11.28.2025 / 6-minute read

Enhancing Raw Material Handling for Malion New Materials with Advanced Pallet Lifts

Project Overview

Guangdong Malion New Materials Co., Ltd., a leading manufacturer of polymer materials, fine chemicals, and new energy products, faced challenges in transporting heavy bulk bags of raw materials across production floors.

By integrating customized pallet reciprocating lifts, the company achieved seamless vertical movement of materials like color masterbatch and lithium battery wet separator raw materials.

This case study analyzes the technical solutions, performance outcomes, and industry-wide applications of these systems.

Basic Parameters

Category	Parameter	Specification
Basic Specifications	Model	FRP-3000HD
	Load Capacity	3,000 kg
	Lifting Height	5-25 m (customizable)
	Platform Size	2,000 × 2,500 mm (standard)
Performance Metrics	Lifting Speed	0.1-1.5 m/s (adjustable)
	Positioning Accuracy	±5 mm
	Maximum Cycles/Hour	105 cycles
	Noise Level	≤70 dB
Power System	Drive Type	Frequency conversion drive
	Motor Power	18.5 kW
	Control System	PLC + HMI
	Power Supply	380V/50Hz (3-phase)
Safety Features	Safety Standards	EN 1570, CE certified
	Protection Devices	Overload protection, emergency stop, limit switches
	Anti-fall System	Dual mechanical safety locks
	Safety Factors	≥5 (structural components)
Structural Design	Frame Material	Q235B carbon steel
	Platform Material	SS304 stainless steel (contact parts)
	Surface Treatment	Epoxy powder coating
	Guide Rail Type	Heavy-duty roller guides
Interface & Integration	Communication Protocols	PROFINET, Ethernet/IP
	I/O Points	16 DI/16 DO (standard)
	Integration Capability	Compatible with AGV, conveyor systems
	Data Collection	IoT-ready for predictive maintenance
Environmental	Operating Temperature	-20°C to +40°C
	Protection Rating	IP54
	Energy Consumption	<15 kW/h (average operation)
	Maintenance Cycle	2,000 hours (recommended)

Challenge

High Load Capacity Needs: FIBCs with polymer resins and pigments demanded robust handling.
Precision and Safety Risks: Unstable transport risked material spillage and equipment damage.
Cross-Floor Efficiency Bottlenecks: Manual transfers slowed throughput in packaging and warehouse zones.

Workflow

Raw Material Unloading: FIBCs transferred from ground floor to elevated production lines via lifts.
Integration with Packaging Zones: Automated handoff to packaging and palletizing stations for masterbatch and battery separator products.
Modular Design: Prefabricated components minimized downtime during installation.

Solution

Heavy-Duty Load Capacity
- Supported loads up to 2,500–3,000 kg, ideal for FIBCs and oversized raw material bags .
- Multi-guide rail structures ensured stability for tall or irregularly shaped goods.
Precision and Synchronization
- ±5 mm positioning accuracy enabled smooth transfers to conveyor lines.
- Encoder-based control allowed seamless integration with existing production and packaging systems.
Safety and Reliability
- Anti-fall mechanisms (e.g., mechanical “sacrificial” locks) and overload detection .
- Redundant electrical circuits with emergency stop functions ensured compliance with industrial safety standards.
Efficiency Enhancements
- Bi-directional “zero idle” operation: Empty pallets ascended while loaded ones descended, cutting non-productive time by 30%.
- Lift speeds of 60–90 m/min under full load, achieving up to 105 cycles/hour