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Check Out How One Major Tire Manufacturer used the Twergo® Heavy Duty Caster

Check Out How One Major Tire Manufacturer used the Twergo® Heavy Duty Caster

Though you might think Twergo® heavy duty casters are reserved solely for major industrial manufacturing facilities, the truth is that they are versatile enough for many applications. In fact, in a recent case study, we were able to fabricate and alter Twergo® heavy duty casters that suited the specific needs of one of the world’s largest tire manufacturers.

The Problem

One of the biggest tire manufacturers in the industry came to us with a unique request. Often, these companies use huge racks that have layers of trays of rubber tread that they use to craft their tires. In the industry, these are called tread trucks, and they are the number one vehicle for moving rubber around the facility. Because this particular manufacturer is so prominent, and because they must produce so many tires, their carts were especially large and required some unique casters. What’s more, due to the unpredictable trajectory of the carts, they were all moved by hand.

The Challenges at Hand

Our team was challenged with removing the amount of force required to start and move the tread trucks throughout the facility. To start, the employees were using 100lbs of force to start the carts, and that’s far more than a single worker should ever exert. This put workers at risk for injuries, especially when they had to move these carts regularly. What’s more, the wheels continued to pick up debris from the floor, which further created friction and made it very difficult for operators.

Caster Concepts’ Solution

First and foremost, Twergo® wheels were attached to 57 Series caster rigs. They used multiple wheels in a single design to provide more load-bearing capabilities, and because they are ergonomic wheels, they reduce friction and make initial push force much lower. Then, with a coating of ErgoTread polyurethane, a specially designed plastic, this returned energy to the wheels and essentially forced debris out of the way. On top of this, we set the rigs up with brushes that would clean the wheels as they rolled, all without adding to the friction.

The End Result

Once the specially-designed wheels were implemented and tested in a quality-control environment, the force required to push and keep the tread trucks moving was reduced from 40% to 60%, greatly reducing the odds of injury. The initial push force started out at a whopping 100lbs, and in most cases, this was reduced to a mere 40lbs, which is much safer for a single operator, even when that operator moves carts multiple times each day. The wheels themselves created less friction and enjoyed greater longevity thanks to the polyurethane coating and built-in brushes designed to keep them clean.

As you can see, our skillful team can create custom solutions for any industry, despite the problems it faces. This major tire manufacturer enjoys reduced injury risk and longer-lasting caster wheels thanks to the innovation and ingenuity of both the Caster Concepts team and the manufacturer’s own engineering team. Any obstacle can be overcome with ease, and it is always possible to improve safety and reduce injury at the same time,


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