This case study documents the execution of one of the most ambitious lifting projects in the history of Sacar del Centro México: the installation of two double-girder overhead travelling cranes – 180/60 and 25/15 tonnes – at the facilities of a leading automotive sector supplier located in Apaseo El Grande, Guanajuato.
From the engineering phase through to commissioning, the project involved specialised lifting solutions for plastic injection moulds, combining innovation, safety and close collaboration with the client to meet the industry’s highest standards.
A strategic supplier in the automotive sector, dedicated to plastic injection moulding for the manufacture of automotive components, was preparing to launch a new process using advanced technology at its plant in Apaseo El Grande. It required a high-capacity, safe lifting solution tailored to the complexity of the injection area.
Sacar del Centro México was selected to design and install crane systems capable of handling big and heavy moulds while ensuring uninterrupted operation. The company worked together with the client for eight months on detailed engineering to guarantee excellence.
The plastic injection area, where the cranes needed to be installed, presented demanding conditions. The total operational travel was 103m within the industrial facility, with a clear span of 45m and an effective height of lift of nearly 11m. The cranes were required to operate simultaneously, complying with a FEM 2m duty classification – suitable for the continuous handling of heavy injection moulds.
The major challenge was the structural design of the bridge girders. Due to the project’s dimensions and capacity, detailed structural calculations were carried out by both internal and external engineering firms. The objective was to ensure that the cranes complied with current Mexican standards and the client’s requirement of achieving a maximum allowable deflection of L/1000.
Sacar del Centro México carried out the installation of two supported double-girder overhead travelling cranes: a primary crane with a 180t main hook and a 60t auxiliary hook, and another with a 25t main hook and a 15t auxiliary hook. Both were mounted on a rail-type runway system, which facilitated their integration into the plant’s infrastructure.
For the higher-capacity crane, open winches from R&M Materials Handling were used, chosen for their responsiveness in critical load applications.
The 25/15t crane was equipped with electric wire rope hoists from the same brand, enabling precise, reliable and low-maintenance lifting. Multiple safety requirements requested by the client were integrated, including anti-sway systems, restricted operation zones, auto-centring functions, anti-collision sensors, remote radio controls, as well as the standard safety systems included in the R&M equipment. This ensured both personnel safety and the continuity of the operational process.
For the electrical power supply of the 180/60-tonne crane, the NRGmaster Energy Chain system was used – a robust and efficient solution that replaced the conventional festoon system, which proved impractical due to the size and weight of the components. The overall system electrification was complemented with Akapp technology, ensuring reliability and performance over long travel distances.
During assembly, various lifting devices were used to ensure a clean and safe installation inside the building. Although the commissioning phase involved a complex connection of wiring and control panels on both the bridges and hoists, the final result was satisfactory. The system’s speeds, travel ranges and functions met the client’s full satisfaction.
Before the project was completed, load and operational tests were conducted using certified structures and controlled weights that simulated real-world conditions. These tests validated the stability, precision and performance of both systems, meeting all the client’s technical requirements.
Both Sacar del Centro México and the client’s operations personnel actively participated in the system validation, confirming compliance with every safety, capacity and control parameter. Today, the cranes are fully operational, delivering complete reliability in the handling of plastic injection moulds.
Thanks to precise technical planning and flawless execution, Sacar del Centro México successfully delivered one of the most ambitious lifting projects in its history – enhancing the operational capacity of a highly competitive plant and reinforcing its commitment to industrial innovation.
