“Switching to TWERGO casters cut push force nearly in half —enabling more employees to move tread carts safely for a smoother production workflow.”
A tire manufacturer known for its premium racing tires relies on large tread racks/carts to move layers of rubber tread through the facility into production. As modern tires get bigger, the amount of rubber tread per cart and the total weight of the carts also increase, making them significantly harder to start and steer.
In addition to heavier carts, raw tire buildup on casters was making the carts harder to push and adversely affecting caster life. With the current caster setup, operators were fighting 78–88 lbs. of force to get a cart moving. That’s not simply inconvenient — it’s a barrier to productivity and a direct contributor to overexertion injuries.
At Caster Concepts, we exist for challenges exactly like this. When a cart becomes too heavy for the workforce, when movement stalls, when standard solutions break under pressure — that’s our call to engineer what others won’t.
Imagine lifting and continuously holding a ~80 lb. object — except you’re doing it horizontally, often while leaning, bracing, and steering. And turning a heavy cart can spike effort even higher due to wheel scrub and friction.
Hoosier turned to Caster Concepts to help them go beyond the standard limitations of their current system. Together, the objectives were clear:
Caster Concepts recommended TWERGO® casters, engineered to dominate friction and transform maneuverability. Built with a multiple-wheel-in-one design, TWERGO delivers movement that standard casters simply can’t match.
To quantify improvement, the tire manufacturer worked with Tyler George, a solutions representative at Caster Concepts and their engineering team. A baseline was established using the existing casters and the test was then repeated with TWERGO casters installed.
| Baseline | Twergo | *Average Reduction | Twergo Caster Used | |
| Cassette cart | 81.68lbs. | 49.28 lbs. | 32.40lbs (39.7%) | 10×3 swivel |
| BID Drum Cart | 70.34lbs. | 42.22 lbs. | 28.12 lbs. (40%) | 8×2 swivel/rigid |
| Cap Strip Cart | 53.04lbs | 33.84 lbs. | 19.20 lbs. (36.2%) | 8×2 swivel/rigid |
| Radial Drum Cart | 83.40lbs. | 50.48 lbs. | Improvement – 32.92 lbs. (39.5%) | 8×2 swivel/rigid |
| Tire Rack- 90° | 75.80lbs. | 43.60 lbs. | 32.20 lbs. (42.5%) | ErgoXcel Maintenance Free Casters |
| Tire Rack- 180° | 64.80lbs. | 43.60 lbs. | 21.20 lbs. (32.7%) | ErgoXcel Maintenance Free Caster |
When push force drops, the upward trend of injuries stops. In Hoosier Tire’s case, the impact was immediate and measurable:
Better ergonomics are just part of the story. With the old casters, the company was averaging 3 months per caster. With the new TWERGO®casters, it’s been 3 years since a replacement, and they are still going strong.
Based on a life expectancy of 5 years and comparing the old casters to the new TWERGO casters, the total cost savings are projected to be $222,500 with an ROI of 876.38%
How much can the correct caster save you? Plug in your own numbers and find out: TCO Calculator – Caster Concepts
An Easy Push to Higher Efficiency.At Caster Concepts, we don’t just manufacture casters. We engineer solutions that move what others can’t. When push force climbs, when standard casters fail, when mobility stands in the way of productivity — that’s where we step in.
If rising load weights or difficult maneuverability are slowing your facility, our team can evaluate your application and build a system that reduces friction, improves ergonomics, and moves your operation forward.
Interested in a push-force test or trial? Let’s talk.
