Safer under the crane in the plastics industry!
Case study · Georg Utz, Kąty Wrocławskie (Poland) · plastics industry
Safe under the crane in plastics production
In the Georg Utz injection moulding hall, an overhead crane carries moulds over walkways used by people. Six LED safety projectors mounted on the crane project a marked danger zone onto the floor. The zone travels with the crane, so everyone nearby can see where the load is about to be.
6 LED projectors on the craneThe zone moves with the loadNo floor painting
Mould changeThe crane moves, and the light lines on the floor move with it.
Regional advisorvisits your hall and sees the crane in operation
Matched to runway heightnumber and power of projectors for your crane
Installation and servicewe handle installation, inspections and service
Online shopcrane projectors available off the shelf at 4safety.pl
The client and the shop floor
An injection moulding plant where loads pass over people
Industry: plastics processing, injection moulding. Georg Utz manufactures reusable plastic packaging: containers, pallets, trays and technical plastic parts. Their products serve logistics and warehousing, automation, automotive, pharma, e-commerce and retail.
The Kąty Wrocławskie plant runs injection moulding machines. Moulds are heavy, so every mould change is done with an overhead crane.
Cranes and other material handling equipment share one feature that floor paint cannot solve: the danger zone moves. It is wherever the load happens to be.
The moment of a mould change
The operator lifts the mould and travels over a walkway. Someone nearby carries containers to quality control, someone else pulls up with a cart of parts. The moulding machines keep running.
The audible signal is easy to missWith machine noise and hearing protection, the crane horn does not always reach pedestrians.
A painted zone stays putFloor lines show the travel path, not where the load is right now.
Pedestrians watch their feet, not the hookSomeone carrying a crate or pushing a cart does not look up every few steps.
Solution
Moving LED marking: the danger zone travels with the crane
Instead of marking the whole hall, we marked the crane itself. The light shows the zone exactly where the risk is.
Six LED safety projectors mounted on the crane
We mounted the projectors on the crane structure. They project clear lines onto the floor outlining the area under the load. When the crane moves, the marking moves too, so workers see the zone wherever the mould is in the hall.
Works where the horn can't be heard
Light on the floor reaches pedestrians even when sound is lost in machine noise. The visual signal complements the crane's audible warning; it does not replace it.
Nothing wears off, no barrier tape to remember
The marking never touches the floor, so forklifts can't damage it. It also doesn't depend on someone setting up posts at every mould change.
Comparison
Crane zone marking: three approaches to the same area
| Painted floor lines | Tape and posts | LED projectors on the crane | |
|---|---|---|---|
| Shows where the load is right now | No, marks the whole travel path | Only where they were set up | Yes, the zone travels with the crane |
| Requires action at every mould change | No | Yes, setting up and removing | No |
| Resistance to forklift traffic | Wears off, needs repainting | Posts get knocked over | No contact with the floor |
| Visibility in noise and with ear protection | Constant, but says nothing about movement | Depends on placement | Clear visual signal in motion |
What your plant gains
One solution, three reasons to implement it
For H&S and EHS
- A concrete technical measure for your risk assessment for crane handling operations, so you have something specific to record as a risk control.
- Fewer “walked under the load” incidents, because the zone is visible before a pedestrian enters it.
- Easy to show during an audit: the measure is visible on the floor, not only in a work instruction.
For production and maintenance
- Mould changes keep their pace, because nobody has to cordon off the walkway every time.
- We plan installation with your maintenance team, fitting it into crane downtime instead of stopping the line.
- Nothing on the floor, so nothing needs renewing after a season of heavy forklift traffic.
For purchasing
- One quote instead of several: selection, projectors, installation and service from one supplier.
- Crane projectors are in our shop with product data sheets, so it's easy to compare models and prepare a specification.
- Flexible payment terms for businesses.
Where else
Moving marking for cranes and other material handling equipment
Wherever a load travels over areas where people work, the principle is the same.
Injection moulding plantsmould and tooling changes
Foundries and metalworkingmoving castings and semi-finished parts
Steel warehousescoils, sheets and bars on overhead travelling cranes
Prefabricationprecast concrete and steel structures
Maintenancehoists and jib cranes along production lines
Crane projectors in our shop
Models we start the selection with
Power and mounting height determine how large and how clear the floor line will be. An advisor will help you choose the right model for your hall.
See all crane projectors
How we work
From site visit to working zone marking
01
Talk to an advisorYou tell us how the crane works and where people walk.
02
Site visitWe check runway height, span and walkways.
03
SelectionNumber, power and placement of projectors.
04
DeliveryTimed to match installation.
05
Installation and trainingMounting on the crane and a short briefing with your team.
06
Service and inspectionsSupport after go-live and expansion to more cranes.
Questions
What people ask us about cranes
How many projectors does my crane need?
It depends on the crane span, runway height and how wide a zone you want to show. At Georg Utz it was six projectors. An advisor sets the exact number after a site visit.
At what height can they be mounted?
The HP 65 W model works at 5–12 m, the HYPER HP 150 W at 8–20 m. A tall hall doesn't rule it out; it just needs a more powerful model.
Do the projectors replace the crane's audible signal?
No. It is an additional visual warning. It works best together with audible signals and your crane operating procedure.
Does installation require stopping production?
Installation takes place on the crane, so we schedule it during crane downtime agreed with maintenance. The moulding lines can keep running.
Can I buy just the projectors, without installation?
Yes. Crane projectors are available in the 4safety.pl shop. If you like, an advisor will suggest which model to choose.
Who handles service?
We carry out installation, service and inspections. After go-live you have a direct contact to your regional advisor.
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