Durable Goods Manufacturer Case Study

Super-sized ASRS Driven by Robust Controls

A cement board manufacturing facility needed a safe and efficient way to store massive 12,000-pound, 12-foot-long fiber cement boards in their new Georgia facility. With support from Mitsubishi Electric, Bastian Solutions designed a 45-foot crane with advanced features like load slippage prevention, anti-sway control and dual-laser positioning to handle the heavy loads with precision.  

The crane was developed as a standalone system, incorporating built-in intelligence for accurate control and performance. Since most cranes have a capacity of 3.5 tons, the load required a ground-up design capable of handling 7 tons. Bastian Solutions’ controls team leveraged controls from Mitsubishi Electric for advanced indexing of the solution without additional software integration. 

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Key Technologies

  • Custom 45-foot tall ASRS (automated storage and retrieval system) crane 
    • Dual mast design for complete load stability with full aisle travel and transfer of 7-ton pallet loads 
  • Controls from Mitsubishi Electric 
    • Some key features included: load slippage prevention, anti-sway control and dual-laser positioning 
  • Dual-laser distance sensor by SICK Sensor Intelligence  
  • Custom racking with 214 pallet positions 
 

Results

  • Safely handled 7-ton pallet loads
  • Tracked product storage with integrated controls
  • Bolstered safety with multiple points of redundancy
  • Shared operations information with external facility systems
 


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