Moving 32-Ton Cable Reels and Fragile Green Tires: How KENGIC Solves Heavy Manufacturing’s Toughest Logistics Dilemma

The Heavyweight Dilemma: Why Standard Automation Fails

What happens when your typical payload isn't a 20 kg carton, but a 30-ton high-voltage cable drum, a 5-ton tire curing mold, or an uncured green tire that deforms under its own weight?

For decades, heavy manufacturing has accepted high scrap rates, dangerous forklift traffic, and sprawling, single-level floor storage as "the cost of doing business."

It doesn't have to be this way.

KENGIC Intelligent Technology (SSE-STAR: 688455) is redefining what’s possible in extreme-load manufacturing. With over 1,500 benchmark projects delivered across 25+ countries, KENGIC bridges the gap between massive physical engineering (payloads up to 30,000 kg, vertical heights up to 45m) and millimeter-precise digital intelligence.

Tire & Rubber: Eliminating Bottlenecks from Raw Material to Finished Tire Delivery

In tire plants, logistics failure isn't just inefficient—it halts the entire production line. KENGIC delivers a seamless, full-process ecosystem spans 5 scenarios:

Raw Materials & Mixing (40–50°C): Integrates AS/RS for raw materials, minor ingredients, master batch, and final batch rubber sheets, all operating under temperature conditioned environments (40–50°C). Dust-proof RFID tracking on pallets, combined with sensors capable of detecting black sheets, boosts storage density by >80% and ensures precise recipe batching.

Semi-Components Line-Side Buffer: Features a Line-Side AS/RS for Semi-Finished Components and a Fully Automatic Cart Loading & Unloading System. Automated cart-direction validation and anti-collision rack designs eliminate shop-floor clutter, enabling JIT component delivery to tire building machines.

Tire Building & Curing: Seamlessly links the Tire Building Logistics System and Curing Logistics System via a dedicated Green Tire Storage AS/RS (High-Speed Miniload SRMs at 300 m/min) and an EMS System.

Finished Goods High-Bay Warehousing: Directly connects the Inspection Logistics System, Inbound Sorting & Palletizing System Heavy Gantry Robots, Finished Goods AS/RS Pallet SRMs up to 36m–45m, Tire Packaging System, and Outbound Sorting & Shipping System High-Speed Loop RGVs for zero-bottleneck dock dispatch.

AGV-Connected Material Transport: Deploys a full-plant AGV Automated Handling System orchestrated by KENGIC's proprietary software suite RDS, WDS, WMS, WCS, and 3D SCADA. Automates 24/7 cross-workshop material flow, eliminating manual forklift hazards and guaranteeing 100% on-time JIT line feeding.

Proven Impact: Southeast Asia Giga-Plant featuring a 36m-tall AS/RS, 150,000 storage positions, and 140 AGVs running 24/7.

Wire & Cable: Turning Massive Cable Drums into Agile Flow

Handling spools from 630mm to 3.5+ meters in diameter with weights reaching 30 tons requires specialized muscle:

Raw & Auxiliary Materials Logistics: Integrates Raw & Auxiliary Material AS/RS for metal rods and XLPE compounds, Automated Splicing for Wire Drawing, Automated End-of-Line Transfer, and on-demand JIT delivery for fine drawing, stranding buffers, and extrusion. Boosts space utilization by >70% and guarantees uninterrupted machine replenishment.

Inter-Process AGV & Conveying Artery: Deploys high-speed AGVs and Heavy-Duty Conveyor System as the central logistics link. Seamlessly interconnects Wire Drawing →→Fine Drawing →→Stranding→→Extrusion, eliminating dangerous manual spool rolling and cross-workshop traffic bottlenecks.

Finished Goods Storage & Dispatch:

Large Reel Storage 32Ton / 4.5m SRM: Floor-level ground storage with automated heavy AGV transfers to testing and packaging areas.

Small Wire Coil AS/RS: High-bay AS/RS 4-tier AGV pallet racks / 12m Stacker Crane AS/RS integrated with inline packaging, auto-labeling, robotic sorting, and truck dispatch to double shipping throughput +100%.

Specialized Heavy-Duty AGV Fleet & Digital Brain: Deploys specialized AGVs including Heavy-Duty Forklift AGVs, Spool-Clamp AGVs, and Spindle AGVs orchestrated by KENGIC's proprietary software suite WMS, WCS, RCS, and 3D SCADA. 

Proven Industry Benchmark: Deployed across a 34,000 m² Wire & Cable Digital Factory with straight-line (I-Flow) logistics and comb-shaped (F-Flow) feeding. Trusted by industry giants.

The Digital Core: Hardware Powered by CMMI Level 5 Software

Every crane, AGV, and conveyor is orchestrated by KENGIC’s self-developed digital platform:

WMS / WCS / RCS: Fleet dispatching with inertia-aware path planning that cuts energy peaks by up to 18%.

3D SCADA Digital Twin & PHM: Real-time physics simulation and vibration telemetry that predicts mechanical wear on bearings and ropes before downtime strikes.

Experience the Future Live in Shanghai September 2026

KENGIC is bringing its next-generation ultra-heavy-duty solutions directly to global industry leaders. Meet our engineering experts at:

 RubberTech China 2026 (The 24th Int'l Exhibition on Rubber Technology)

Sept 15–17, 2026 | SNIEC, Shanghai
Spotlight: Green Tire Zero-Deformation AS/RS, Mold Auto-Changeover & Gantry Palletizing.

Wire China 2026 (The 12th All China - Int'l Wire & Cable Industry Trade Fair)

 Sept 21–24, 2026 | SNIEC, Shanghai

Spotlight: 32T+ Cable Drum AS/RS, Reel-Clamping AGVs & 360° AI Defect Vision.

Ready to transform your plant? [Book an on-site consultation at marketing@kengic.com or visit www.en.kengic.com