Overcoming space constraint with specially designed EOT cranes in a two-tiered arrangement

About Varroc Polymers Pvt. Ltd.

Varroc is a USD 1.2 billion group with global presence that caters to various requirements of the automotive industry. They manufacture a vast range of tooling and auto components such as plastic modules, engine valves, machined forgings, exterior lighting and electrical systems.

Varroc Polymers Pvt. Ltd. is a subsidiary of the Varroc Group and was established in 2010 to make plastic moulds required for manufacturing various types of automotive components. These components such as headlamp covers, mudguards, etc. are mainly used in the trimming of prototypes and subsequently mass manufactured.

At Varroc, three Double Girder cranes in a two-tier arrangement facilitate handling at every station, overcoming bottlenecks. Carefully planned and designed cranes perfectly fitted in their existing plant integrate the shop-floor handling.

The handling challenges at Varroc

The plant was in advanced stages of construction when Varroc approached ElectroMech for their requirement of cranes. When our engineers studied various aspects such as the building structure, production flow, handling requirements, etc. they realised the space constraint and limitations of the already constructed bays. The cranes were required at almost every stage of manufacturing, which included raw material handling, handling at various workstations, despatch bay as well as for the maintenance of presses. The customer expected us to design customised material handling solutions consisting of cranes of different capacities and capable of handling multiple applications.

Solutions from ElectroMech

In order to effectively meet the challenges, we suggested the use of three cranes operating in a two-tier arrangement. The first crane of 30/15t capacity and 16m span is to be used to handle the incoming material from raw material storage area to the main manufacturing bay. The same crane was recommended for use at the despatch bay for handling finished products and also during maintenance of presses. The crane capacity was decided after taking into consideration all these requirements. This crane is at a higher level compared to the other two cranes. For meeting the handling requirements on the main shop-floor, two more cranes operating at a lower level were recommended. These two cranes, each one with 14.9m span and 20t capacity assist handling during the die making process.

Careful planning was done considering the layout of the equipment on the shop-floor as well as the two-tier arrangement of the cranes. To maintain high levels of safety, our design experts equipped the cranes with anti-collision mechanisms between the two tiers of the cranes. This has enabled Varroc to carry out operations on the shop-floor safely and efficiently.

Looking at the space constraint, typical construction of bays and the handling need at almost every workstation, our engineering team designed the cranes with minimum headroom and minimal end clearances.

As the primary application of these cranes is to handle large dies, moulds and assemblies where tilting operation is essential, precise control and smooth motion are a must. After a thorough understanding of the requirement and its criticality, ElectroMech recommended use of cranes fitted with advanced technology hoists. This proved to be a perfect solution for the tilting operations. These cranes with VFD controllers ensure precise inching control and jerk-free handling while providing utmost safety.

These three cranes together ensure complete integration of various handling requirements in this modern tool room.

How Varroc benefited from ElectroMech solutions

  • Faster completion of the project due to indigenous manufacturing and efficient ElectroMech team
  • Cost saving with ingenious design manufactured in India
  • Efficient handling to result in higher plant productivity


  • Space constraint and limitations of bay structure due to already constructed building
  • Handling requirements existed almost at every workstation due to heavy loads of moulds being made
  • Complete integration right from raw material stores to despatch bay was essential
  • Highly reliable solutions were required while restricting the initial investment


  • Cranes with two tier arrangement, along with the anticollision mechanism to prevent collision between cranes and to ensure safer operations on the shop-floor
  • Cranes were designed in such a way that the headroom requirement was minimum and required very low end clearances
  • Layout of cranes designed in such a way so as to ensure crane availability almost at every point on the entire shop-floor
  • Completely indigenous ElectroMech cranes that are cost-efficient and highly reliable
  • A compact design which enhances productivity by best suiting the complex requirements at Varroc


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