Vacuum hose lifters for aluminium sheets:
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24 April 2026 | Reading time: 5 minutes
At LO-CAT SYSTEMS GmbH, aluminium sheets for aircraft outer skins – measuring up to two by three metres and weighing up to 60 kilograms – are processed in a circular rolling mill. The safe loading and unloading of these sheets has long been a physically demanding bottleneck in the manufacturing process.
The delicate surfaces of the components must not be damaged or deformed in the process. At the same time, each sheet must be positioned precisely to ensure consistently high quality in subsequent processing.
By using our heavyLIFT vacuum hose lifter, LO-CAT has fundamentally transformed this process: today, a single employee can feed the aluminium sheets into the round roller in an ergonomic, controlled and precise manner.
This enables up to 100 sheets to be processed per day – faster, safer and significantly less physically demanding for the employees.
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The starting point: precision meets stress
Here’s how we worked with LO-CAT SYSTEMS to optimise the handling of aluminium sheets for aircraft skins:
An overview of the requirements
| Parameters | Characteristic |
| Material | Aluminium |
| Sheet thickness | 6 - 8 mm |
| Component size | up to 2 x 3 metres |
| Weight | up to 60 kg |
| Process | Loading and unloading of round rolling machine |
Large, delicate components combined with manual processes – a combination with scope for improvement.
Before: Manual handling of aluminium sheets as a bottleneck
Before the optimisation, the sheets were moved manually. This led to increased labour costs as well as risks to safety and quality.
- Two employees required
- High physical strain when lifting heavy aluminium sheets
- Safety risks due to sharp-edged components
- Risk of damage and deformation
“Before we started using the heavyLIFT, we always needed two employees to move the sheets together.” — Thomas Becherer, Production Manager, LO-CAT SYSTEMS GmbH
Even a temporary crane solution failed to deliver a lasting improvement, as it was inflexible and could only be operated to a limited extent.
Our solution: heavyLIFT vacuum hose lifter
With the heavyLIFT vacuum hose lifter, we have developed a solution that is precisely tailored to LO-CAT’s requirements.
Technical specifications at a glance
| Feature | Benefits |
| Adjustable suction crossbar | Adaptation to different sheet metal sizes |
| 4 gimbal bellows suction cups | Secure gripping even of curved components |
| Extended suction cups | Direct removal from the round rolling machine |
| Intuitive control | Sensitive, precise positioning |
| Quick-release valve | Controlled and fast unloading |
“During busy periods, around 100 sheets are fed into the rolling mill every day. Thanks to the heavyLIFT’s adjustable control handle and its mounting on a pillar-mounted jib crane with an adjustable angle limiter, this is achieved with exceptional precision.” — Manuel Gruber, Sales Engineer, Timmer GmbH
Result: More efficient processes and precise handling
Since the introduction of the heavyLIFT, the process has improved significantly. The system is operated by a single person, whilst precision and process reliability have increased. In addition to improving efficiency, the system ensures reproducible results in day-to-day operations. What was once a labour-intensive manual task has become a finely controlled process.
Focus on quality: Gentle handling of sensitive components
In aerospace manufacturing, damage-free handling is crucial. Even the smallest surface defects can lead to rejects.
“The aluminium coating is highly sensitive. It is important that the sheets are lifted gently and positioned precisely.” — Gerhard Walleser, Quality Assurance, LO-CAT SYSTEMS GmbH
The controllable movements of the vacuum hose lifter significantly reduce the risk of damage.
Frequently asked questions about vacuum hose lifters / lifting aids:
No. The suction feet are specifically designed for different requirements and surfaces. No marks are left even on highly sensitive, polished or painted surfaces, or on unpainted composite materials.
Our vacuum hose lifters are equipped with a mechanical check valve. In the event of a power failure, the load descends slowly and in a controlled manner rather than falling uncontrollably, protecting both the operator and the expensive component.
Ergonomics and ease of use in everyday work
Another key benefit is the ergonomic relief it provides for staff. There is no need for heavy lifting whatsoever, and movements can be controlled with precision. The intuitive operation also reduces training times, thereby increasing the team’s acceptance of the new solution.
“With just one finger, I can determine where and at what height I place the components.” — Gerhard Walleser, Quality Assurance, LO-CAT SYSTEMS GmbH
Service and collaboration
In addition to the technical solution, close coordination throughout the project was also crucial. We supported LO-CAT SYSTEMS from planning right through to commissioning and continue to provide operational support.
“From project planning to commissioning, we felt well looked after at all times.” — Thomas Becherer, Production Manager, LO-CAT SYSTEMS GmbH
Outlook
The expansion of production capacities at LO-CAT brings new requirements – and further applications for our vacuum lifting technology
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| Area | improvement |
| efficiency | Reduced labour costs, higher throughput |
| Quality | Gentle, precise handling |
| Ergonomics | Less physical strain |
| Safety | Minimised risk of injury |
“Our new production hall is currently under construction in Weil am Rhein. If we need further lifting systems for the new building, we know exactly who to turn to.”— Thomas Becherer, Production Manager, LO-CAT SYSTEMS GmbH
CONCLUSION:
Ready for Take-off:
Efficient material handling in the aviation industry
The successful implementation of our vacuum hose lifters in aircraft construction impressively demonstrates how demanding material handling, the highest standards of occupational safety and ergonomic relief can be combined.
This reference underscores Timmer’s expertise as a partner for bespoke lifting solutions in high-tech production. You too can rely on our experience for optimised workflows and healthy employees.
Click here for an overview of our hose lifters.
