Project Details
Introduction
At Hin Chong, we specialise in transforming aging hydraulic lift systems into modern, efficient Motor Room-less (MRL) traction lifts that deliver superior performance and long-term value. This case study highlights our successful conversion of a second cargo lift for an SGX-listed solutions manufacturing company, demonstrating the trust and confidence earned through exceptional results on their first cargo lift conversion in 2023.
The client's decision to engage Hin Chong for their second cargo lift conversion exemplifies the strong partnership we build through technical excellence, transparent communication, and unwavering commitment to minimising operational disruption during critical infrastructure upgrades.
The Challenge
Problem
The manufacturing facility operated two hydraulic cargo lifts, both exceeding 20 years of age. Due to aging components, parts obsolescence, and systems reaching their end-of-useful lifespan, the cargo lifts were experiencing increasingly frequent breakdowns that disrupted critical manufacturing operations.
The escalating breakdown frequency created significant operational challenges. Repair costs were rising exponentially as failures became more serious and complex to resolve. Sourcing obsolete hydraulic components often required extended lead times from overseas suppliers, resulting in prolonged lift downtime that impacted production schedules and warehouse logistics.
As the cargo lifts were vital to the company's daily operations for moving heavy materials and finished products between floors, management faced mounting pressure to address the reliability issues decisively. Following the exceptional success of the first cargo lift replacement completed by Hin Chong in 2023, the client confidently proceeded with the second cargo lift conversion in 2025, benefiting from having one fully operational new lift to support operations during the conversion process.
Solution
We proposed converting the aging hydraulic cargo lift to a modern Motor Room-less (MRL) traction lift, mirroring the successful approach implemented on the first cargo lift in 2023. This conversion would eliminate the fundamental limitations of hydraulic technology while delivering substantial operational and cost benefits.
Hydraulic lifts represent older technology that is being progressively phased out due to several inherent drawbacks:
- Larger Space Requirements: Hydraulic systems require substantial space for oil tanks and hydraulic equipment
- Higher Energy Consumption: Hydraulic motors consume significantly more power than modern traction systems
- Lower Speed: Hydraulic technology operates at slower speeds compared to traction lifts of equivalent capacity
- Maintenance Complexity: Hydraulic lifts inevitably face oil leaking issues over time, requiring frequent maintenance and oil replacement
- Environmental Concerns: Hydraulic oil presents potential environmental hazards if leaks occur
In contrast, modern MRL traction lifts offer compelling advantages:
- Compact Design: Motor Room-less technology eliminates the need for dedicated machine rooms, maximizing usable building space
- Energy Efficiency: Permanent Magnet motor technology reduces power consumption substantially
- Lower Maintenance: Simpler mechanical systems translate to reduced maintenance requirements and long-term cost savings
- Faster Operation: Traction systems deliver quicker travel speeds enhancing operational efficiency
- Reliability: Modern components with readily available spare parts ensure minimal downtime
After comprehensive assessment confirming technical suitability, we recommended the hydraulic-to-traction MRL conversion, which the client readily endorsed based on their positive experience with the first conversion.
Our project priorities were clearly defined:
- Match or Exceed First Lift Quality: Deliver results equal to or better than the highly successful first cargo lift conversion
- Maintain First Lift Functionality: Ensure the 2023-installed cargo lift remained fully operational throughout the project
- Complete Within Timeline: Finish the conversion within the 6-8 week projected duration
Key Results and Outcomes
The cargo lift conversion was completed successfully in 6 weeks, meeting our timeline commitment and maintaining zero disruption to the client's manufacturing operations. Throughout the project, the first cargo lift installed in 2023 operated flawlessly, providing uninterrupted vertical transportation for critical materials and products.
The converted cargo lift now features entirely new components including a modern MRL traction motor with Permanent Magnet technology, microprocessor-based controller, new car operating panel (COP), hall operating panel (HOP), door operator system, and completely refurbished lift car interior. The pit and shaft areas were thoroughly cleaned and updated with new safety systems meeting current BCA standards.
Post-conversion performance has been exemplary. The new traction system operates significantly faster than the old hydraulic lift while consuming substantially less energy. Initial power consumption monitoring indicates energy savings consistent with the first cargo lift conversion, providing measurable cost reductions in ongoing operations.
The client expressed strong satisfaction with the conversion results, noting that the second cargo lift performs as excellently as the first. Having both cargo lifts now operating with modern, reliable technology provides the manufacturing facility with dependable vertical transportation capacity crucial for maintaining production schedules and meeting customer commitments.
All components are covered by our comprehensive 5-year extended warranty, providing the client with budget certainty and peace of mind. We continue to maintain both cargo lifts under our monthly preventive maintenance program, ensuring optimal long-term performance and addressing any minor adjustments proactively.
Conclusion
This successful second cargo lift conversion reinforces Hin Chong's position as the trusted partner for industrial lift modernisation projects requiring technical expertise, minimal operational disruption, and proven results. The client's decision to return to Hin Chong for their second conversion demonstrates the exceptional value we delivered on the first project and our ability to consistently meet demanding industrial requirements.
With both cargo lifts now modernised with state-of-the-art MRL traction technology, the manufacturing facility benefits from enhanced reliability, reduced energy costs, simplified maintenance, and the confidence that comes from having mission-critical equipment backed by comprehensive warranties and professional ongoing support.
For manufacturing companies, warehouses, and industrial facilities facing similar challenges with aging hydraulic cargo lifts, Hin Chong offers proven expertise in hydraulic-to-traction conversions that deliver tangible operational and financial benefits while minimising disruption to critical business operations.
