Improving Material Handling Across Two Steel Production Processes at Walters Inc.
Walters Inc. is a leading structural steel fabricator supporting major projects across North America. At its Princeton, Ontario facility, the team uses advanced equipment to process and fabricate steel for a wide range of structural applications.
The facility had two production areas with very different material-handling challenges.
Acculift worked with Walters to develop two purpose-built lifting systems, each designed around the equipment, workflow and operating requirements of its production area.
The CHALLENGE
The facility had two production areas with very different material-handling challenges.
The first involved a CNC processing machine used to drill structural steel, including I-beams, channels and HSS. As material moved through the machine, cutoffs and remnant pieces could be left inside the processing cell.
For example, a 40-foot beam might only require 30 feet for the finished component, leaving a 10-foot remnant that still needed to be safely removed and stacked.
Without a dedicated lifting system, operators might have to manually handle smaller pieces or rely on a forklift to access the area. Bringing a forklift into the cell was difficult because of the machine layout, light curtains and surrounding equipment.
The second challenge came from the welded wide-flange beam production line, where the lifting requirements were significantly heavier and more complex. The team needed greater capacity and the ability to perform multiple lifting functions within the same work area.
The SOLUTION
Acculift reviewed the equipment, lifting requirements and workflow of each production area to develop a crane solution suited to the application.
A Dedicated Lifting System for the CNC Drill Line
For the CNC processing cell, the priority was ease of movement and precise load positioning rather than high lifting capacity.
Acculift supplied and installed a ceiling-mounted enclosed-track bridge crane system with a 4,000 lb capacity, a 25-foot aluminum bridge and an electric chain hoist. The enclosed-track system was selected to provide easy movement and precise load positioning within the processing area.
The crane allows operators to remove and stack cutoffs directly within the processing cell, reducing the need for forklifts and manual handling of heavy steel.
“It was exactly what we needed. It was set up exactly how we were looking for.”
Before moving forward, Steve Van Manen, Plant Manager at Walters, also visited Acculift’s Woodstock location and saw a similar system in operation, which helped the team understand how the system moved and how it would function in their own facility.
Dual Hoists for Welded Wide-Flange Beam Production
For the welded wide-flange beam production line, Walters needed a higher-capacity lifting system capable of supporting multiple stages of production within the same work area.
Acculift supplied and installed a 44-foot-span overhead crane equipped with two 5-tonne hoists. The crane also includes dual-speed bridge and trolley motion, radio control and collision-avoidance functionality.
One hoist operates with a rotating device, allowing steel components to be turned so employees can access and weld the opposite side. The second is equipped with lifting clamps used to load material into the production line.
With both lifting functions integrated into one crane, operators can load and rotate steel components throughout the production process.
Designed Around the Application
The equipment itself was only one part of the project.
The Acculift team worked through the engineering and dimensional requirements before installation, including visiting the facility to confirm field measurements and ensure the supplied systems matched the actual operating environment.
Steve said the responsiveness throughout that process stood out.
“Responses were fast. I did not have to chase or look for responses. The team was good with the information I was looking for.”
That preparation carried through installation.
Because the cranes were being installed within active operating areas, keeping the project on schedule was important to minimizing disruption to production. According to Steve, both installations were completed within the timeframe Acculift had committed to.
The RESULTS
Both systems now provide Walters with dedicated lifting solutions designed around its production requirements.
At the CNC drill line, operators can remove and stage steel remnants without relying on forklifts to access the processing cell, reducing manual handling and improving material movement.
At the welded wide-flange beam line, operators can load and rotate steel components using one overhead crane, supporting multiple production functions within the same work area.
Both systems were installed within the committed timeframe, minimizing disruption to ongoing production.
“There were zero issues with anything from start to finish, from the engineering and sales side all the way through installation. Responses were fast, I didn’t have to chase for information, and everything was completed within the timeline we were given.”
Steve Van Manen, Plant Manager at Walters Inc.
Together, the two projects demonstrate why the right crane starts with understanding the application. By looking at how material moves, what operators need to accomplish and how the lifting equipment fits within the surrounding production environment, Acculift delivered two purpose-built systems designed to make material handling safer, more practical and more efficient.
Got questions?
Whether you’re improving material handling in an existing production area or planning a new crane installation, Acculift can help.
Our team works with you to understand your equipment, workflow and lifting requirements, developing solutions designed around the realities of your operation.
Contact us to discuss your next lifting project.
