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PULP & PAPERpage 20
HEATHROW AIRPORTEXPANDS WITH THE HELP OFKONECRANES (UK) Ltd.page 6
STANDARD AND STEEL page 3
Double Eagle Steel Coating Co.
Georgia-Pacific Finland Oy
Konecranes world No.8 pdf 4.8.2003 11:40 Sivu 25
TECHNOLOGY ANDPERFORMANCE
Developing leading-edge technology for the material
handling industry – this is our commitment at KCI
Konecranes’ Standard Lifting Equipment. We bring our
customers the latest in modern lifting equipment built to pro-
vide exceptional performance, reliability and safety. Through a
potent combination of technical innovation and decades of
experience we can tailor optimum solutions for each cus-
tomer.
Standard Lifting Equipment offers a wide variety of lifting
products from 100 kg up to 100 tonne capacity for many differ-
ent industries and applications. Our product range consists of
industrial cranes and an extensive selection of crane compo-
nents, including wire rope hoists, chain hoists, electrical control
systems, workstation cranes, jib cranes and explosion proof
components.
We have a track record of being the first in our industry to
introduce important new lifting solutions. The new CXT wire
rope hoist design is one of our most recent innovations. Its
compact design combined with stepless speed control and
built-in safety features guarantees a level of performance that
fulfils even the most demanding expectations.
But, our work never ends. If we are to offer new products
and solutions tomorrow we must stay focused on our goals
today. A thorough understanding of our customers’ needs
combined with a work force of experienced, highly trained
and motivated personnel ensures that we will continue on our
chosen path of leadership in overhead material handling.
This issue of Konecranes World focuses on KCI’s standard
lifting equipment business. It includes informative stories about
customer applications from all around the world and the latest
product news. I hope that you’ll enjoy the articles and hopeful-
ly find some new ideas for the lifting needs in your own busi-
ness.
For further details we’ll invite you to visit our homepage at
www.konecranes.com and try our interactive crane design
tools. On this page you can also find our global contact
address list to reach the KCI Konecranes representative near-
est you.
With best regards,
Pekka Päkkilä
President
Standard Lifting Equipment
2 K O N E C R A N E S ’ W O R L D N o 8
PUBLISHER KCI Konecranes PlcStandard Lifting EquipmentP.O.Box 664, FIN-05801 Hyvinkää, FinlandTel. +358-(0)20 427 11Fax +358-(0)20 427 3099
EDITOR IN CHIEF Timo Toni, Marketing DirectorStandard Lifting Equipmenttel. +358-(0)20 427 3040Fax +358-(0)20 427 [email protected]
PRODUCTION OnePartner Oy and KCI Konecranes Plc
COPYRIGHTS KCI Konecranes Plc
www.konecranes.com
STANDARD AND STEEL.....................................................3
HEATHROW AIRPORT EXPANDS WITH THE HELP OF KONECRANES (UK) LTD. ..................................................6
PRIM & KONECRANES’ RECIPE FOR GROWTH BLENDS PRODUCTS AND SERVICE ...................................9
CUTTING-EDGE PLASTICS MANUFACTURER RELIES ON CXT CRANES ..........................................................11
CHAIN HOISTS – ONWARDS AND UPWARDS! ................12
KONECRANES VLC IS GOING STRONG IN RTG'S ...........14
NEW COMPANY ESTABLISHED IN KOREA ......................14
KCI KONECRANES INTO JAPAN ....................................15
KCI KONECRANES DELIVERS HOT METAL CRANES TO NUCOR STEEL ..........................................................15
PILKINGTON KEEPS THE GLASS MOVING, THANKS TO OUTSOURCED CRANE SERVICING ...........................16
CRANE LAUGH .............................................................17
THE NEW REMOC RADIO CONTROL IS DESIGNED FOR ERGONOMIC AND PRODUCTIVE USE ....................18
CONTROLPRO FOR INCREASED SAFETY AND PERFORMANCE CONTROL............................................18
KONEDUCTOR POWER SUPPLY SYSTEMS .......................19
HOISTING IN HAZARDOUS ENVIRONMENTS – NEW EXPLOSION-PROOF CXT WIRE ROPE HOIST ...................19
PULP & PAPER ..............................................................20
DELIVERY OF THE 5000TH EOT CRANE IN AUSTRIA.........21
NEW INDUSTRIAL CRANE PLANT IN GERMANY SUPPLYING CENTRAL EUROPE.......................................21
A SAGA OF DRUMS AND WIRE ROPES ..........................22
CORPORATE FIGURES ...................................................24
KCI KONECRANES GROUP AT A GLANCE .....................24
THIS MAGAZINE FOCUSES ON OUR STANDARDLIFTING EQUIPMENT BUSINESS AREA.
CONTENTS:
Konecranes world No.8 pdf 4.8.2003 11:38 Sivu 2
3N o 8 K O N E C R A N E S ’ W O R L D
Double Eagle Steel Coating Com-
pany is the largest producer of
electro-galvanized steel in the
world. It is a co-owned venture of U. S.
Steel Corp. and Rouge Steel Co. based in
Dearborn, Michigan, near the Rouge
Complex where Henry Ford pioneered
the assembly line manufacturing process
during the early years of the automobile.
Available through parent companies,
Double Eagle’s rolled steel products are
predominately used by automotive man-
ufacturers and suppliers for parts such as
doors and body panels, as well as other
industries where high quality, corrosion
resistant sheet steel is required.
Double Eagle contacted KCI
Konecranes in July of 2001, requesting a
STANDARD AND STEELTwo words almost never found in the same sentence (or on the same quotesheet) when specifying cranes for the North American steel industry. But asDouble Eagle Steel Coating Co. discovered, a standard crane product from KCIKonecranes performed extremely well under pressure – with far better value anddelivery than a traditionally-specified steel mill crane.
Konecranes world No.8 pdf 4.8.2003 11:38 Sivu 3
quote for a backup maintenance crane
to supplement an existing 25-ton process-
duty crane in its galvanizing plant. Its
Class E Kranco crane had been used for
15 years in the harsh environment above
the galvanizing line, and the line’s main-
tenance requirements were increasing.
Planning an extensive renovation of the
galvanizing plant, Double Eagle needed
to accomplish the overhaul without
impacting production.
Double Eagle’s strategy was to pur-
chase a new crane that could handle
the same capacity as the existing crane –
25 tons – to do routine maintenance while
the original process duty crane was used
to move out and replace all of the equip-
ment identified for renovation. This
involved doing maintenance on plating
tanks plus all of the ancillary equipment
associated with them, including large
diameter rolls, passline rolls and the main
conductor rolls for each tank, each of
which weighs in at 23 tons.
According to Steve Strawsburg,
Konecranes’ sales representative for Dou-
ble Eagle, the renovation project was on
a fast track and delivery was the number-
one priority.
“The crane was described to me as a
back-up maintenance unit over the high
bay coating line. There were no written
specs initially other than the original
crane’s drawings. Based on their descrip-
tion and time frame I developed a quote,
making clear that this was a CMAA Class
“D” crane which came nowhere near
meeting traditional steel mill specifica-
tions,” Strawsburg said.
In a series of round-table discussions
between Strawsburg and Double Eagle,
Double Eagle representatives and consul-
tants accustomed to specifying steel mill
cranes repeatedly questioned the
crane’s capabilities, going through every
aspect in great detail.
“Due to the project timing, delivery
was paramount in our requirements,” says
Frank Carnevale, Engineering / Mainte-
nance Manager for Double Eagle. “We
were looking for an inexpensive crane
that we could put up in the bay quickly.
We knew going into the purchase that it
would not be a typical steel industry
crane. We knew we were dealing with a
standard product hoist assembly.”
But the crane was only intended for
maintenance and backup, and the
importance of meeting the timetable
tipped the scales in favor of the
Konecranes proposal. Double Eagle
decided to go forward with the pur-
chase: a 25-ton single hoist, double box
girder crane from Konecranes’ broad
range of standard industrial cranes. Fully
inverter-driven with variable speed
remote control, it spans a 72-foot high
bay and delivers 106 feet of lifting height.
The crane also features a powered, rotat-
ing bottom block that enables the opera-
tor to rotate the deflector and conductor
rolls into the correct angle for delivery to
the tanks. The new crane was only weeks
away from its scheduled installation when
unforeseen circumstances took the
plant’s primary Class E crane out of ser-
vice. The new crane was promoted from
backup to primary crane virtually
overnight.
“Everyone we dealt with at
Konecranes – from sales through delivery
– made good on their promises,” said
Carnevale. “Delivery was our most critical
item at that point, and the crane was
here within a day of when we expected
it.”
The new standard series crane from
Konecranes became the sole mover of all
the equipment – both routine mainte-
nance and renovation – for the plating
tank replacement. It did its own equip-
ment maintenance tasks to keep produc-
tion going and all of the remove-and-
replace work for the renovation as well.
“This was a very large renovation,” said
Carnevale, “and it was our only crane for
two months. We still don’t consider it to
be a process crane, since it’s not used
every hour of every day. Yet, over the
course of that two months we made as
many lifts with it as we thought we’d
make over two years.”
4 K O N E C R A N E S ’ W O R L D N o 8
Konecranes world No.8 pdf 4.8.2003 11:38 Sivu 4
5N o 8 K O N E C R A N E S ’ W O R L D
John S. Kennedy Jr. is Konecranes’
General Manager Operations, USA Indus-
trial Cranes. According to Kennedy, the
superior crane performance experienced
by Double Eagle isn’t surprising, because
a similar experience curve about the val-
ue of Konecranes’ standard hoist technol-
ogy occurred in the paper industry some
years ago.
“The paper industry was and is a very
demanding market segment, and in that
regard is somewhat similar to the steel
industry,” says Kennedy. “When a steel
line or paper mill goes down it’s big mon-
ey, and nobody wants the crane to be
the reason.”
Konecranes has introduced standard
lifting products as an option to the paper
industry, and those products have proven
themselves with years of satisfactory per-
formance. “The paper industry had long-
standing preferences for lifting equip-
ment, and they typically provided all of
the specifications when they placed an
order,” Kennedy said. “Ultimately, we
were able to convince them that by
telling us what they needed to accom-
plish rather than how the crane should be
built, we could often design a solution
from a line of cost-effective standard
components larger than the entire prod-
uct range of most of our competitors. Bot-
tom line, we were able to deliver superior
lifting technology at a substantially better
value.”
Konecranes’ pre-engineered solutions
became so successful that today they
are considered to be the standard in the
pulp and paper industry worldwide.
Kennedy believes this can also be the
case for certain portions of the steel
industry, where conventional solutions in
some applications can be replaced with
cost-effective standard solutions.
“The challenge is ours to prove that
these products will do the job,” says
Kennedy.“We don’t want to extend our
standard products into an application
where those products aren’t well-suited.
We still have a custom product for those
special and most demanding applica-
tions. But for some coil-handling, tube
mills, machine maintenance, pickling,
shipping bays and other similar steel mill
tasks, we can offer technologically superi-
or, cost-effective standard crane solutions
rated up to Class E, well-supported by the
Konecranes global service network and
unmatched product warranty.”
For example, Konecranes’ SM series
cranes can be rated up to 400 tons; and
are available in speeds, duty cycles and
capacities well beyond that which is cov-
ered by Konecranes’ CXT line. Although
SM cranes are still considered standard
products, they offer a wider variety of
motor and speed options and many spe-
cial features, extending into Class E capa-
bility.
Change begins with a single step, or
in this case, a single customer with a
problem to solve. According to Frank
Carnevale, Double Eagle’s purchase from
KCI Konecranes turned out to be an
excellent investment for both its plant ren-
ovation and for future operations.
“This crane made sense for us. With
the renovation finished, we now have two
cranes that give us long-term benefits in
terms of reduced downtime and the abili-
ty to do multiple tasks at once, instead of
just tasks in series with one crane,” says
Carnevale. “As for performance, operat-
ing now in what we consider a pure main-
tenance mode, our Konecranes pur-
chase is doing the job we need for sub-
stantially less cost than a direct replace-
ment or duplicate of our original crane.”
“Konecranes was able to perform at
the level we required with its ‘modern’
solution,” Carnevale said.“If we hadn’t
been able to get this crane when we
needed it our downtime cost would easily
have been many times the cost of the
crane. Compared to the cost of not hav-
ing it, the price of the crane itself was
minor.” ■
For further information:John S. Kennedy Jr.,
General Manager Operations, USA Industrial Cranes
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 5
6 K O N E C R A N E S ’ W O R L D N o 8
HEATHROW AIRPORT
EXPANDSWITH THE HELP OF KONECRANES (UK) Ltd.
Heathrow is the world's busiestinternational airport and the world's secondbusiest cargo port. Regarded as the hub ofthe aviation world, over 90 airlines havemade Heathrow their base. With such aninflux of both passengers and cargo therehas long been a need for expansion andfor over ten years there has beendiscussion about a fifth terminal.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 6
7N o 8 K O N E C R A N E S ’ W O R L D
T5 becomes a realityFinally, in 2001, a decision was made
and T5 was no longer a pipedream. The
vision was that T5 would be one of the
world's most exciting airport terminals,
visually attractive, easy to get to and
through, comfortable and accessible for
all. To address the hot topic of air traffic
control at Heathrow, a new state-of-the-
art control tower will also be built.
The new terminal will supplement
Heathrow's existing four terminals, allow-
ing the airport to grow in the future and
accommodate the most advanced air-
craft including those not yet in service
such as the Airbus Industries A380. Fortu-
nately, the actual site for the terminal lies
between the two existing runways so the
core terminal building and two satellite
buildings are ideally located and do not
require additional land for their construc-
tion. Transport links are of key importance
and T5 is designed to be a world-class
public transport interchange served by
rail and road links.
A Herculean task A stand-alone construction, the new
terminal will be completed over an esti-
mated five to six-year period providing
some 6,000 construction jobs. New termi-
nal buildings, baggage bays, parking
ramps, fuel ports and transportation ways
for passengers between terminals all have
had to be developed from scratch, and
with minimal effect on current Heathrow
operations. The new terminal will eventu-
ally have the capacity to accommodate
around 30 million passengers and will
occupy a site of 260 hectares, just under
a quarter of the 1,200 hectares occupied
by Heathrow currently.
Enter KONECRANES (UK) Towards the end of 2001, Express
O’Rourke JV Limited asked KONECRANES
(UK) Ltd, to provide a number of cranes
for use in the custom built Rebar Factory,
to be built at Colinbrook near Slough, a
few miles from Heathrow Airport. The fac-
tory was to be specifically designed for
the manufacture and distribution of the
special reinforcing rods used in the con-
struction of the terminal’s huge concrete
structures.
KONECRANES (UK) Ltd had previously
delivered cranes to each of the JV part-
ners in this project, albeit at different loca-
tions. Initially, nine CXTS overhead cranes
were delivered in 2001 to an Express Rein-
forcements factory near Bristol in the
south west of England. Then a number of
Goliath cranes were delivered in 2002 to
another joint venture project involving
O’Rourke for the construction of the new
rail link between central London and the
Channel Tunnel.
The new Rebar facility required fifteen
cranes, types CXTD and CXTS, three 10t
CXTS of 28m span to operate in a com-
mon bay 116m long. These cranes were
supported by seven 10t CXTS models of
24m span, operating in 3 bays each of
116m in length, where 1 of these shared a
track with 2 x 10t CXTD models of 24 span
and a 1 x 10t CXTS of 12 m span also in a
116m long bay.
Additionally, two 10t CXTD cranes,
each with two 5t CXTD hoists and an M6
(duty) were installed where the hoists are
set at fixed centres and used in tandem.
These cranes work in a reception area
complete with extended runway to allow
the unloading of steel from railway wag-
ons. One of these cranes has an open
cabin, joystick control, partial platform
and the facility for the end user to add
hook-on magnets if required. The cranes
also utilise Remox remote radio control
with pendant back up, with one of the
twin trolley cranes equipped with a joy-
stick radio for use with a magnet. The oth-
er cranes rely on pushbutton control. With
the exception of the twin trolley cranes at
A6/M6, the duty is A5/M5, all long travel
speeds are 0–63 m/min via DynAMove
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 7
8 K O N E C R A N E S ’ W O R L D N o 8
inverter controls, all traverse drives are
0–32 m/min via DynADrive and all hoists
are 8/1.3 m/min via Pole Change control.
“We believe the original enquiry was
based on the success of the delivery to
Express Reinforcements, where we deliv-
ered seven cranes of similar dimensions to
do a similar job. The cranes have per-
formed well and this almost certainly led
to the enquiry for the terminal 5 project,”
said Gordon Adie, head of KONECRANES
(UK) Ltd.
Faster operating speeds, maximised throughput
Despite the size of the cranes the
operating speeds are fairly fast which was
an essential factor as the client had expe-
rienced disappointing results when using
cranes with lower speeds. High levels of
throughput were essential to obtain the
manufacturing program required for the
overall project. With this in mind, it was
agreed that the DynA Technology per-
fected by KCI KONECRANES should be
used so speeds could be controlled to
maximise throughput with no adverse
effect on the mechanisms or structures.
Overload protection, anti-collision moni-
tors, end of travel 2 step limit switches and
2 step traverse limit switches were also
added to provide as much operator safe-
ty as possible.
“Once we had the enquiry we jointly
selected the specification for this facility
at Heathrow, making the necessary
changes from the previous contract to
suit a higher throughput and layout.”
recalls Adie. “The cranes at Heathrow
have faster travel speeds to suit the
longer building and a number of double
girder cranes to suit a different handling
scheme and higher loadings in two key
areas.” Adie adds.
Signed, sealed, deliveredThe order was placed at the end of
October 2002 for delivery to start at the
end of February 2003 with the largest
cranes first. It took time to get dimensional
approval and the outdoor specification
was only added for 2 cranes at the end of
December 2002.
“Our ability to meet the change in
their requirements with the minimum of
effort yet still meet the delivery require-
ments, coupled with a fair price, led to
KONECRANES (UK) Ltd winning this con-
tract,” explained Adie.
The cranes were all delivered on time
and were erected by end of March 2003.
The last crane (10t (two x 5t) CXTD models
with provision for magnets) was installed
in April 2003. It was triumph indeed that
KONECRANES (UK) Ltd. secured this con-
tract against stiff UK and international
competition, Perhaps a key overriding
factor in the procurement of this presti-
gious contract was an unblemished track
record with each of the joint venture
companies and unmatched delivery per-
formance. “We were pleased to work
with the client to obtain the best offer
possible, with cranes suitable for the job in
hand that would prove, as in previous
contracts, to be up to the job – reliable,
easy to operate and maintain.” con-
cludes Adie. ■
Gordon Adie, Managing Director, Konecranes (UK)
“Our ability to meet the change in theirrequirements with the minimum of effort yet stillmeet the delivery requirements, coupled with afair price, led to KONECRANES (UK) Ltd winningthis contract,” explained Gordon Adie, head ofKONECRANES (UK) Ltd.
KONECRANES erection supervisor surveys his work on completion of erecting the 15 cranes, prior to the machinery moving in.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 8
9N o 8 K O N E C R A N E S ’ W O R L D
PRIM & KONECRANES’ RECIPEFOR GROWTH BLENDS PRODUCTSAND SERVICEThe sale of more than 1500 cranesand 1700 hoists in three year’s timeindicates that PRIM SpA, KCIKonecranes’ licensee in Italy, hasdeveloped a successful salesapproach for the Italian market.
“Establishing a proactive relation-
ship with customers, taking
care of their problems and
proposing innovative service solutions up
front determines whether we continue to
sell to that customer,” says Mario Girelli,Managing Director of PRIM SpA. “In addi-
tion, it is important that the products we
offer are state-of-the-art in terms of tech-
nology, performance and reliability.
”Girelli believes this combination of
proactive service and superior technolo-
gy was the reason Konecranes products
were selected recently by two high-pro-
file industrial groups in Northern Italy
whose existing fleet of lifting equipment
had been purchased from German and
Italian vendors.
TESMEC GROUP and REGGIANIMACCHINE choose CXT quality and PRIM’s maintenanceservices
TESMEC GROUP and REGGIANE MAC-
CHINE are building a new production
facility in Grassobbio near Bergamo con-
sisting of three warehouses covering
28,000 square meters, and plan to add
another 6,000 square meter warehouse
soon.Machinery assembly for both com-
panies will be carried out at this new
industrial complex, which also includes
offices for management, technical design
and sales.
Konecranes supplied 31 overhead
traveling cranes for the Bergamo facility,
including single and double girder
designs. The cranes are equipped with
CXT hoist units in capacities of five, 10, 12
and 20 tons, and will be used to handle
goods in the production area, as well as
receiving and shipping. The scope of sup-
ply also includes scheduled maintenance
and parts for a period of 5+5 years.
TESMEC GROUP is one of the leading
Italian manufacturers of machines and
tools for voltage lines and telecommuni-
cation lines suitable for stringing both
overhead and underground cable. The
company also manufactures digging
machines used in difficult soil conditions
including solid rock and equipment used
in offshore applications.
REGGIANI MACCHINE designs, manu-
factures and sells textile printing and tex-
tile ennobling machines. REGGIANI MAC-
CHINE products are recognized by textile
ennobling companies as top-tier solutions
based on a very modern, high-technolo-
gy platform. TESMEC GROUP is linked to
REGGIANI MACCHINE as the source of its
equity capital.
CXT fits service center profile for leading international specialsteel distributor
Italy is one of the most important mar-
kets worldwide for special steel and high
speed steel. Böhler Uddeholm Italia SpA
initially purchased four KCI Konecranes
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 9
suspended single girder overhead travel-
ling cranes equipped with CXT hoist units
in 5 and 3,2 ton capacities for their Steel
Point service center in Milan. Steel Point
handles most of the orders collected from
Italian customers by Böhler of Austria and
Sweden’s Uddeholm, two of the world’s
best known and highly regarded special
steel brands. Together, they account for
roughly 28 percent of the international
tool steel market. The parent ownership
group Böhler Uddeholm AG of Vienna,
Austria is active on five continents, and its
directly-controlled sales companies are
among the world’s leaders in the special
and tool steels business.
Distribution of Böhler and Uddeholm
division products ranging from tool and
special steels to high speed steel is man-
aged partially through exclusive dealers
and partially direct to the customer.Both
divisions require a high service level and
short delivery time, which is why Steel
Point operations run continuously from
6:00 a.m. Monday – 6:00 p.m. Saturday
with three daily shifts. To maintain cus-
tomer expectations, all machinery includ-
ing cranes must be ultra-reliable and able
to operate continuously without failure.
Due to the design of the Steel Point
warehouse calling for bridge cranes to
be suspended from the roof without sup-
port pillars, weight of the cranes was a
major factor in selecting Konecranes CXT
products. The warehouse has a span of
36 meters, with the span divided in two
sections of 18 meters each. For each sec-
tion different cranes are in operation:four
on the right side and one on each side of
the left section.
Other factors influencing Böhler Udde-
holm Italia SpA’s decision to purchase
Konecranes’ CXT cranes were its space-
saving design and reduced hook
approach dimensions that enable it to
operate very close to building walls. Stan-
dardization and the ability to interchange
components with other CXT hoist units of
different load capacities was also a fac-
tor. But it should be noted once again
that the service capability of Prim SpA
also helped make the difference – and
the sale. Prim SpA was able to install the
new cranes and 115 meters of runway in
only two weeks during the month of
August, during the customer’s normal
summer shutdown. They also agreed to
supply scheduled maintenance for three
years.
In the final analysis, the PRIM
Konecranes’ product mix of reliability,
flexibility, technology and service has
proven to be profitable for both customer
and supplier, as Böhler Uddeholm Italia
SpA placed a new order for two addition-
al CXT cranes as we went to press with
this issue of Konecranes’ World. ■
10 K O N E C R A N E S ’ W O R L D N o 8
CXT suspended cranes installed at Boehler Uddehlom Italia's Steel point service center in Milan.
Mario Girelli, Managing Director,
Prim SpAwww.primgru.com
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 10
11N o 8 K O N E C R A N E S ’ W O R L D
Can you give us a brief background ofKonzelmann, its development and prod-ucts?
Konzelmann is a mid-sized manufac-
turer of plastic products. The company is
41 years old and is in its second genera-
tion of family ownership with about 90
employees. We produce various types of
plastic parts and products, mainly for the
dental, pneumatics and automobile
industries. Our specific know-how is in the
fabrication of high precision plastic – it is
our speciality. Konzelmann also has the
reputation of being a strong develop-
ment partner. Our customers work with us
at a very early stage in the development
of their new products. We do our own
tool manufacturing and also have the
engineering capacity to develop pre-
series tools and prototypes.
How did you get into contact with KCIKonecranes?
When we began planning our new
factory building we were not aware of
KCI Konecranes. However, the construc-
tion company we were working with had
a strong track record of previous projects
with KCI Konecranes. They introduced
your company as a potential supplier for
our cranes, which led to our first personal
contact.
Please describe your lifting needs and thespecific requirements you had for a cranesupplier.
Our manufacturing process required
cranes to service the plastic injection
moulding machines for changing the
tooling and tooling transportation. Cranes
were also needed in the tooling manu-
facturing area to handle the tooling and
half-finished products during fabrication.
The two factory halls called for six
cranes with spans of 18,71m and 11.14m
and load handling capacity of one and
two tons. In a very early stage of the plan-
ning process we prepared a detailed
requirement specification for the cranes.
It was important for us to purchase mod-
ern technology for all functions, but most
of all we needed the maximum possible
lifting height in order to get optimum
usage of our factory interior.
With these requirements, what were theprimary reasons you selected KCIKonecranes as the supplier of yourcranes?
In building the new factory we want-
ed to focus our efforts on certain critical
matters related to our manufacturing
process. That’s why we wanted to rely on
a dependable manufacturer who could
provide good technology and above all
CUTTING-EDGE PLASTICS MANUFACTURERRELIES ON CXT CRANESWhen German plastics manufacturer Konzelmann GmbH built its newmanufacturing plant in 2001, their state-of-the art facility in Löchgau nearStuttgart was equipped with only one brand of lifting equipment – CXTCranes from KCI Konecranes. Konecranes World asked Mr. FrankGreminger, Konzelmann’s plant manager, how the relationship with KCIKonecranes came about.
straightforward and effortless project han-
dling and delivery. During the planning
phase the very competent guidance and
support provided by KCI Konecranes con-
vinced us that KCI Konecranes would fulfil
these requirements.
In dealing with the measurements and
data required by the architect, advice for
planning installation and start-up or tech-
nical questions, our needs were fully
addressed at all times. As the financial
and commercial factors of the offering
were also in line with our requirements, we
decided to select KCI Konecranes as our
crane supplier.
After the order was placed, what wasyour experience regarding delivery andperformance of the cranes?
The manner in which our order was
handled and the practical co-operation
we experienced during delivery proved to
us that our decision in choosing the crane
supplier was the right one. I can say that
we are very satisfied with the initial plan-
ning and advice, the delivery and installa-
tion and now the after-sale service. We
have also experienced quick response in
solving any problem that arises, and spare
parts delivery has been rapid. The service
we have received from our KCI
Konecranes representative has been and
continues to be very good. The cranes
have now been in operation for six
months and we are absolutely satisfied.
Mr. Greminger, thank you. We are glad tohave you and your company as satisfiedcustomers and we wish you continuedsuccess in your business. ■
For further information:W.R. Conrad, Sales Baden-Würtenberg
Konecranes T&H GmbHwww.konecranes.de
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 11
12 K O N E C R A N E S ’ W O R L D N o 8
The design of our hoist units is the
result of the combined efforts of
a number of KCI Konecranes
teams whose experience and
technological acumen has led
to a revolution in the construc-
tion of chain hoists. Early efforts were a
great success, and today three further
frame sizes have been added to the
range for capacities between 60 kg and
7500 kg. KCI Konecranes now offers the
most compact and complete range of
electric chain hoists in the industry.
However, technology cannot be
allowed to stand still and KCI Konecranes’
research and development is already
investigating possible adaptations and
future applications such as a special
chain hoist to cater for the windmill mar-
ket. XN units are now being tailored for
Chain hoists –
Onwards andUpwards!It is only a few years ago since theXN05, the first generation of XNelectric chain hoists, appeared on themarket. State-of-the art features, suchas a combined brake and anoverload slipping clutch assemblyoffered optimum levels of safety foroperators. If a hoist was overloadedthe slipping clutch would engage,and by releasing the button on thependant, the load would remain inplace – a feature not found on any ofour competitors' chain hoists.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 12
13N o 8 K O N E C R A N E S ’ W O R L D
specific uses on a weekly basis -whether
it’s mining in New Guinea or handling
loads in a marine environment in Norway,
chain hoists from Konecranes can pro-
vide the right solution.
The Light Lifting Equipment Market –trends lead to positive changes
Providing light lifting equipment for
individual workstations equates to a high-
er long-term trend in demand on the mar-
ket as a whole. KCI Konecranes products
meet this demand by providing a large
range of lifting equipment with vertical
and horizontal movement to cater for 60
to 7.500 kg loads. Such provision means
that immediate advantages are gained
in the safety of material handling, increas-
ingly ergonomic working environments
and a significant reduction in process
times.
“You might say we are the light part
of the Group’s lifting capacity, but with a
15% annual sales increase in this market
segment, we are gaining more weight
each day” Jean-Maxime Guhur, Presi-
dent of KCI Chain hoists says with a smile.
XN chain hoists have not only revolu-
tionised the world of Chain Lifting, but
with advanced manufacturing processes,
have contributed to even faster delivery
times. We believe well-managed distribu-
tion is imperative in good customer ser-
vice and this is exactly why Konecranes
maintain an organisation with close cus-
tomer relationships and local coverage.
The Light Lifting Equipment range –making light work of materialhandling
XN Electric chain hoists represent a
compact solution for all lower and medi-
um load hoisting applications. Perfectly
adapted to industrial requirements, XN
electric chain hoists use high technology
for increased reliability and modern
design for easy and ergonomic load han-
dling. In applications where the impor-
tance of hygiene and safety in produc-
tion is paramount, electric belt hoists are
the ideal choice. Industries like food, agri-
culture, chemicals and precision indus-
tries all benefit from the inherent qualities
of electric belt hoists. The XB Electric Belt
hoist boasts many exclusive patented
features to make it THE “clean hoist”: the
polyester belt runs without grease and the
stainless steel version is perfectly suited to
the steamy conditions so often found in
food production.
KCI Konecranes’ XM workstation
cranes are ideally suited for productive
and ergonomic material handling in man-
ufacturing and assembly operations
where loads of up to 2000 kg have to be
transported. XM cranes provide solutions
for customers' exact load, span and oper-
ational requirements. Due to a modular
design, XM also offers a flexible solution
for the transportation of light loads
between workstation units. Effortless load
handling and monorail, single or double
girder cranes, curves, turntables and
switches mean tailor-made solutions are
readily available.
Jib Cranes are commonly used for
load handling around machines or in
confined spaces.
Customised mechanical lifting at
every workstation is often essential for effi-
cient production and sufficient load han-
dling capacity. KCI Konecranes supplies
an extensive range of jib cranes for lifting
capacities of 80 kg to 5000 kg equipped
with chain or wire rope hoists.
On the up, thanks to new improvedproduct ranges
We believe in maximising customer
satisfaction and this is exactly the reason
why our sales team is always on hand to
reply to questions and inquiries. Whether
it’s information about our product range
or questions about special applications,
we’re happy to help. KCI Konecranes’
engineers are constantly studying market
requirements to provide the appropriate
technology for the specific application.
Standardised solutions are modified to suit
different applications and new innovative
products are developed.
Thanks to our on-line tools selecting
and configuring the lifting systems is now
easier than ever. Once selected and con-
figured requests for lifting systems can
then be forwarded to the closest local
sales contact for a quotation. Next, a KCI
Konecranes representative will make
immediate contact to provide the neces-
sary information. We are committed to
constantly updating and improving our
on-line tools and see them as a highly
important customer service measure.
Despite a tough market situation
where many suppliers are experiencing
difficulties we have experienced a period
of growth. Our success, we believe, is
attributed to constant developments in
our product offerings. New products and
wider ranges make it easier for our cus-
tomers – a greater choice from one sup-
plier. ■
For further information:Jean-Maxime Guhur, President,
KCI Chain HoistsTel. +33 2 3738 9595, Fax +33 2 3738 9623
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 13
Konecranes VLC has received a
number of new orders for Rubber
Tyred Container Handling Gantry
Cranes (RTG's) from North and Central
America during the first months of 2003.
Majority of the cranes will be made in
Europe and delivered to site fully erected.
The customers are APM Terminals (Eliz-
abeth, New Jersey and Houston, Texas),
Maryland Port Authority (Baltimore), Geor-
14 K O N E C R A N E S ’ W O R L D N o 8
C O R P O R A T E N E W S C O R P O R A T E N E W S
KONECRANES VLC IS GOING STRONG IN RTG's
To strengthen the market position in
the large Korean hoist and industrial
crane market KCI Konecranes estab-
lished in the beginning of 2003 a new
company Konecranes (KOREA) Co.,Ltd.
The President of the company is Mr.
Hyong Duk Choi. The sales office is locat-
ed is Soul and headoffice and logistics
center is in Kimhae in the southern part of
Korea close to Pusan. ■
Mr. Hyong Duk Choi, President1003 , Byongdong-Ri, Hallim-Meyon, Kimhae City,
Kyongsangnam-Do (Kyongnam).621-873.Korea
New company established in Korea
Two of the three RTG’s delivered to PSA Sines Terminal in Portugal 2002.
gia Port Authority (Savannah), and Oper-
adora Portuaria de Manzanillo (Mexico).
The total number of new cranes is 27.
All of above are repeat orders, which
indicates that our customers have been
very satisfied with the earlier deliveries.
Konecranes VLC has gained the num-
ber one position in the world amongst the
high capacity RTG suppliers. All new gen-
eration Konecranes RTG’s are with 16
wheels and have no hydraulics in them.
High performance is achieved with
Konecranes’ state-of-the art Active Load
Control System and Konecranes’ AC dri-
ves. Typically the cranes have been spec-
ified for 50 LT lifting capacity, with one-
over-five lifting height and a span of six-
plus-truck lane.
All these features give following advan-
tages to the operator:
• More productivity (boxes / hour)
• No need for special reinforced runways
• Low fuel consumption
• Low level of pollution
• costs
These new orders bring the total num-
ber of Konecranes' RTG's to 153. ■
C O R P O R A T E N E W S
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 14
15N o 8 K O N E C R A N E S ’ W O R L D
C O R P O R A T E N E W S C O R P O R A T E N E W S C O R P O R A T E N E W S
Konecranes America Inc. has the
contract to supply two key hot met-
al cranes and a service crane to
Nucor’s steel mini-mill in Jewett, Texas,
USA. This transaction marks the first time
Nucor has bought from KCI Konecranes,
and the first time an American steelmaker
has purchased hot metal cranes featuring
In April 2003 KCI Konecranes closed the
agreement with Meidensha Corpora-
tion of Japan (part of the Sumitomo
Sphere) to become joint venture partners
in Japan.
“Meiden being the most well-known
and the oldest hoist brand in Japan and
KCI Konecranes the world leader in
advanced hoisting technology the com-
bination of the two will create a strong
and paramount player in the domestic
Japanese market”, conclude Mr. Katao-ka, President of Meidensha Corporation
and Mr. Gustavson, President of the KCI
Konecranes Group.
KCI Konecranes owns 49 % of the Joint
Venture’s shares, Meiden Hoist System
Company Ltd (MHS).
Under the Joint venture partnership
MHS has introduced to the Japanese
market a new hoist range based on
Konecranes technology. The technology
has been adjusted to meet with local
industry standards and technical specifi-
cations.
The MHS headquarters and manufac-
turing plant are located in Nagoya. ■
For more information, please visit: www.konecranes.com
KCI KONECRANES INTO JAPAN
Osaka
Wakayama
ToyamaKanazawa
Nagoya Shizuoka
Hamamatsu
YokohamaTOKYO
Kyòto
Gifu
SendaiNiigata
Nagano
Kòriyama
Iwaki
Utsunomiya
Aomori
Sapporo
Hakodate
Kushiro
Nemuro
Abashiri
Wakkanai
Asahikawa
Akita Morioka
Kòbe
HiroshimaOkayam
a
Nagasaki
Sasebo
Kitakyùshù
Kumamoto
Òita
Matsuyama
Kòchi
Kagoshima
Honshù
Osumi-Shoto
Oki-Shotò
Gotò-Rettò
Tsushima
Sodo-Shima
Okushiri-Tò
Rishiri-Tò
Rebun-Tò
Hokkaidò
Shikoku
Kyùshù
JAPAN
Kiso
Tone
EAST CHINA SEA
YELLOWSEA
S E A O FJ A PA N
PA C I F I C
O C E A N
KCI KONECRANES DELIVERS HOT METALCRANES TO NUCOR STEEL
The trolley for the Charge crane on the final testrun with Nucor team present in Hyvinkää KCISpecial Cranes works before shipping toHouston.
AC variable frequency motors, which
offer significant maintenance savings
over traditional DC controls.
Nucor is building a new melt shop to
Jewett steel mill, which will include a new
ladle crane, charge crane and a caster
service crane supplied by KCI
Konecranes. The charge crane is a CMAA
Class “F” crane rated at 200 tons with two
auxiliary hoists rated at 75 and 25 tons.
The ladle crane is essentially the same
configuration without the 25-ton auxiliary.
The caster maintenance crane is rated at
100 tons with a 35-ton auxiliary. All three
cranes feature innovative AC drive sys-
tems with variable frequency controls and
WLAN diagnostics. The cranes also fea-
ture numerous safety systems to safe-
guard both employees and production. ■
Truck transportation from Hyvinkaa works toMäntyluoto port, port of Pori. Trolley widthoccupied whole width of road. Transportationrequired special arrangements and about 250km (160 ml.) transportation took 12 hours.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 15
16 K O N E C R A N E S ’ W O R L D N o 8
Pilkington (Australia) has a total of
about 60 cranes at its site in Dande-
nong, with ten of these cranes in
production areas and about a dozen in
despatch.
“We are hugely dependent on our lift-
ing equipment,” said Dandenong site
despatch manager Mark Forbes. “We
freight about 110,000 tonnes of glass a
year and if we lose a crane, despatch
stops. We simply can’t afford downtime.
And in fact it’s now quite rare to have
any.”
Pilkington makes many types of glass
products at Dandenong, including auto
glass, laminated safety glass, mirrors,
annealed glass for windows, and glass
panels for sliding doors. The plant manu-
factures around the clock, every day of
the year, although downstream functions
such as warehousing and despatch work
to more normal hours, operating a morn-
ing shift and an evening shift.
The despatch department at Dande-
nong has one 25 tonne crane, with the
Pilkington keeps the glass moving,thanks to outsourced crane servicing
Australia’s premier glass manufacturerhas achieved very low levels ofdowntime in the crucial despatchdepartment at its majormanufacturing site in Victoriafollowing the signing of acomprehensive crane maintenanceagreement with Konecranes.
remainder ranging in capacity from 7
tonnes down to 3.2 tonnes. Most are over-
head hoists that track across the ceiling
of the warehouse, remotely controlled by
radio.
“Our servicing has not only reduced
downtime, but more importantly has
identified areas where Pilkington’s equip-
ment could be upgraded to improve its
performance,” said Brad Leckie, Victoria
and Tasmania branch manager for
Konecranes, which manages the three-
C O R P O R A T E N E W S C O R P O R A T E N E W SC O R P O R A T E N E W S
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 16
17N o 8 K O N E C R A N E S ’ W O R L D
CRANE LAUGH
year-old crane maintenance contract at
the site.
“For example, we have installed two
new hoists as well as production cranes.
We also installed accessories such as
radio controls that
replaced manual pen-
dants, a Dynahoist to
enable matching speeds
on hoists, and travel
inverters to improve
crane performance and
handling.
“As well, we created
exclusion zones for the
cranes, to automatically
lock them out of produc-
tion or warehousing
areas that they shouldn’t
travel into,” he said.
Before Konecranes’
contract with Pilkington,
the glass makers man-
aged crane mainte-
nance work themselves
but found advantages in outsourcing to
specialists.
“Our arrangement with Konecranes
means we now need to spend less
resources on maintenance planning and
management. They do all that for us. We
also require fewer engineers on site. In
fact, most manufacturing companies of
our size will outsource their maintenance
work for these reasons,” Mr Forbes said.
“Konecranes inspect and maintain to
the Australian Standard, prioritising work
that needs doing and reporting to us reg-
ularly. They’ll make suggestions if we have
any problems and are very good at pro-
viding quotes for repairs or upgrades.
They also attend to any breakdowns and
can be here on site within an hour. There
are no ‘issues’ in our contract with
Konecranes,” he said.
Using its experience with more than
200,000 cranes of all
makes worldwide,
Konecranes’ inspection
and assessment proce-
dures are based on the
premise that systematic
and regular preventive
inspections of equip-
ment are the key to
safe, reliable and cost-
effective performance.
“We are continually
addressing the potential
downtime issues for
clients through our regu-
lar assessments and ser-
vicing,” said Mr Leckie of
Konecranes.
“The programmes
applied to Pilkington’s
Dandenong site are designed to go
beyond preventive and predictive main-
tenance, to a top-tier solution of reliabili-
ty-based maintenance management.
The service agreement integrates
Konecranes’ expertise with Pilkington’s
own, to achieve the best blend of on-site
and outsourced knowledge.”
Konecranes has more than 100 spe-
cialists in commissioning and mainte-
nance at 24 locations throughout Aus-
tralia and New Zealand. ■
For further information:Mr Edward Yakos, Managing Director,
Konecranes Pty [email protected]
C O R P O R A T E N E W S C O R P O R A T E N E W S C O R P O R A T E N E W S
Mr Brad leckie, Victoria and TasmaniaBranch Manager of Konecranes.
KCI Konecranes is one of thesponsors of the EFQM Forum2003, 8–10 October, Finland withthe theme “Inspired People DriveSuccess”. KCI Konecranes is con-tinuously investing in Perfor-mance Excellence and Qualityin its activities. The EFQM, Euro-pean Foundation for QualityManagement, is a EuropeanQuality organisation dedicatedto assist organisations throughoutEurope to participate in activitiesleading ultimately to excellencein customer and employee satis-faction, impact on society andachieving global competitiveadvantage.
www.efqmforum2003.org
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 17
18 K O N E C R A N E S ’ W O R L D N o 8
S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S
ControlPro for increased safetyand performance control
ControlPro is an unique and
advanced electronic control
device, which measures, calculates,
monitors and controls the performance,
safety and condition of the crane. It
makes the crane easier and more safe to
operate.
Basic overload protection and inter-
mediate load limits programmable
according to application requirements
increase personnel safety. In high temper-
ature environments and exceptional
peak usage situations additional perfor-
mance guarantee is provided by con-
stant temperature control and thermal
protection of the hoisting motor.
Versatile data about the actual
usage of the hoist and crane makes plan-
ning of maintenance easier. KCI
Konecranes pendant and radio controls
can be equipped with displays to bring
crane usage and condition information
down to the production and mainte-
nance personnel. This saves time and
enhances safety awareness. Cranes with
several hoists can be equipped with a
ContrlPro system, which continuously
monitors the accumulate load handled
by each hoists and protects the lifting of
too heavy loads. ■
The new RemoC radiocontrol is designed forergonomic and productive use
RemoC is handy to use and carry as
the transmitter’s strap gives a perfect
grip. All operating elements are located
in the front panel of the transmitter ensur-
ing that each function is easily located –
even in a rushed/emergency situation.
The extremely fine touch provided by sen-
sitive 2-step pushbuttons ensure easy and
safe speed control. RemoC’s new fre-
quency sharing technology offers flexibili-
ty because two or three cranes can use
the same frequency without disturbing
each other.
All RemoC system parameters are
stored in a unique microchip. In case of
mechanical damage to the transmitter
the chip can be moved to a sparetrans-
mitter. The remote control of the
crane can continue immedi-
ately without any new setup of the
system.
RemoC is designed for control of
cranes with one hoist and three
movements.
The model RemoC Optic is made
for the control of cranes with two hoists
and provides interactive communication
with KCI Konecranes crane safety and
performance control system ControlPro.
Constant information of the load being
lifted as well as information on crane per-
formance and usage can be read from
the display. ■
L A T E S T
N E W S
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 18
19N o 8 K O N E C R A N E S ’ W O R L D
S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S
This new line of hoists is characterised by
high performance and high standard
of safety. Its innovative and compact
design provides maximum utilisation of
factory space.
The advanced explosion proof tech-
nology is based upon European stan-
dards and the components are tested
and approved by independent notified
Hoisting in hazardousenvironments – Newexplosion-proof CXT wire rope hoist To further strengthen our position as a supplier to chemical andpetro-chemical plants, oil refineries, gas power plants and otherapplications operating in hazardous environments, KCI Konecraneshas developed the new explosion-proof CXTex wire rope hoist range.
bodies. The new hoist range is also
designed to meet the recent ATEX Direc-
tives that became mandatory July 1,
2003. The most standard ex-proof classifi-
cation for CXTex is EEX de IIB T4 but EEX de
IIC T4 is also available.
Currently CXTexhoists are available for
loads up to 40 ton lifting capacity, with
higher capacities available later in 2003.
KCI Konecranes’ explosion proof
product line also includes industrial and
jib cranes, electric chain hoists and belt
hoists. ■
Veijo Mattila, Sales Manager, Ex-proof Products, KCI Hoists Corporation
L A T E S T
N E W S
KONEDUCTOR power supply system has
now two alternative model ranges.
KONEDUCTOR power supply with con-
tinuous copper conductors is ideal for
long track lenghts and high capacity sys-
tems. It is available in unlimited track
lenghts and can be installed both indoors
and outdoors under widely varying
weather conditions. Due to the compact
design the system requires minimal space.
The copper conductors carrying the elec-
tricity are inside the plastic housing and
all components are designed for safe use.
The advantage of KONEDUCTOR-X
premounted bars is quick installation and
easy modification. Joining of two bars
and fixing them to the hangers does not
require any screws or tools. Extension and
replacing of single bars between any joint
is fast and easy. The design provides free
expansion of the copper strip and plastic
housing. Copper strips are connected
with a copper clamp. During tempera-
ture changes the clamp allows the cop-
per ends to move closer or wider from
each other without effecting the reliable
current connection. ■
For more information please visit us at:www.konecranes.com
Jari Jalkanen, Electric’s Product & EngineeringManager, KCI Hoists [email protected]
KONEDUCTOR power supply systems
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 19
20 K O N E C R A N E S ’ W O R L D N o 8
S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S
Despite regular maintenance the
crane was becoming increasingly
unreliable due to aging components.
Repairs to the old UN3 hoists were not
practical or cost-effective because
replacement parts were becoming obso-
lete, causing Georgia-Pacific to take one
of the crane's three hoists completely out
of service. Replacement of only one trol-
ley was not possible because the hoists
were used together and hoisting speeds
had to be similar. Also, Georgia-Pacific
required creep speed to be as slow as
possible to ensure safe operation. In order
to turn this situation around, Konecranes
recommended that all three hoists be
replaced.
Scope of modernisationThe scope of the modernisation
included three complete new CXT trol-
leys, frequency controls for the hoist and
trolley and new festoon cables. The exist-
ing frequency controls for the bridge dri-
ves and the radio controls were to be
KCI Konecranes uses CXT hoists to modernise a critical maintenance crane for Georgia-Pacific Finland Oy Crane K3882was originally deliveredto Georgia-Pacific's Nokia mill in1971. Commissioned as amaintenance crane for the wet end ofthe paper machine, its main functionwas to replace the paper machine'sdrums. Because it was also the spareunit for the dry end’s tambour crane,K3882 was a critical element of theproduction process, which focuses onsoft paper products such as napkinsand tissue.
PULP & PAPER
retained and incorporated into the new
control system. Konecranes was asked to
submit a proposal for the new equipment
and a detailed plan for its installation.
Crane down-time to carry out the mod-
ernisation had to be kept to an absolute
minimum to avoid disrupting Georgia-
Pacific's production.
The Konecranes solutionAs the project got underway, the
main issue for the customer was installa-
tion time. Konecranes developed a plan
involving careful co-operation with Geor-
gia-Pacific's production schedule which
allowed them to continue using the crane
during installation, reducing the total shut-
down time to only eight hours. To make
this feasible, all the new equipment was
tested and connected over a two-day
period in the hoist factory before it was
shipped to the Nokia mill.
Olli Riipanen, the Konecranes Nordic
electrician who conducted the factory
tests also supervised installation at the site
to ensure a smooth transition. The crane's
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 20
21N o 8 K O N E C R A N E S ’ W O R L D
S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S S L E Q N E W S
Technical specifications
• 3 CXT 20 000 kg hoists mounted on
double girder trolleys
• Maximum load of modernized crane
with load summation 25 000 kg
• Hoisting speed 4 m/min variable
(DynALift2L015V)
• Traversing speed 25 m/min variable
(DynAMove2T)
• New bridge panel, festoon cables
and pendant station
• Revised wiring diagrams incorporat-
ing existing components
existing hoists remained operational dur-
ing the one-week installation period while
the new control components, including
bridge panel, festoon cables and pen-
dant station were mounted at the other
end of the crane. During the final part of
the hookup, the crane was shut down
completely for eight hours while the old
bridge inverter was replaced with the
new panel and the existing radio control
and main power were reconnected.
When the project was complete,
Konecranes' promise to limit Georgia-
Pacific's downtime to only eight hours
without the crane in operation was ful-
filled. Thorough preparation, ongoing
communication with the customer and
extensive tests prior to delivery made that
possible. Konecranes also supplied Geor-
gia-Pacific with updated documentation
and wiring diagrams to help expedite
future maintenance.
According to Product Manager for
Industrial Cranes and Components PenttiMäkelä, Konecranes' close relationship
with the customer was key to being able
to satisfy their needs.
“We have a service agreement at the
Nokia mill and are very familiar with how
Georgia-Pacific manages their equip-
ment and production process,” says
Mäkelä. “When we promised that we
would limit their shutdown to only eight
hours, they trusted us. If you understand
the tremendous cost of downtime in the
paper industry, then you can also appre-
ciate the value of that trust.” ■
For further information:Pentti Mäkelä, project manager,
Industrial Cranes and ComponentsKCI Hoists Corporation
KCI Konecranes opened in September
2002 a state-of-the-art Industrial Crane
plant in Liebengrün, Germany.
The plant is constructed for manufac-
turing of box girder cranes up to crane
spans of 30 meters and lifting capacity up
to 100 tons. It is equipped with most mod-
ern production methods, new logistic
concept and IT solutions to guarantee
high efficiency and flexibility for a volume
of 1000 box girders per year.
In this plant Konecranes manufactures
industrial cranes for the Central European
market. ■
New Industrial Crane Plant inGermany supplying CentralEurope
In the first quarter of 2003 Konecranes
delivered the 5000th EOT crane in Austria
to Gruber & Kaja Druckguß- und Metall-
warenfabrik GmbH in Traun, Upper Aus-
tria.
Gruber & Kaja is an important supplier
of die-cast products to the automotive
industry. The crane will be used to erect
and maintain the die-cast machinery,
also to change and move the casting-
moulds.
Gruber & Kaja and KCI Konecranes
look back on more than 20 years of
cooperation. In the early days, when the
original plant was located in the city cen-
ter of Traun, Konecranes was already sup-
plying the hoists and cranes for the facili-
ty. In 2001 Gruber & Kaja expanded its
operations and built a new die-cast plant
in St. Marien, close to Traun.
In this first stage of the expansion, a 20
ton crane from Konecranes was installed
and taken into operation in the die-cast
works. At the beginning of 2003 the com-
pany continued its expansion program
and again chose Konecranes products
for their die-cast plant. The crane sup-
plied by Konecranes handles a load of up
to 20 t and has a span of 20.9 m. It has a
stepless trolley and bridge drive, which is
standard on CXT cranes and offers great
advantages to the user, especially for the
handling of the extremely expensive cast-
ings-moulds. In addition, the crane is
operated with a Konecranes Remox
remote radio control, which allows the
operator to move freely when handling
the moulds.
We are very proud at Konecranes to
have been chosen again to work with
Gruber & Kaja and that we were able to
meet their high requirements with regards
to quality of product, order processing
and delivery time. ■
Delivery of the 5000th EOTCrane in Austria
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 21
A Saga of Drumsand Wire Ropes
22 K O N E C R A N E S ’ W O R L D N o 8
@ K O N E C R A N E S K N O W - H O W
All our competitors had wire rope
hoists that followed a very similar
design. The designs were influ-
enced by industrial standards governing
wire rope hoist design and by the type of
wire ropes available at the time. In the
past 20 years new developments in wire
rope technology meant that much heav-
ier loads could be lifted with same diame-
ter of wire rope. For safety reasons, indus-
try standards specified the minimum ratio
between the rope and hoist drum diame-
ter. Such factors resulted in hoist designs
all having close to the minimal drum
diameter to fulfil the safety requirements
whilst at the same time, limiting costs,”
says Ari Kiviniitty, Managing Director of
KCI Hoists Corporation.
KCI beats with a different drumKCI Konecranes came up with the
revolutionary and inherently simple con-
cept of using a large diameter drum in
order to optimise space. The use of a
large drum alone would lead to space
limitations however; the new drum was
designed to actually incorporate the
motor internally. A larger drum with an
internally mounted motor constitutes the
optimum use of space – the large circum-
ference drum was born.
Many advantages were immediately
apparent when using a short, fat drum.
For instance, the horizontal travel of the
hook during lowering is minimal, which
means loads are easier to position. Fur-
thermore, the rope’s life is also increased
due to being coiled around a larger
diameter drum. A drum with double the
diameter of traditional designs means
greater longevity for the rope. As the new
design is also narrower, the hoist can be
positioned much closer to factory walls
and floor space can be bettered utilised.
Clearance can also be optimised, both
on the floor and the ceiling. Ultimately,
even smaller buildings can be built.
Control – a key factorInverter control was a key factor in
the development of new wire hoists as,
previously, there was only two or even
one speed, which caused the loads to
swing. The new inverter works like an
automatic gearbox speeding up and
slowing down gradually. This stepless
speed feature and smooth movement
used to be an option but now this is stan-
dard across our range – much to the dis-
appointment of our competitors.
The reason this feature became stan-
dardised was because production vol-
umes allowed us to offer the inverter con-
trol feature across the product range –
the large amount of time and money
invested in this kind of technology had
paid off. Consequently, this is now a fea-
ture that customers expect when looking
for new cranes and wire rope hoists. A fur-
ther advantage of using Konecranes
products is that, unlike our smaller com-
petitors, we are able to use high volume
components due to the modular design
of the product range. This in turn leads to
improved reliability.
Planes, cranes and automobilesWire rope hoists are used in numerous
end products i.e. industrial cranes, jib
cranes, monorail systems and fixed posi-
tioned hoists, so KCI’s whole volume
could be utilised.
The new wire rope hoists now cover all
KCI’s product platforms to deal with dif-
fering loads, using four different drum
diameters to cover six frame sizes. The
largest of KCI’s wire rope hoists, designed
for a load handling capacity of up to 80
tons, have motors positioned outside the
drum however space and height are still
optimised as a result of their side by side
configuration.
Two motors, like in aeroplanes, means
additional safety and reliability because if
one stops the machine does not come to
a halt. In fact the machine can be used
with lighter loads when using our electron-
ic control system limiting the maximum
load to half the total capacity. If a brake
The innovative wire rope hoist rangecame about as a result of an in-depthmarket and technology study carriedout between 1998 – 99 in which KCIKonecranes established that a highperformance, space saving designcould be utilised in a new generationof hoisting devices. They had to bestrong and reliable with easy loadhandling characteristics. Newcustomer requirements dictated aneed for new technologies andfeedback echoed both theirrequirements and their ideas for newproducts.
Two motor design for additional safety.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 22
23N o 8 K O N E C R A N E S ’ W O R L D
fails there is another brake in the other
motor and, let’s face it, buying one back-
up motor is cheaper than one huge
motor. The load distribution to the motors
is critical and this was tested thoroughly
and studied with the most advanced
computer modelling available. KCI
Konecranes’ R&D utilised very advanced
modelling and calculation tools in design-
ing the new hoist range – an investment
which brings our customers the ultimate in
safety and reliability.
In terms of construction, our steel parts
in smaller frames are pressed parts like in
the automotive industry, or to use the offi-
cial term “deep drawn.” KCI’s production
volumes mean we can invest in tooling
and therefore offer customers better val-
ue for money and consistent high quality.
Higher performance for price is what we
are aiming for and inverters as standard
are a good example of our commitment
to providing industry-leading products.
Our technology also means that we can
easily replace old hoists running on old
steel crane structures as we utilise a small-
er trolley with greatly improved features,
speeds and controllability.
Timed to perfectionKiviniitty goes on to say, “modular pro-
duction platforms mean that solutions
can be tailor made and our construction
methods are such that we can make spe-
cial adjustments to suit the customer's
needs while still using standard volume
parts. We use advanced computer pro-
grams to design and calculate the best
solution for customers' specific material
handling requirements.”
“Our delivery times are the best in the
world due to modularity and flexibility in
production combined with a global mar-
ket presence. In addition to actually com-
ing up with the ideas, we had to spend
millions on developing such revolutionary
designs. As KCI Konecranes is now
approaching 20.000 units sold worldwide,
we think the timing for our R&D efforts was
perfect.” ■
Ari kiviniitty, Managing Director, KCI Hoists Corporation
The CXT hoist range is designed using advanced modelling and stresscalculation tools ensuring ultimate reliability.
The innovative CXT technology provides superior benefits.
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 23
KCI KONECRANES GROUP
AT A GLANCE
VS
008
. ON
EPA
RTN
ER/S
P-PA
INO
OY
6/20
03
Sales* by Business Area
* Including internal sales
Total Sales 713.6 MEUR
Sales by Market*
Sales by Industry
Personnel By Business Area
Americas242.4 MEUR
34 %
Nordic and Eastern Europe
179.4 MEUR25 %
EU(without Nordic)
220.9 MEUR31 %
Asia-Pacific70.9 MEUR
10 %
StandardLifting
Equipment204.5 MEUR
26 %
HeadquartStaff1092%
Special Cranes68515%
MaintenanceServices
2,69862%
OEMCrane Builders
3 %
Others6 %
Pulp and Paper9 %
Power Plants6 %
GeneralManufacturing
22 %
Automotive 4 %
Primary Metals9 %
Shipyards 11 %
Resellers9 %
Petrochemical3 % Construction
2 %
Steel & otherwarehousing
3 %Transport,
Shipping1 %
Harbours 11 %
1 %Refuse
Handling
StandardLifting
Equipment94921%
Special Cranes209.2 MEUR
27 %
MaintenanceServices
372.4 MEUR47 %
CORPORATEFIGURES
Headquarters:KCI KONECRANES PLCP.O.Box 661 • FIN-05801 Hyvinkää • FinlandTel +358 (0)20 427 11 • Fax +358 (0)20 427 2099 www.konecranes.com
PLEASENOTE!Our new company name is
KCI Konecranes Plc
SE
Konecranes world No.8 pdf 4.8.2003 11:39 Sivu 24