it hangs. Clamping suits full, rigid cartons, where the force passes through the carton walls into the goods inside.

Tool frame, pneumatic cylinder and handles Tool gripping two cartons on a pallet stack

Operation

  1. Push the hoist along the rail to the pallet and lower the tool onto the two cartons.
  2. Press clamp with the confirm button; both pads grip the cartons.
  3. Lift, then steer the tool by the handles to the packing bench or another pallet.
  4. Lower the cartons, press release with the confirm button and raise the tool.

Key specifications

  • Rail5T ceiling-mounted rail, labelled 250 kg
  • HoistFullSharp electric hoist running on the rail
  • ToolPneumatic carton clamp, two cartons per lift
  • ControlsClamp/release with confirm button; hoist control on the tool
  • Air supplyCoiled hose hanging along the rail
  • Operation1 person

Benefits

No carrying by hand

The hoist lifts the boxes; the operator only steers and presses buttons.

Two cartons per trip

The tool grips two boxes side by side, halving the number of trips.

No floor space used

The ceiling rail runs along the aisle, leaving the floor clear.

Applications

  • Finished goods stores and packing areas moving cartons to and from pallets
  • Full, rigid cartons that are tiring to carry all day
  • Long aisles serving several workbenches
  • Plants reducing bending and reaching for workers

Frequently asked questions

When should cartons be clamped instead of vacuum lifted?

Cartons under about 50 kg with a flat, sealed top are quicker to vacuum lift. Cartons over about 80 kg with full, rigid contents are safer to clamp, since the force goes through the walls into the goods. For 50 to 80 kg FullSharp checks the actual carton before choosing.

Will the clamp crush the cartons?

Not when they are full and rigid, as the goods inside take the clamping force. Empty or soft-filled cartons dent easily; for those a vacuum lifter or a bottom-support tool is better.

What if the warehouse has no compressed air?

The clamp cylinder needs compressed air. Without an air line, a small compressor can be fitted near the rail, or FullSharp can suggest an electric clamp or a vacuum lifter instead.

See also the 5T steel rail, the article cartons too big for vacuum lifting, 5T rail projects and carton lifting projects.