Smart Upgrade for Heavy Loads: Solving the Paper Mill Handling Crisis
Project Background: Material Handling Dilemma in Tunisian Paper Mill
A paper mill group in Sousse, Tunisia (120K tons annual capacity) long suffered from log transportation inefficiencies. Traditional forklifts (1,800kg load capacity) lacked specialized gripping devices, leading to three operational pains: ① 12 monthly 滑落 (slip) accidents with irregular logs; ② frequent hydraulic failures in dusty environments (180K TND annual maintenance); ③ 60% manual handling violating Tunisia's Occupational Safety Law. Post-expansion, material turnover surged 40%, exceeding equipment capacity.
II. Pain Points: Transition from "Inefficient Manual Labor" to "Intelligent Handling"
1. Efficiency: Original equipment transported 120 tons per shift, requiring 2 extra forklifts and 8 workers in peak seasons, raising energy costs by 35%.
2. Safety Compliance: Tunisia Labor Inspectorate mandated 6-month automation upgrade, threatening 500K TND fine for non-compliance.
3. Environmental Adaptation: Mill humidity >85% year-round, wood dust concentration 2x national standard, requiring IP54 protection.
4. Cost Control: Aimed to reduce downtime from 40 to <10 hours monthly via equipment upgrade.
III. Solution: ZT935 Loader + Hydraulic Log Grapple for Scenario-specific Needs
Leveraging ZT935 loader parameters (doc ), we customized a professional handling system:
1. Main Machine Specifications
· Load & Power: 3,000kg rated load with 1.7m³ bucket, suitable for logs 30-120cm in diameter; Cummins 6BT5.9-C125-II engine (92kW/480N·m) maintains 90% power in dusty conditions .
· Maneuverability: 35° steering angle with 4,800mm minimum turning radius enables U-turns in 5m-wide workshops; 417mm ground clearance adapts to mill rails and slopes .
2. Log Grapple Technical Highlights
· Gripping System: Five-claw hydraulic drive (110kN force) with wear-resistant alloy teeth, improving wet log stability by 70%, eliminating slipping risks.
· Protection Design: Silicone rubber dust strips on the housing, combined with the loader's hydraulic sealing, achieve IP54 protection, reducing dust ingress by 85%.
· Intelligent Aid: Integrated automatic leveling (≤2° error) and 3,150mm max dump height enable 4-tier shelf stacking directly .
IV. Project Achievements: Tri-dimensional Performance Improvement
1. Capacity Breakthrough: 280 tons/shift transportation (150K tons annual), saving 900K TND in forklift purchases.
2. Safety Compliance: Manual intervention reduced to 12%, zero accidents, passing INSTM audit ahead of schedule.
3. Cost Optimization: Annual maintenance dropped to 60K TND (67% reduction), energy consumption down 22%, 14-month payback period.
V. Client Testimonial: "Redefining Paper Mill Handling Standards"
Amine Ben Amor, Logistics Director, commented: "The ZT935's 3,000kg load matches perfectly with the grapple's 110kN grip—we once moved a 2.8-ton wet log bundle, impossible with previous equipment. "
VI. Industry Insight: Value of "Scenario Adaptation" in Industrial Equipment
This case validates the professional transformation path for heavy loaders in paper mills: combining "main machine parameters (35° steering/4.8m radius) + industry-specific attachments" turns standard equipment into customized solutions.
