TIPPERS & MOVING FLOORS

HYVA IS ON A MISSION TO BRING TIPPING INTO THE 21ST CENTURY

TIPPING SOLUTIONS SPECIALIST, HYVA, PROVIDES A COMPLETE PRODUCT PORTFOLIO BACKED BY A GLOBAL SERVICE AND SUPPORT NETWORK INCLUDING THE ALPHA SERIES FRONT-END TIPPING CYLINDER WHICH DELIVERS RELIABLE PERFORMANCE WITH HIGH QUALITY AND LOW WEIGHT COMPONENTS.

Hyva is one of the world’s leading providers of innovative and highly efficient transport solutions for the commercial vehicle and environmental service industries. With over 20,000 customers and more than 40 per cent global market share in front-end tipping cylinders, Hyva’s solutions move the world.

Today, after being in operation for more than 40 years, Hyva is present in 110-plus countries, has more than 30 fully owned subsidiaries, has reached extraordinary service coverage and leverages a manufacturing base that includes 12 production facilities across China, India, Brazil and Europe

Your worldwide solutions provider

The growth and success of Hyva is built on two key aspects of its operation – the quality and innovative nature of the company’s solutions, and the excellence of its customer support. The first of these, product quality, is illustrated by the fact that Hyva today offers the strongest front-end hydraulic telescopic cylinder in the world, as well as fixed mounted and rolling truck cranes, container lifting systems (hookloaders and skiploaders) and waste collection units. These solutions are used worldwide across a range of sectors including transport, construction, mining, materials handling and environmental services providers.

Service quality, too, is a fundamental part of the Hyva business philosophy: With operations in more than 110 countries, the company operates one of the world’s most extensive customer support networks in the industry. It is a network which has earned Hyva an

international reputation for excellence in customer care.

Realising the need for safer tipping solutions

Hyva is leading a global trend to improve safety on the road, at job sites, and even among the community – tipping related accidents will become something of the past.

The new Hyva Smart Guide aims at providing critical information to the driver to enable decision making and preventing accidents from happening. Looking towards the future, Hyva is working on a new line of Digital Tipping Solutions (DTS) systems that feature advanced control mechanisms aimed at (semi-) autonomous tipping. This technology fuels the new line of ‘SMART’ products which aim to improve tipper control for drivers everywhere.

Following trends in electrification Hyva sees opportunities to further reduce emission by optimising energy usage and optimising tipping. With Smart, Hyva is setting a step in the right direction to achieve truly sustainable zero-emission transport.

Available now, Hyva offers its Hyva Smart Guide System which provides safety signals relating to side load and overload conditions, payload indication and blackbox storage data. It also features fleet management software to help businesses improve tipper operator behaviour as well as boost safety and productivity.

This guidance system has been extensively validated around the globe from hot temperature mining in India to the arctic climate in Russia.

“We are committed to being the world’s best provider of tipping solutions

Hyva tippers are deployed worldwide.

to the commercial vehicle industry,” said Michiel Moorthamer, Line of Business Director Tipping Solutions at Hyva. “To live up to that promise, taking into account the latest trends, we are dedicated to providing solutions to the tipping truck and trailer industry that are a perfect fit for electric trucks, actively preventing tipping accidents to happen, improving efficiency to the daily operation as well as allowing body builders and trailer manufacturers to add more value to their products.”

Innovative leaps and bounds

The Alpha Series front-end tipping system, which made its initial market debut in 2014, is still the benchmark in the industry today. It can operate up to 250 bar and is lighter, faster, safer and more efficient. It is also the latest and fifth generation of front-end tipping solutions released by Hyva and is available worldwide. The Alpha generation has made a significant difference and is increasing the productivity of tipping trucks and trailers.

But the next big leap in tipping solution market, according to Hyva, will not be through better hardware, but through advanced control systems providing better control, more insight and greater safety for drivers.

“The next step for Hyva will be to have intelligent control systems to bring tipping into the 21st century” said Erik Knippels, Product Manager Digital at Hyva. “These will allow optimal utilisation of the tipping system with maximum efficiency in any operating condition.”

Hyva Smart in-situ.

FAST FACT

Hyva has a dedicated department for the development of advanced control systems and smart products.

TIP TOP

THE LATEST TIPPER CHASSIS FROM SCHMITZ CARGOBULL IS WEIGHT-OPTIMISED FOR MORE PAYLOAD AND HAS BEEN RE-DESIGNED WITH AN UNDERRIDE GUARD TO COMPLY WITH NEW LEGISLATION. IN ADDITION TO TRAILER INNOVATION, THE MANUFACTURER ALSO DETAILS ITS SUCCESS WITH THE PRODUCTION OF ITS OWN RUNNING GEAR.

The S.KI tipper trailer’s steel chassis frames have always been characterised by an ideal balance between weight optimisation, robust durability and tipping stability. The fundamental redesign of the modular frame has achieved weight savings enabling up to 180 kg more payload for the S.KI tipper trailer, depending on length and specific frame design. The revised design of the crossbeams provides even greater stability and ensures a longer service life of the chassis due to optimum corrosion protection. Schmitz Cargobull grants customers a 10-year warranty against rust-through for the galvanised S.KI frame generation.

The new LIGHT frame of the short S.KI variants was specifically developed for payload-optimised use on roads, construction sites, and light off-road routes. This innovation is one of the lightest steel chassis frames on the market.

The modular system offers the right frame for every application: four different frame lengths are available (system lengths 7.2, 8.2, 9.6, 10.5), depending on the application, load level and desired body volume. In addition to the STANDARD version, a LIGHT version for especially high payload or a HEAVY-DUTY version for particularly heavy-duty use are also available.

Since 1 September 2021, new vehicles must be equipped with an underride guard that complies with ECE-R58.03. The launch of this new underride guard ensures all of the new directive’s criteria are met. At the same time, the weight has been reduced and handling improved. The folding mechanism allows for easy operation from the side, while also protecting resources. The new underride guard also offers high ground clearance of 728 mm when folded up. This enables easy manoeuvring up to the road paver.

More than 1.6 million axles already produced

The success story continues: Schmitz Cargobull has been producing its own ROTOS running gear at the production plant in Altenberge

since 2004. More than 1,600,000 axles have already been produced. This shows how successful the Schmitz Cargobull development has been with customers.

The constant optimisation of the Schmitz Cargobull ROTOS axle has been intensified in recent years, as the running gear has a decisive influence on the life cycle costs of the trailers. Absolute directional stability, high suspension comfort, low heat load on the bearing, optimum braking performance combined with the safety features of innovative driving stability and braking programs, ensure that the commercial vehicle is ready for use. From the production site in Altenberge, the Schmitz Cargobull plants in Vreden (D), Gotha (D), Toddin (D), Panevėžys (LT), Adapazari (TR), Zaragoza (E) and, most recently, the plant in Manchester (UK) are also supplied with the axles on a daily basis. Currently, around 95 percent of all trailers delivered from the Altenberge production site are equipped with the Schmitz Cargobull axle developed inhouse. Across the group, this figure is over 90 percent.

Since the introduction of the ROTOS axle, the product range has been continuously expanded and now offers our customers the

This tipper features lighter weight steel chassis.

possibility of using almost all axle variants. In addition to the standard axle with 22.5’ disc brake, a MEGA axle with 19.5’ disc brake is also available. The range is completed by a self-steering axle. The cornering characteristics, especially when driving in tight circles, where tyre damage can often occur through contact with the inner curbs in roundabouts, are significantly improved by the trailing steering axle. Another advantage of the steering axle is significantly reduced tyre wear of the overall chassis.

Within the full service contracts, the customer can also conclude a separate service for the tyres.

www.cargobull.com

The re-designed underride guard satisfies compliance requirements following new legislation.

HALLCO:

EDGEDRIVEN TO THE

IN LINE WITH ITS ‘BE GLOBAL – ACT LOCAL’ PHILOSOPHY, HALLCO INDUSTRIES HAS THE MARKET PRESENCE AND THE TECHNICAL EXPERTISE TO DELIVER EFFICIENT MOVING FLOOR SYSTEMS THAT ARE TAILORED TO THE NEEDS OF THE OPERATOR.

From Tillamook, Oregon, Hallco Industries has since expanded its manufacturing facilities in the US and Europe, with distribution facilities in Oregon, Ohio, North Carolina as well as Belgium, England, Brazil and Australia.

Hallco Industries has the capability to service the world with lightweight moving floor systems to large high strength systems from either of its production facilities.

“Our globally located distribution facilities give us the ability to be fully global and truly local with service and product specifications for every region,” said Luke Almond, CEO Global of Hallco Industries. “We are able to provide both high volume production capabilities and individual special project/boutique to service every customers’ specific needs. The technical knowledge of our team allows for service in the field, training dealers, as well as end-users on the proper care and maintenance of the systems. Also, dealers stock new trailers with Hallco systems, spare components and parts; they also have trained technicians to make any necessary repairs or upgrades.”

Meet Luke Almond – Hallco Industries CEO Global

Born and raised in New South Wales, Australia, Almond came from a trucking family background where he worked in the family business from sweeping the floor as a kid to labouring during school and university holidays. He would go on to managing the company trucking fleet before joining the Hallco team.

“So, I was an end user before getting into manufacturing,” he said. “I try to continually feel and understand what the customer wants and needs and bring that through our production process and service needs. Downtime is a word we try and never have our customers say.”

Almond has also spent the last 12 years living overseas working in various industries in Asia, Europe, South/Central America and the last seven years before Covid in the US.

“This has given me a broad global understanding of different business practices and cultures,” he said. “Accommodating to the truly diverse markets and the way business is conducted has been helped by living in such varied cultures all over the world.”

Hallco Industries CEO Global, Luke Almond.

A look at the NEXUS and other state-of-the-art drive units

To best support the market segments that Hallco Industries is in, the moving floor specialist has developed the NEXUS drive unit in Europe. Mindful of providing equipment that is user friendly, the manufacturer also provides its Hallco HMI interface.

NEXUS is fully metric in all aspects as opposed to some of Hallco’s US-focused products where imperial is necessary.

NEXUS is a three-cylinder drive with a 40,000kg capacity. it is the lightest drive unit

Hallco HMI base control and enclosure.

available for its intended market operation, meaning Hallco can give back net weight to the trailer manufacturer and payload for the end user.

This drive, according to Almond, is very efficient.

“By managing turbulence of the hydraulic oil in our system through our Hallco design HDS control valve and large direct ports within our hydraulic power unit we can manage temperature,” he said. “This means NEXUS runs cooler and lowers its residual temperature faster than other equivalent systems. Temperature management is very important for system reliability, uptime and operating life.”

The HDS control valve within NEXUS, which controls the floor switching, start/stop and load/unload operations is very modular in design and allows for easy adaptation to change the valves operating function from a manual, electric/manual [hybrid] or full electric depending on the trailer builder or end user’s specific needs.

“Actually it is a very simple four-bolt fixing that allows this fast conversion which helps for retro fitting as well,” Almond added.

For hybrid and electric control NEXUS has

Hallco Belgium facility – manufacturing assembly.

a Hallco designed HMI system that interfaces very easily with the HDS valve and provides a very instinctive user experience.

“The main base HMI function buttons are surface mounted on the enclosure, the function buttons are colour and symbol identified and illuminate when the function is operating,” said Almond. “Furthermore, our remote options (wired & wireless) fully integrate into the HMI to provide the same user experience. This is very important with our remote operation because full synchronisation with the main base HMI allows the operator to directly operate the system either from the remote or simultaneously with the main base HMI. It makes for a far safer and easier system operation. As you can see, user experience is important to Hallco.”

Meanwhile, the aluminium I-4MAX Beast drive has been built for weight savings, strength and corrosion resistance.

The new Brute drive features streamlined design and a powerful 40-tonne drive system, which pulls the drive out from under the trailer and puts it on the nose for easier maintainability.

Also, new electronic controls are expected to make the transition to electric vehicles in the future simpler especially with the inclusion of some automation capabilities.

NEXUS drive unit mounted to a 360-degree rotation assembly jig.

A top view of the NEXUS drive unit.

More than just a moving floor system provider

Hallco Industries, according to Almond, doesn’t just make hydraulics and floor systems.

“We help customers problem solve, so whatever the challenge, we work with our customers closely to deliver a solution that fits for them,” he said. “This ranges from diverse product types for hauling to trailer specifications and stationary bin applications.”

Industry, in general, seeks change what with evolving technological, economic and environmental factors. The team at Hallco continue to innovate as a result.

“A prime example we have seen is the need for more leakproof applications as tighter restrictions and EPA laws increase,” said Almond. “Hallco has developed the new Brute leakproof drive with its streamlined design and powerful 40-tonne drive system which pulls the drive out from under the trailer and puts it on the nose for a leak proof pan to stop any spillage or dripping on the roads.”

The systems that Hallco Industries provide allow for increased volume over tipping/end dump trailers and are generally safer to unload at a farm or site that has uneven ground.

“Tippers need even level ground to tip safely, they also have to be careful with overhead objects which can come into contact with the tipping body when unloading, this is not an issue with moving floor trailers,” said Almond. “Moving floor trailer have further operational advantages as they can accommodate palletised return loads by running the floor in a ‘load function’ or if the floor has been adapted correctly at build, forklift trucks can drive directly into the trailer all of which increases trailer utilisation.”

Why Hallco stands out in the market

The team at Hallco Industries have the ability to manufacture across a full spectrum of moving floor needs.

“We offer systems from 3,500 kg for smaller needs to 40,000-plus kilograms for large heavy duty applications, basic manual configuration to fully electric and hybrid integration,” said Almond – adding that Hallco also provide both threecylinder and true six-cylinder drive units for a balanced push-pull configuration. “We have traditional undermount hydraulics and our famous Brute front mount systems for leakproof operations.”

Hallco’s patented ACCELERATOR technology enables a floor system to switch from a three-step cycle to a two-step cycle at the push of a button and on the fly which allows the system to unload a number of loaded products 30 per cent faster.

Specific customer designs can also be manufactured from hydraulic pack and size, frame and housing components, floor style and material to suit any application.

“Our 1”x2” (25mm x 50mm) subdeck when welded into a trailer creates a stronger overall trailer to help prevent longitude twist in the chassis as the trailers moves around corners and in landfills,” said Almond. “The wide subdeck also improves overall impact protection by offering a wider surface area for our slats to lay on. Furthermore, the slats glide easily in a horizontal fashion without twisting and binding.”

Hallco drive units are also manufactured in a way to create the shortest path to travel for hydraulic oil.

“This means that the oil will stay cooler,” Almond said, “which results in not needing a larger oil reservoir saving much needed weight for payload.”

Accommodating international requirements

Hallco Industries’ products are used in all manner of industries, climates and cultures worldwide from Europe to North America to Asia down to Australia and Chile/Argentina.

“Our products and aftersales service are available across the world,” said Almond. “With manufacturing facilities in both the US and Europe. This is combined with distribution facilities strategically placed to cover all continents including Brazil, England, Australia servicing Australasia and Europe servicing Africa.”

Every continent, Almond said, has vast differences ranging from legal to cultural in terms of how its moving floor systems are used.

There is left- and right-hand drive; legal trailer widths, lengths and max load weights which often differ per country and state; preference for electronic versus manual control; variations in trailer design particularly due to the freight task; and the factor of distance for hauling loads.

“With these considerations in mind,” Almond said, “Hallco Industries must design and produce moving floor systems accordingly.”

www.hallcoindustries.com

BRUTE moving floor system.