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Transfer Cart Solutions for Heavy Industry Facilities

Heavy industry facilities – particularly steel plants and foundries – are tasked with the safe transport of materials weighing several tons and often subjected to extreme temperatures. The transfer of molten metal ladles, massive steel coils, or bulky casting molds is a critical process, both in terms of workplace safety and production efficiency. Traditionally, these operations have relied on forklifts or overhead cranes, which present capacity limitations and significant safety risks.

This is where industrial transfer carts step in as an innovative solution for heavy load transportation. Equipped with high load capacities and advanced safety systems, these specialized vehicles ensure the safe, fast, and efficient movement of heavy and bulky loads within the facility. Quickly becoming a preferred alternative to traditional equipment like forklifts and bridge cranes, Seyiton transfer carts enhance safety standards and reduce operational costs in industrial logistics.

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Seyiton Industrial Transfer Cart Types

For heavy industry applications, Seyiton offers a wide range of industrial transfer carts. Depending on the load route, power source preference, and operational requirements, facilities can choose from cable reel-powered, rail-guided, rail-less, or battery-powered models.


Cable Reel Transfer Carts

These vehicles are powered via a retractable cable reel mounted on the cart itself. Compared to battery-operated or wireless inductive systems, cable reel models are more cost-effective while offering similar performance. Typically operating along a fixed route or track, these carts are ideal for facilities where a predefined transfer path is sufficient. Although limited by cable length, they are a robust solution for linear and repetitive transport tasks.


Rail-Guided Transfer Carts

Designed to operate on steel rails embedded into the factory floor, these carts move along linear paths and offer an excellent solution for regular, heavy-duty transport between stations. Capable of reaching speeds up to 40 meters per minute, rail-guided models are widely used in heavy industry environments. For example, in steel production facilities, these carts are frequently employed to transfer molten metal ladles from furnaces to casting areas, or to carry steel coils between rolling mills and storage zones. The rail system ensures safe and stable transportation, minimizing the risk of load sway or tipping during transfer.


Rail-Less (Rubber-Tired) Transfer Carts

Rail-less transfer carts are capable of freely navigating flat factory floors—such as concrete or asphalt—without the need for fixed tracks. With rubber-coated wheels and multi-directional steering capabilities, they provide flexible movement across complex plant layouts. These models are especially suitable for facilities with multiple production halls or dynamic spatial arrangements. Rail-less carts can access areas unreachable by overhead cranes or fixed conveyors, granting full mobility and operational flexibility inside the plant. They are typically powered by on-board batteries but can also be adapted to use cable reel systems if required.


Battery-Powered Transfer Carts

These carts draw power from high-capacity rechargeable batteries, eliminating the need for external cables. As a result, they offer uninterrupted mobility across large areas and variable routes. Battery-powered carts are ideal for indoor use, producing no exhaust emissions and operating with minimal noise, making them safe and environmentally friendly. Seyiton battery-powered transfer carts are designed for long operational durations on a full charge and support fast-charging or battery-swap systems to maintain production continuity. Both rail-guided and rail-less battery-operated models are available and can be optionally equipped with autonomous navigation technologies (AGV/AMR) to suit the facility’s automation level. For example, a Seyiton cart with a 70-ton load capacity can reach up to 40 meters per minute, safely and efficiently transporting heavy goods across the factory. One of the key advantages of battery-powered systems is their ability to operate independently of external power infrastructure, offering complete flexibility and the ability to reach any point within the facility.

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Applications in Heavy Industry: From Molten Ladles to Steel Coils

Seyiton industrial transfer carts can be customized to meet a wide range of critical transport needs in heavy industry. Some of the most prominent applications in steel and foundry facilities include:

Molten Metal Ladle Transport:
In foundries, ladles used to carry molten metal are not only extremely heavy but can also reach extreme temperatures of up to 1400°C. Transfer carts are used to safely move these hot ladles from the furnaces to the casting lines. For example, Seyiton manufactured a 35-ton capacity ladle transfer cart for a foundry in Sweden. This cart is built with heat-resistant materials capable of withstanding temperatures up to 1400°C and is equipped with a specialized tilting mechanism for controlled pouring of molten metal. Thanks to its integrated cradle and tilting system, it ensures safe transfer and precise pouring of liquid metal. This eliminates the swinging risks associated with crane-based transport, significantly improving workplace safety.

Steel Coil (Rolled Sheet) Transport:
Steel coils produced in rolling mills and sheet metal processing plants are large rolls that can weigh tens of tons. During storage or feeding into the production process, transfer carts offer an ideal solution. Rail-guided or battery-powered coil transfer carts, equipped with V-shaped cradle modules, securely hold and transport the coils—eliminating the risk of tipping or falling that may occur with forklifts. A great example is Seyiton’s 70-ton capacity battery-powered steel coil transfer cart, used by Termo Teknik. This cart enables the safe and efficient movement of heavy steel coils from truck unloading areas to the production line. Featuring Vulkollan-coated wheels, the system operates smoothly without damaging the floor and offers the operator safe control via wireless remote.

Casting Mold and Heavy Component Transport:
Casting molds and large cast parts used in foundries are bulky and sensitive loads. Transfer carts are preferred for placing these molds into furnaces or moving them to cleaning or machining stations after casting. Rail-guided transfer carts are particularly suited for this task, enabling large molds to be delivered with millimeter-level precision to designated points within the plant, thus speeding up the production flow. Similarly, in steel factories, large billets, slabs, or blocks that emerge from casting operations can be transported to cooling areas using high-tonnage transfer carts. These vehicles can be fitted with custom cradles or hydraulic lift platforms tailored to the shape and weight of the load, ensuring safe and efficient transport of all types of heavy components.

Key Advantages of Transfer Carts in Heavy Industry

Heavy industry facilities gain numerous advantages by incorporating Seyiton industrial transfer carts into their operations. The main benefits are outlined below:

Transport Safety:
Transfer carts are equipped with special mechanisms and sensors that ensure loads are securely stabilized during movement. For instance, V-cradle modules or locking systems prevent the cargo from slipping or tipping throughout the route. Additionally, features such as laser scanners, flashing warning lights, and emergency stop buttons provide a safe environment for both the operator and surrounding personnel. Compared to forklifts or overhead cranes, the risk of accidents due to falling, collisions, or swaying is significantly reduced with transfer carts. This not only enhances workplace safety but also minimizes disruptions in production processes.

High Load Capacity:
Designed specifically for heavy-duty operations, transfer carts offer far greater load capacities than traditional handling equipment. They can carry dozens or even hundreds of tons in a single trip, making it possible to transfer large parts directly along production lines. For example, a molten metal ladle or steel coil far beyond the capacity of a standard forklift can be easily transported by a properly configured Seyiton transfer cart. High capacity also means fewer transport cycles are needed, thus increasing operational speed and throughput.

Labor Efficiency:
Transfer carts enable more work to be done with fewer operators. A task that would require multiple forklifts and several workers can be completed with a single operator—or none at all in the case of autonomous models. This translates into significant savings in labor and operational costs. It also allows skilled personnel to focus on more value-added tasks, increasing overall productivity. Operator training is fast and straightforward thanks to intuitive control interfaces, allowing staff to safely operate the system in a short amount of time.

Production Continuity:
Uninterrupted production is critical in heavy industry. Transfer carts ensure steady material flow, preventing delays and keeping production lines consistently supplied. For example, ensuring a ladle reaches the casting mold on time in a foundry, or that hot steel is quickly moved to the next stage in a rolling mill, is vital for product quality and energy efficiency. The ability to integrate carts with automation systems—and even deploy 24/7 autonomous solutions—eliminates disruptions caused by human error. In addition, safer transport reduces accident-related downtime, ensuring continuous operation and greater output within shorter timeframes.

Flexibility and Integration:
Seyiton transfer carts feature modular designs that can be tailored to the specific needs of each facility. Add-ons such as V-shaped cradles, scissor lift platforms, or ladle tilting mechanisms allow for safe and efficient handling of various load shapes and sizes. Available in both rail-guided and rubber-tired versions, these carts can easily adapt to the physical layout of any plant. For instance, one facility may require rail-based delivery to fixed points while also needing free-roaming transport across different zones—Seyiton’s versatile carts support both scenarios. This flexibility makes transfer carts a superior alternative to fixed systems like conveyors, which are harder to reconfigure when production layouts change. Moreover, modern Seyiton carts can be integrated with IoT-based monitoring, remote control, and even autonomous navigation systems, enabling seamless compatibility with Industry 4.0 environments.

Advantages of Transfer Carts Compared to Forklifts, Cranes, and Conveyor Systems

Among the alternative systems used for heavy load transportation are forklifts, overhead cranes, and conveyor lines. However, Seyiton industrial transfer carts offer several advantages over these traditional methods:

Compared to Forklifts:
Forklifts are often insufficient for transporting loads above a certain tonnage and pose a stability risk when handling large-volume items. In contrast, transfer carts can handle significantly higher capacities and fully support the load from underneath, eliminating the risk of tipping. Forklift operations also typically require more personnel, whereas a single transfer cart can perform the same task—often with just one operator, or none if the system is autonomous. Additionally, forklifts are not suitable for extreme environments, such as areas near molten metal, whereas specially designed ladle transfer carts can be manufactured with materials resistant to high temperatures. Transfer carts also overcome the maneuvering limitations of forklifts in narrow spaces, thanks to multi-directional wheel systems that allow smooth navigation even in tight corridors.

For more information, see our comparison article: “Transfer Cart or Forklift?

Compared to Cranes:
Bridge or gantry cranes are used for overhead transport but typically operate along fixed routes and can move a load from one point to another only in a single path. In contrast, multiple transfer carts can operate simultaneously across various ground-level routes, increasing capacity and reducing bottlenecks. Suspended loads carried by cranes are prone to swaying or collisions, whereas transfer carts carry loads securely at floor level, minimizing such risks. Moreover, crane systems involve high installation and maintenance costs, while transfer carts offer a flexible and mobile solution that can be deployed wherever needed. For example, a rail-guided transfer cart can transport heavy loads in areas where cranes cannot reach, effectively eliminating the need for additional crane infrastructure. Finally, transfer carts enable simpler material flow without requiring extensive coordination between crane operators.

Compared to Conveyor Systems:
Conveyor belts and roller transfer systems are useful for continuous flow operations, but their routes are fixed and lack flexibility. When a production layout changes or material needs to be transported to a different area, conveyor systems may become inadequate. Transfer carts, on the other hand, can take over the function of multiple conveyor lines if needed and deliver materials to various locations with the same vehicle. Additionally, while conveyor systems ensure uninterrupted flow, a single failure can shut down the entire line. Transfer carts operate independently, meaning a malfunction in one unit does not halt the entire system. From a maintenance perspective, transfer carts offer easier intervention due to their modular structure, whereas conveyor systems are generally more difficult and time-consuming to repair. In summary, while conveyors are rigid and limited in scope, transfer carts provide greater layout flexibility and adaptability to evolving production needs.

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