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Pit‑less Reciprocating Lift for Hygiene Products｜14.5m, 4 Stops, 96 Pallets/Hour

Q: How do you achieve 14.5m travel with 4 stops? Is levelling accurate?

We use a high‑rigidity frame + T90 car rails + TK5A counterweight rails . Each stop has an independent level sensor. The PLC memorises each position and applies dynamic error compensation. Levelling repeatability ≤ ±5mm, suitable for pallet jack access. The 4 stops (basement, 1F, 2F, 3F) cover the entire process from raw material receiving to finished goods dispatch – no manual intermediate handling.

Q: Can the chain and motor withstand 40 m/min and thousands of cycles per day?

We use 16B roller chain (safety factor ≥8) and a high‑power VFD motor with forced cooling. The chain is designed for infinite fatigue life. Acceleration/deceleration is smoothed by the VFD to reduce shock. In actual operation (approx. 1,200 cycles/day), no chain replacement or motor overheat alarm occurred over 3 consecutive months. Triple mechanical fall protection (speed limiter + safety gear + lifting mechanism) ensures the car will not drop even if the chain breaks.

Q: How do the 16 conveyor sections coordinate? Will they jam or idle?

Each conveyor section has a load sensor and is networked to the lift PLC. The PLC monitors the load status of every section. A section runs only when upstream is loaded and downstream is free. The in‑car conveyor automatically runs forward or reverse based on the floor direction. The HMI displays a dynamic simulation showing real‑time status of all conveyors and the car, allowing operators to anticipate congestion. In practice, throughput reaches 96 pallets/hour consistently without jamming or excessive idling

POSTED: 6/5/2026

Overview

Project type: Chain reciprocating lift (pit‑less installation)
Industry: Hygiene products (diapers, sanitary napkins, tissue paper) – production & warehousing
Key features: Pit‑less (100mm concrete slab + steel plate), 14.5m ultra‑high travel, 4 stops / 4 levels, 40 m/min high speed, 96 pallets/hour throughput, 16 roller conveyor sections, triple fall protection

The client producing disposable hygiene products such as diapers, sanitary napkins and wet wipes. These products are bulky, lightweight and have extremely high dispatch frequency, often stored in multi‑floor warehouses. With e‑commerce and retail demanding “same‑day delivery”, the factory needed fast, stable and automatic material flow from basement (raw materials/packaging) to the third floor (finished goods).

Challenges

No pit available: The site has no pit and cannot support a traditional deep‑pit lift.
Tight space requiring material turning: Straight‑through access is impossible – material must change direction inside the shaft (Z‑shaped access).
High cycle speed: Lift speed up to 60 m/min with automatic conveyor handover to minimise manual handling.
Multi‑pallet compatibility: Must handle two pallet sizes – 1150×1150mm (9‑leg) and 1200×800mm (grid) – with long‑side entry.
High safety standards: Automotive parts are sensitive to impact and scratches; light curtains, cargo dimension detection, and redundant fall protection are required.
Height difference at 2nd floor mezzanine: The steel platform may not align perfectly with the lift infeed; height adjustment needed.
Urgent delivery: Order placed December 29, required shipment by January 30 (including New Year holiday).

Core Specifications

Parameter	Value
Rated load	500 kg
Travel height	14,500 mm (4 stops: B1,1F,2F,3F)
Car internal size (W×D×H)	Adapted to pallet 1100×1300×1750mm; internal height 2200mm (excluding conveyor)
Access direction	Single‑side along 3,500mm
Lifting speed	40 m/min
Throughput	96 pallets/hour
Chain	16B
Guide rails	T90 (car) + TK5A (counterweight)
Safety devices	Speed limiter + safety gear + lifting mechanism + polyurethane buffer
Floor doors	PVC high‑speed doors ×4 (W1800×H2200mm), yellow with window
Enclosure	Yellow diamond mesh on four sides
Total conveyors	16 roller conveyor sections (including 1 in‑car)
Control	Siemens PLC + 10″ touch screen per floor (dynamic simulation, fault alarm, cycle counter)
Installation	Pit‑less (100mm concrete slab + steel plate)
Colour	Yellow (doors, guardrails, mesh)
Order date	October 26, 2025
Shipment date	October 27, 2025
Installation period	Within 45 days

Solutions

3.1 Pit‑less high‑travel design

Structure: Main frame made of 100mm square tube, connectors 100×50×6mm rectangular tube – rigid enough for 14.5m travel.
Installation: A steel plate is laid on the existing 100mm concrete slab to increase bearing area. The lift is anchored via foundation bolts. Car infeed height is adjusted by conveyor levels – no pit needed.
Guide rails: T90 car rails + TK5A counterweight rails ensure vertical accuracy over 14.5m.

3.2 Precise 4‑stop levelling

Travel & stops: Total travel 14,500 mm, stopping at basement, 1F, 2F and 3F (4 levels).
Positioning: Level sensors on each floor; PLC memorises positions; levelling accuracy ≤ ±5 mm.
Access direction: Single‑side entry/exit along 3,500mm direction, fitting the factory layout.

3.3 High‑speed, high‑frequency drive system

Motor: High‑power VFD motor (not explicitly rated, but sized for 16B chains and 40 m/min).
Throughput: 40 m/min lift speed, 500kg capacity, single cycle approx. 40 seconds – achieving 96 pallets per hour.
Reversible operation: Both conveyors and lift can run forward/reverse for bi‑directional material flow.

3.4 Full‑floor roller conveyor integration (16 sections total)

Location	Conveyor specification	Qty
In‑car	L1800×W1800mm (internal width)	1
B1	L1600×W1600×H600mm (standard roller)	5
1F	L1600×W1600×H90mm (three‑section)	5
2F	L1600×W1600×H90mm (three‑section)	3
3F	L1600×W1600×H90mm (three‑section)	3

Each conveyor width 1600mm, compatible with pallet jacks and pallet size 1100×1300mm.
Conveyors are interlocked with the lift: each conveyor section maintains a load‑detected state; PLC controls start/stop.

3.5 Triple fall protection & intelligent monitoring

Mechanical fall protection: Speed limiter + safety gear + lifting mechanism (elevator‑grade) – automatically locks the car if overspeed occurs.
Electrical safety: 10″ touch screen on each floor shows dynamic simulation, real‑time position, fault codes; audible/visual alarm on fault.
Data statistics: The touch screen records daily and cumulative cycles – useful for production management.
Enclosure & guarding: Yellow diamond mesh on four sides; yellow guardrails with warning signs on both sides of conveyors.

Details

Product Certificates

FAQ

Conventional lifts require a 600‑1000mm pit to accommodate cylinders and base structures. Our pit‑less design mounts the main frame directly on the 100mm concrete slab. A thick steel plate distributes the load, and foundation bolts secure the unit. The cylinders and chain multiplier are arranged within the frame – no downward extension. This eliminates excavation, saves approx. USD 12,000‑15,000 in civil work, and shortens installation by 2‑3 weeks.

We use a high‑rigidity frame + T90 car rails + TK5A counterweight rails. Each stop has an independent level sensor. The PLC memorises each position and applies dynamic error compensation. Levelling repeatability ≤ ±5mm, suitable for pallet jack access. The 4 stops (basement, 1F, 2F, 3F) cover the entire process from raw material receiving to finished goods dispatch – no manual intermediate handling.

We use 16B roller chain (safety factor ≥8) and a high‑power VFD motor with forced cooling. The chain is designed for infinite fatigue life. Acceleration/deceleration is smoothed by the VFD to reduce shock. In actual operation (approx. 1,200 cycles/day), no chain replacement or motor overheat alarm occurred over 3 consecutive months. Triple mechanical fall protection (speed limiter + safety gear + lifting mechanism) ensures the car will not drop even if the chain breaks.

Each conveyor section has a load sensor and is networked to the lift PLC. The PLC monitors the load status of every section. A section runs only when upstream is loaded and downstream is free. The in‑car conveyor automatically runs forward or reverse based on the floor direction. The HMI displays a dynamic simulation showing real‑time status of all conveyors and the car, allowing operators to anticipate congestion. In practice, throughput reaches 96 pallets/hour consistently without jamming or excessive idling

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