James Cropper Plc a leading manufacturer of a wide range of specialist paper products, invited Keymas Controls and Automation to tender for the creation of a new raised production area and pallet handling method. After surveying the site and observing the restrictions on available space, Keymas presented a proposal that would create additional floor space by utilising the existing building height to the full and positioning a new mezzanine floor over the top of an existing mezzanine.

Previously a fork lift truck could service the needs of the first floor mezzanine, but the additional height demanded a much safer alternative method for handling pallet loads, and a two stage pallet elevator was installed to link all floors to ground level. Required to smoothly transport heavy loaded pallets of different sizes, the elevator is fully guarded and fitted with safety features to protect operatives. The drive unit is fitted with an overload device which holds the pallet elevator in position should a fault trigger the safety device, and sets of limit switches at the various levels ensure stability of load as the motor is automatically slowed to a pre-set stop position.

The time for manufacturing and delivery was very tight, as Croppers had a restricted installation period scheduled for over the Christmas shut down. The system had to be completed within this