38 kilos made easy:
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01.09.26 | Reading time: 4 Minutes
In flat roof insulation, rock wool is a popular insulating material. In daily processing, however, the material presents an enormous challenge for manufacturing: the panels are bulky, unwieldy and have a considerable dead weight.
Vogelsang GmbH & Co. KG from Sendenhorst-Albersloh specialises in the fabrication of insulation materials and individually planned gradient insulation systems. In order to make the loading of the CNC cutting machine with heavy rock wool panels ergonomically efficient, the company has been using a bespoke lifting solution from our company since August 2025.
| Challenges | Achievements |
| Move rock wool panels weighing up to 38 kg (1.20 x 1.00 m, 200 mm thick) without damaging the material | Custom-designed clamping gripper for porous materials |
| Porous material prevents normal vacuum suction | Rapid project implementation in under six months |
| Cumbersome, physically demanding manual loading | Noticeable relief for the back and a short learning curve |
| A high daily output of 60 to 100 sheets in the cutting process | Flexibility thanks to the ability to move units around using a forklift truck |
Who is Vogelsang GmbH & Co. KG Dachdämmtechnik?
Vogelsang GmbH & Co. KG has been an expert in the field of roof insulation for 25 years and specialises in the precise fabrication of insulation materials. The company focuses on bespoke sloped insulation for flat roofs, which is designed and cut to size on a project-by-project basis.
At a glance: Vogelsang GmbH & Co. KG
- Location: Sendenhorst-Albersloh (North Rhine-Westphalia)
- Focus: Slope insulation and insulation material fabrication
- Materials used: EPS (Styrofoam), rigid PIR foam and heavy-duty rock wool
- Manufacturing: Precision cutting using CNC cutting machines
Why do rock wool panels pose particular challenges for manufacturing?
Whilst insulation materials such as EPS or PIR are lightweight, rock wool is considerably heavier. Since the introduction of a new CNC cutting machine in 2025, the physical strain on the Vogelsang team has increased significantly.
The most commonly used panels measure 1.20 × 1.00 metres, are 200 mm thick and weigh around 38 kg each. With a throughput of 60 to 100 panels a day, simply handling them by hand soon reached its limits.
“Every roof is different. That’s why we first draw up the appropriate plans and then cut the insulation boards to size for each specific job.” — Matthias Vogelsang, owner of Vogelsang GmbH & Co. KG
Why couldn’t the rock wool simply be sucked in using a vacuum?
At the LogiMAT trade fair in Stuttgart, owner Matthias Vogelsang was specifically looking for a suitable lifting solution. During discussions with our technical advisers, it quickly became clear that, due to the porous surface structure of rock wool, conventional vacuum lifting is not possible.
So we came up with a bespoke solution:
- Instead of a vacuum suction pad, we designed a special mechanical gripper.
- The material is not sucked in, but is clamped securely and firmly.
- To ensure a perfect fit, Vogelsang supplied a sample to our factory in advance, so that the gripper could be tested and optimised directly on the original material.
“With applications like these, it’s all about understanding the customer’s process in detail and using that understanding to develep. The particular challenge lay in gripping the heavy yet delicate material securely without complicating the workflow.” — Dirk Lütke-Bohmert, Sales Engineer at Timmer
How does our heavyLIFT hose lifter support our day-to-day workflow?
Our heavyLIFT air-operated cylinder has been in daily use at Vogelsang since August 2025.
- Loading the CNC machine: The pneumatic lifter picks up the 38 kg slabs directly from the pallet and positions them effortlessly on the cutting table.
- Removing cut-to-size sheets: With traditional pitched-roof panels, the heavyLIFT also lifts the fully cut panel in one piece and places it onto a destination pallet.
- Intuitive operation: The system can be operated safely by different staff members within a few minutes, without the need for extensive training.
What are the benefits of the mobile crane unit in manufacturing?
As well as simply providing lifting support, a high degree of flexibility was important to Vogelsang. As the manufacturing process had been redesigned to incorporate the new cutting machine, a mobile column-mounted slewing crane unit provided the ideal degree of manoeuvrability.If required, the entire lifting equipment can be easily lifted by a forklift truck or pallet truck and moved to another location within the hall. This means that the hall layouts can be adapted at any time.
"For a special solution including a new design of the suction cups, the timeframe of under half a year was absolutely impressive." — Matthias Vogelsang, Owner of Vogelsang GmbH & Co. KG
FAQ vacuum hose lifter
Frequently Asked Questions
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Why can’t rock wool panels be lifted using a standard vacuum suction pad?
Rock wool has an open-pored surface. Air is drawn through the material, rather than a stable vacuum forming.
We design mechanical clamping grippers for materials of this kind. They grip the panel from the side and hold it securely in place – without damaging the insulation material.
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How is a specialised gripper designed for a specific material?
We start with a sample from the customer’s production run. The gripper is designed, tested and adjusted based on this original material – clamping force, contact surface and gripping points.
This means the solution works perfectly from the very first time it is used on site, without the need for a cycle of adjustments during operation.
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How heavy can the loads be?
At Vogelsang, sheets measuring 1.20 × 1.00 m, 200 mm thick and weighing around 38 kg are handled. Depending on the model, our vacuum hose lifters can lift loads of up to 300 kg.
As well as the weight, the surface and the geometry of the load are crucial.
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Can the lifting solution be used later on at another location in the hall?
Yes. At Vogelsang, the heavyLIFT is mounted on a mobile column-mounted slewing crane, which can be picked up and moved using a forklift or pallet truck.
No foundations, no ceiling fixings – the location can be changed at any time.
CONCLUSION:
Handling that protects materials and promotes long-term health
The Vogelsang case study demonstrates that even difficult materials such as porous rock wool can be moved effortlessly with the right lifting technology. Our heavyLIFT hose lifter provides long-term protection for staff health, increases cost-effectiveness in CNC cutting and prepares the production facility for further growth.
“The hose lifter enables gentle and cost-effective handling of the material whilst safeguarding the health of our staff.” — Matthias Vogelsang, owner of Vogelsang GmbH & Co. KG
Do you process unwieldy or porous materials and are you looking for a bespoke solution?
For an overview of our hose lifters: Click here.
