How to choose the correct lifting solution

A lifting solution is not just a "device that lifts", but part of the work process. A correctly chosen lifting solution can speed up work phases, reduce unnecessary movements and smooth out the production rhythm – the wrong choice, on the other hand, quickly emerges as slowing down the work process with slow gripping and positioning phases, and increased interruptions. When the load, grip and work area meet the strengths of the correct lifting solution type, work proceeds with less adjustment and at the same time the burden on personnel decreases.

Ergonomics and safety go hand in hand with productivity here. When many lifts are made, even small compromises multiply: uncertain grip, awkward control or inadequate positioning increase manual handling and risky work postures. A suitable lifter helps keep the load under control, reduces physical strain and makes lifting predictable even in varying situations.

In this guide, we clearly compare different lifting solutions – vacuum tube lifters, pneumatic lifters, electric chain hoists, electric wire rope hoists, manipulators and lifting trolleys – and explain what they are best suited for.

Selection of lift solution: ergonomics, safety and costs

The choice of lifter type directly affects how the work actually flows in everyday life. When the lifter suits the load and work phase, lifting takes place in a controlled manner and in the same way time after time. This reduces "minor adjustment", which slows down work and increases risks, especially when in a hurry.

Work safety and load reduction are particularly evident in repetitive work: the right lifter reduces manual handling, reaching and twisting movements. When the load is under control and operation is natural, working postures improve and errors (e.g. swaying loads or slips) decrease.

Work speed and repeatability are often the "hidden benefit" that makes the investment worthwhile. The fastest solution is not necessarily the largest or most powerful lifter, but the one that makes gripping, lifting and positioning as straightforward as possible. When the same movement succeeds in the same way every time, quality also improves and training becomes easier.

Investment vs. lifecycle cost should be viewed as a whole. The purchase price is only part of the cost: maintenance, operating energy (electricity or compressed air), wearing parts and downtime affect what the lifter costs per year. For example, a solution that saves minutes in each work cycle often pays for itself faster than a cheaper alternative that slows down work or requires more maintenance.

Premises and installation can limit options surprisingly much. Ceiling height and the amount of floor space available affect what is even sensible to implement. If work stations change, fixed installation is not always the best; however, if the work area is extensive and movements repeat on the same routes, a rail solution can be very efficient.

What is worth surveying before comparison

Before comparing various lift solutions, gather basic data. It makes the selection quick and reduces the risk that the solution works "on paper" but fails in practice.

• Load weight (min–max) and variation: is it always, for example, 20 kg or does it vary between 5–60 kg? Variation significantly affects the choice of lifter as well as the gripper and thus the material handling.
• Gripping surface: is the surface tight or porous, even or uneven, hot, oily or dusty? This often determines whether vacuum is suitable or mechanical gripping is needed.
• Number of lifts: are there a few lifts per day or dozens per hour? In repetitive work, ergonomics and ease of use are emphasized, while in occasional lifts, flexibility and ease of deployment matter.
• Is rotation/tilting/positioning required with millimeter precision: if the object must be placed precisely on a jig or machine, simple "up–down" is not enough.
• Work area: reach, lifting and transfer distance as well as ceiling height. Also traffic routes, doorways, thresholds and floor condition matter if a mobile solution is being considered.

When these matters are clear, it is easy to match lift solution to the need: what solves the gripping, what makes positioning smooth and what fits the space without making the workstation cramped or impractical.

Lift solutions in a nutshell (who they suit)

• Vacuum tube lifter
• Best for fast repetitive work: packing, picking, palletizing, loading
• When loads have a surface suitable for vacuum (e.g. boxes, sheets, sacks with suitable sides)
• When the load to be lifted is porous. A vacuum tube lifter achieves greater suction force.
• Pneumatic lifter
• For workstations that require speed and agility
• When the object needs to be positioned, e.g. glass
• Energy-efficient and quiet lifter
• Electric chain hoist
• General solution for versatile lifting: production, warehouse, maintenance
• When precision and speed are required
• Electric wire rope hoist
• When precision and speed are required
• For hall and process environments where lifts are regular and loads are larger
• When you want to control directly from the object
• Manipulator
• When lifting requires eccentric force
• For assembly and manufacturing where position and precision are decisive (jigs, machines, lines)
• Best when maximum control and ergonomics are desired for difficult objects
• Lifting trolley
• When lifting needs are mobile: multiple workstations, maintenance, small batches, changing tasks
• When fixed installation is not desired or cannot be done
• Good "general tool" for short transfers and lifting where the need arises