Reducing workplace injury with modular workstation cranes
Manual handling remains one of the most common causes of workplace injury across manufacturing, engineering, and logistics environments in New Zealand. Repetitive lifting, awkward load positioning, and the movement of heavy materials place significant strain on workers and increase the risk of musculoskeletal injuries.
Matthew Prestidge, managing director of Stratalign Limited, says many workplaces are still relying on processes that expose workers to unnecessary risk.
“Manual handling is one of those problems everyone knows exists, but it often becomes normalised on the shop floor. People lift, carry and reposition materials day after day, and over time that strain adds up,” Prestidge says.
“As manufacturers continue to focus on productivity and safety, there’s growing recognition that the solution is not simply telling workers to lift better – it’s removing the need for manual lifting wherever possible.”
One solution increasingly being adopted across manufacturing and engineering facilities is the use of modular workstation crane systems. Often referred to as hollow-profile cranes, these systems are designed to lift and move loads along both X and Y axes within a defined working zone.
Prestidge says the systems allow operators to move materials quickly and precisely while minimising physical strain.
“Instead of relying on two or three people to lift or reposition heavy components, a single operator can safely manage loads using a hoist and trolley system. That changes both the safety profile and the efficiency of the operation.”
Capable of handling loads of up to 2,000 kilograms, workstation cranes enable heavy items to be positioned accurately without the repetitive strain associated with manual handling.
A typical workstation crane consists of several key components. Hollow-profile runways or tracks allow the crane bridge to move north–south along the workspace. The bridge beam spans the runways and carries a hoist trolley, from which an electric or manual chain hoist performs the lifting operation.
Prestidge says the hollow-profile steel design provides several practical advantages over traditional systems.
“The bridge and trolley run inside the profile, with trolleys gliding on sealed-bearing nylon wheels for smooth and quiet movement. Because the wheels run on internal surfaces, they are protected from dust and debris that often accumulate on traditional I-beam crane flanges.”
He adds that the profile design also provides automatic alignment, preventing racking and ensuring reliable operation over time.
Systems can be ceiling mounted or supported by freestanding columns, depending on the building structure and operational requirements.
Prestidge says modular systems developed by Erikkila offer further advantages for modern engineering facilities.
“Erikkila has spent more than a century developing lifting equipment for evolving industrial environments. Their lightweight modular design supports safe and efficient material handling while allowing manufacturers to maintain flexible production layouts.”
According to Prestidge, the goal is simple: “Reduce the physical strain on workers while improving the speed and accuracy of material handling across the facility.”
Sponsored content: For more information call 09 263 7725, email sales@stratalign.co.nz or visit www.stratalign.co.nz.