“High-performance Vulkollan® polyurethane wheels are engineered to eliminate delamination and reduce maintenance downtime by 90% in demanding Australian environments.”
1. Background & Challenges
The facility is a state-of-the-art AS/RS (Automated Storage and Retrieval System) operated by a leading Australian cold-chain logistics provider. Running 12 stacker cranes at heights of up to 30 meters, the facility operates 24/7 to meet high consumer demand.
The client faced several critical issues:
Delamination: Under high-speed acceleration and frequent braking, the original wheels suffered from heat buildup, causing the polyurethane tread to peel away from the metal core every 6 months.
High Maintenance Costs: Each wheel replacement required 4+ hours of downtime and specialized high-access equipment, costing thousands of AUD in lost productivity.
Noise & Vibration: Worn wheels created excessive noise and vibrations, which occasionally interfered with the precision of the cranes' laser positioning sensors.
Environmental Factors: The Australian summer heat combined with high-intensity indoor duty cycles placed extreme thermal stress on the wheel materials.
2. The Solution: Custom Engineering with Vulkollan®
The project team collaborated with local Australian material handling experts to design a customized drive and guide wheel solution using premium-grade materials.
Technical Specifications:
Material: Switched to Vulkollan® (a high-performance cellular polyurethane), widely recognized in Australia for its superior dynamic load-bearing capacity.
Hardness: Optimized to 93–95 Shore A to provide the perfect balance between grip (to prevent slipping) and durability.
Bonding Process: Utilized high-tensile cast iron hubs with advanced chemical bonding pre-treatment to ensure zero risk of delamination under peak loads.
3. Results & Performance Metrics
After 18 months of operation, the facility reported the following improvements:
Key Metric | Original Wheels | New Polyurethane Wheels | Improvement |
Service Life | 6 - 8 Months | 36+ Months (Projected) | 4.5x Increase |
Annual Maintenance Downtime | 24 Incidents | 2 Incidents (Routine only) | 90% Reduction |
Operating Noise | 85 dB | 72 dB | Significant Reduction |
Positioning Accuracy | ± 5mm | ± 1mm | Enhanced Precision |
Key Benefits Summary:
Thermal Stability: Even during Australian heatwaves, the wheels maintained physical integrity without softening or losing shape during high-speed runs.
Energy Efficiency: The lower rolling resistance of the high-grade PU material resulted in a 3-5% reduction in power consumption per crane.
Operational Continuity: The risk of emergency "catastrophic" wheel failure was eliminated, ensuring a reliable supply chain.Reduce Your Maintenance
Downtime Today"Get a customized quote for high-performance polyurethane wheels and extend your equipment life by up to 4x.[Request a Free Consultation]
