Case Study: Industrial manipulator for casting

In the world of industry—especially in sectors like casting—manually handling heavy and often hot components is part of everyday operations. While it may seem like a routine task, it brings serious consequences, from the risk of injury to decreased efficiency. That’s why companies are searching for innovative solutions that not only protect workers, but also streamline production. The case study below shows how pneumatic industrial manipulators are transforming the way heavy-duty industries approach material handling.

What challenges did operators face before process automation?

Before implementing an innovative solution, the daily work in the casting facility involved manually lifting freshly cast, hot components from a pallet or table and moving them to the next stage of production. This manual task came with a number of serious challenges.

The previous process looked as follows:

Operators manually gripped the components—often wearing gloves—and had direct contact with high-temperature cast parts. They then had to tilt and rotate each piece themselves to prepare it for the next production stage.

This approach presented several major challenges:

The facility’s management realized that this approach was not only hazardous and physically taxing for staff but also inefficient and costly in the long run. A solution was needed to ease the physical burden, enhance safety, and boost operational performance.

How THEMA’s industrial manipulator revolutionized work in the foundry

To streamline processes and reduce risks for operators, the foundry decided to implement a pneumatic industrial manipulator. With over 30 years of industry experience, THEMA focuses on delivering ergonomic solutions that protect human health and enhance workplace safety.

The key to success was THEMA’s “Zero Gravity” technology.

Pneumatic manipulators use compressed air to balance the load’s weight, allowing the operator to move it smoothly and almost effortlessly. In practice, even heavy castings can be handled with ease and full control.

In response to the plant’s needs, a pneumatic manipulator was designed with the following key features:

The operation sequence with the new manipulator became simple and safe:

1. Internal gripping: the manipulator precisely grips the component from the inside.

2. Lifting and tilting: the pneumatic tilting system adjusts the orientation of the part.

3. Rotating: the pneumatic motor rotates the element, allowing for inspection or precise placement.

4. Safe placement: the product is gently and precisely released in the target position.

Operator safety is a top priority. The manipulators comply with European safety standards such as the Machinery Directive 2006/42/EC. They are equipped with a built-in air tank that allows the cycle to be completed safely in the event of a power failure, preventing uncontrolled dropping of the load. Additional systems such as the THEMA Safety Valve and anti-drift brakes monitor movements and prevent unintended displacement.

What changed after implementing the manipulator?

The implementation of the THEMA manipulator brought a number of transformative benefits to the foundry, significantly improving working conditions and operational efficiency.

• Increased safety: the most important change was the complete elimination of direct contact between operators and hot surfaces. This reduced the risk of burns and serious injuries, resulting in a safer working environment and fewer accidents.
• Improved ergonomics and reduced operator fatigue: the manipulator took over the physical effort of lifting and handling, minimizing operator fatigue and physical strain. Tasks became accessible to any worker, regardless of their physical strength, which also improved motivation.
• Higher efficiency and productivity: tasks that previously took minutes are now completed in seconds thanks to smooth, controlled movements and a fast cycle time. This accelerated production processes, reduced delays, and significantly increased overall efficiency. A single operator is now able to perform the work of two or more people, leading to lower labor costs.
• Increased precision and quality: the manipulator's repeatable and precise movements minimized the risk of product damage due to mishandling. Modular gripping heads ensured consistency in handling all casting variants.
• Long-term savings: investing in a manipulator is not just a one-time expense, but a long-term saving due to reduced injury-related costs, fewer absences, and the low maintenance costs of pneumatic manipulators.

Manipulators that reshape the industry

The foundry case study demonstrates that THEMA pneumatic industrial manipulators are far more than just tools. They are a strategic investment that fundamentally transforms workflows in heavy industry. By eliminating manual strain, increasing safety, and optimizing processes, THEMA manipulators enable companies to effortlessly elevate their production, while also safeguarding the well-being and health of their employees. In the face of rising market demands, employee care and operational efficiency are becoming key competitive advantages—and solutions like those offered by THEMA are becoming the new standard in modern industry.

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