Category: Blog

Handling heavy loads in manufacturing is a persistent challenge. Key issues include operator safety, costs from non-productive times, and the risk of damaging transported products. Sectors such as automotive, steel, power generation, nuclear, and heavy carpentry frequently face these challenges. For example, the automotive industry often needs to move press molds, while the steel industry handles heavy raw, semi-finished, and finished products. Efficient and safe handling of power transformers, chillers, and turbines is critical for the power generation sector.

 

Problems with Tractor-Trailer Systems

The traditional tractor-trailer system has several significant drawbacks.

Safety Concerns:

• Lack of Certification: Forklifts or small electric tractors are often not certified for towing specific trailers, which can compromise safety.
• Inadequate Braking: These tractors may struggle to effectively brake trailers on inclines, leading to hazardous situations.
• Complex Maneuverability: Articulated tractor-trailer systems are challenging and risky to maneuver, especially when reversing.
• Operator Risks: Walk-behind electric tractors (pushers/pullers or tugs) can cause severe accidents if brakes fail or on inclines, potentially harming the operator.
• Tipping Hazards: High-speed turns can result in trailers tipping over.
• Human Errors: Mistakes such as improper hitching or leaving the trailer brake engaged can lead to dangerous situations.

High Operating Costs:

• Longer Handling Times: Maneuvering tractor-trailer systems is complex, requiring longer routes and more time-consuming positioning at loading and unloading stations.
• Large Space Requirements: These systems need significant space within the facility, which can be economically valuable.
• Energy Inefficiency: Moving three components (tractor, trailer, and load) is less efficient and increases energy consumption.
• Increased Maintenance Costs: Maintaining two separate vehicles (tractor and trailer) raises operational costs.

 

Advantages of Battery-Powered Carts

Enhanced Safety:

• Certified Design: Self-propelled carts are certified to handle and brake specified loads safely. They are tailored to meet customer-specific requirements (load type, flooring, slopes, etc.).
• Remote Control Operation: Remote controls or pendant push buttons keep operators at a safe distance, providing optimal visibility and reducing risk.
• Stability: Software-controlled steering prevents tipping.
• Collision Avoidance: Advanced systems, including laser scanners, further mitigate risks by monitoring movements in both directions.

Improved Operational Efficiency:

• Shorter Handling Times: The compact build of self-propelled carts allows for quicker handling and more direct routes.
• Optimized Space Usage: These carts require less space, making them ideal for facility layouts. Morello’s omnidirectional steering carts enhance space utilization even further.
• Energy Savings: Only the cart and load require power, significantly lowering energy consumption compared to tractor-trailer systems.
• Reduced Maintenance: With only one vehicle to maintain, overall costs are lower.

 

Comparison with Multiple Trailer-Tractor Systems

Even in setups using a single tractor with multiple trailers, battery-powered self-propelled carts outperform. A system utilizing a self-propelled cart with a liftable loading platform and several steel “pallets” offers distinct advantages:

• Lower Costs: Steel pallets, lacking wheels or steering mechanisms, are cheaper than full trailers.
• Operational Efficiency: These carts streamline operations, reducing both management and maintenance expenses.

Conclusion

Battery-powered self-propelled carts provide a modern, safe solution for handling heavy loads. They deliver substantial benefits in safety, operational efficiency, and cost-effectiveness over traditional tractor-trailer systems. Designed to meet specific customer needs, these carts offer tailored solutions for diverse industrial applications.

To learn more about our self-propelled carts, visit our page here.

For more details or a personalized quote contact us here.

Importance of Worker Safety

Handling heavy loads within manufacturing environments presents significant safety challenges. The use of outdated, uncertified, or homemade equipment, as well as machines that involve suspended loads, greatly increases these risks. These hazards can result in severe injuries to workers and substantial damage to materials and facilities.

 

Financial Impact of Inefficient Load Handling

Inefficient heavy load handling can be highly costly due to the extended time, large spaces, and multiple pieces of equipment required for transportation. This inefficiency can lead to production delays, causing financial losses.

 

Protecting Materials from Damage

Inappropriate handling of heavy loads not only poses risks to workers but also to the materials themselves. The size and weight of these loads necessitate specialized equipment to ensure they are transported without damage. Using unsuitable machinery can lead to costly material damage and production delays.

 

The Solution: Specialized Handling Equipment

To mitigate these issues, it is crucial to employ equipment specifically designed for heavy load handling. Morello’s battery-powered self-propelled vehicles provide an excellent solution, offering enhanced safety and efficiency.

 

Morello’s Battery-Powered Transport Carts

Morello’s self-propelled battery-powered transport carts are among the best solutions for heavy load handling. These carts ensure maximum stability during transport, eliminating the risk of suspended loads. They can navigate freely over various terrains and operate effectively even in confined spaces.

Benefits of Using Morello Transport Carts:

• Enhanced Safety: The carts are designed to minimize accident risks with their stable structure and specific risk analyses for each machine.
• Material Handling Efficiency: Their flexibility and ability to lift the load platform reduce the need for additional equipment like cranes.
• Reduced Intralogistics Costs: The efficiency and speed of these carts decrease downtime and related costs.
• Optimized Operations: The versatility of these carts allows for efficient space and time management during heavy load handling.

 

Advanced Technology with Morello AGVs

Morello also offers Automated Guided Vehicles (AGVs) for further optimization. These vehicles operate autonomously, reducing the risk of human error and increasing operational efficiency.

Advantages of Morello AGVs:

• Safety Features: Integrated laser scanners detect and avoid obstacles autonomously.
• Continuous Operation: AGVs can function 24/7, enhancing productivity.
• Cost Savings: Reduced labor needs and increased efficiency lead to significant cost reductions.

 

Contact Us for More Information

For more details on Morello’s transport solutions, visit our product pages:

• Battery-Powered Self-Propelled Vehicles
• Automated Guided Vehicles (AGVs)

If you need a personalized quote or more information, contact us.

Optimize your production with Morello’s innovative solutions, ensuring safer and more efficient heavy load handling.

Our material handling equipment company offers unique expertise in automated guided cart manufacturing. The company designs and builds customized trolleys and handling equipment for heavy loads including massive power transformers, large naval vessel, die, mold and tooling for metalworking industry.

One of the fastest growing industries handling solutions is AGV cart or Automated Guided Vehicle blending smart technologies for significant benefits across many industries.

Key features of Morello automated guided cart

Custom-built vehicles, our AGV carts are designed according to specifications agreed with the client featuring extremely high load capacity of up to one thousand tones. Morello AGV cart is computer controlled, driverless vehicle for transporting heavy loads, with automatic self-loading and unloading capabilities if required. Our AGV is actually an online robot responding in real time to frequent changes in production operations and absorb the impact of real time decision making. The AGV is pre-programmed, moves autonomously without the presence of an operator, within factories and warehouses both indoor and outdoor.

Multiple steering options provide maximum maneuverability to navigate in the tightest of spaces. The AGV Cart’s guidance system often uses laser technology but may alternatively follow marked lines, wires on the floor, GPS and sensors, use vision cameras or magnets. Maximum maneuverability is obtained with the omnidirectional AGV ensures autonomous move of each wheel.

Integrated into production and warehousing software systems, our AGV carts will transmit information with movement log and tracking to optimize systems and processes. The specifications of the AGV for your specific use case are drawn up together with Morello technical team who has the experience to outline and provide optimal solution.

AGV Cart is customizable and cost-effective material handling equipment allowing for modern logistics in manufacturing and warehousing operations offering concrete operational advantages.

Advantages of Automated Material Handling

We define 6 main areas perfectly suitable for automated material handling solutions using AGV carts to get advantages compared to standard material handling solutions.

AGV are driverless vehicles and as a result the labor costs and staffing becomes operational saving. . AGV’s can provide continuous 24/7 operational availability by removing the need for human resource management. The management and staffing issues related to qualified licensed drivers with appropriate training and safety management procedures are also taken out of the equation.

AGV cart technologies have built-in safety features for enhanced safety eliminating any risk of injury to people. Today’s sensor and smart visioning technologies provide safeguards and eliminate the human-error factor and risk of driver distraction which can cause unfortunate accidents.

AGV can work in volatile and dangerous industrial environments hostile to human beings. Morello offers ATEX certified AGV carts which are essential in certain industries such as oil and gas or the chemical sector. Whether the risk is assessed as a volatile setting, an explosive risk or the risk of manually handling heavy loads the AGV is a risk-free solution for both operators and the company as a whole.

High levels of precision and productivity define technologies used in automated guided cart in operations and materials handling. The very nature of using programmed AGV carts means that first time positioning delivers greater operational productivity. On a recent client project a Morello AGV obtained a loading and unloading precision with maximum five millimeters range for a large and heavy material handling.

Thanks to the safety and precision factors mentioned above damage reduction is one more advantage. Even more importantly the concern of damage and injury to people is eliminated providing peace of mind and a safer working environment for all employees.

AGV in enterprise’s operating systems ensures accuracy and traceability with all movements clearly programmed, logged and tracked. We transform automated materials handling results into benefits for inventory accuracy and the traceability of products and materials.

Morello AGV solutions ensure benefits for operations in a wide range of industrial sectors including power generation sector, oil and gas, large turbines, and electric motors, automotive industry tubing, coil and plates and metalworking sectors.

For any company investing in heavy-load material handling equipment, numerous factors influence the purchasing decision: cost-effectiveness, productivity, maintenance requirements, environmental impact, operator skills and training, space optimization, energy consumption, travel distances, and more. However, safety remains the most critical factor, especially for companies that consider people their most valuable asset.

Among the main categories of equipment used for handling extremely heavy loads, we focus on:

• self-propelled heavy-duty trolleys on wheels or rails
• bridge and jib cranes
• upenders and tilting machines
• heavy-duty forklifts
• other specialized handling solutions

Handling extremely heavy loads involves significant risks that must not be underestimated. The primary hazards include:

• Crushing injuries caused by falling or unstable loads
• Risks related to poor ground conditions, such as uneven surfaces or obstacles
• Equipment malfunctions or structural failures
• Operator-related risks, including insufficient training or distractions
• Accidents caused by inadequate operating procedures or unsuitable equipment
• Collisions and unsafe maneuvers, which may also damage factory infrastructure
• Environmental risks, such as slippery floors, obstacles along the route, suspended cables, wind, and other external factors

As a leading manufacturer of self-propelled trolleys for industrial heavy loads, Morello offers unique expertise in advanced technologies for safe and efficient indoor and outdoor material handling within production plants.

LOW-RISK SOLUTION: SELF-PROPELLED TROLLEYS FOR HEAVY LOADS

Battery-powered self-propelled trolleys represent one of the safest solutions for transporting extremely heavy loads within industrial facilities, for several key reasons:

• The load is supported by industrial-grade wheels designed for heavy-duty applications
• Operators control the trolley remotely via dedicated control interfaces, remaining at a safe distance
• Loads are positioned in a stable and secure manner on large steel platforms
• Movement is smooth and fully controlled, with safe and gradual braking

Thanks to advanced sensor technology, self-propelled heavy-load trolleys can detect obstacles or personnel along their path and automatically respond to the situation. Depending on the operating environment and application, multiple sensor systems can be integrated into the vehicle to further enhance safety.

Additional advantages include:

• High positioning and movement precision, minimizing the risk of collisions or damage
• Silent operation and zero emissions, thanks to fully electric drives
• No oil leaks or spills, as electric motors replace hydraulic or diesel systems
• Minimal operator training requirements, as the vehicle can be operated efficiently after approximately one hour of basic training.

Morello’s OMNI trolleys feature independent wheel control, with each wheel equipped with its own motor, braking system, and hydraulic height adjustment. This configuration allows the trolley to compensate for uneven floors and slopes while keeping the load perfectly level at all times.

Operation in confined spaces is a standard capability of self-propelled trucks. For applications requiring the highest safety and precision levels, AGV trolleys offer fully automated operation using the most advanced navigation and safety technologies. For hazardous areas, ATEX-certified trolleys are available for use in explosive environments involving volatile substances.

OVERHEAD AND BRIDGE CRANES – HIGHER-RISK HANDLING SOLUTION

Overhead and bridge cranes are among the highest-risk solutions in heavy material handling and must be operated exclusively by properly trained and experienced personnel. This is essential to prevent damage to loads, plant infrastructure, and most importantly injuries to operators and other personnel.

Crane operations involve lifting loads suspended at height, stabilizing them, minimizing oscillation, and moving them across distances within the facility, often above other equipment or people working in the area.

Chains, slings, and shackles must be carefully selected and rated to withstand extreme loads. However, their use introduces significant risks, particularly during load attachment and detachment, where operators must work in close proximity to both the load and the lifting accessories. Serious injuries, including finger crushing, can occur, and unfortunately, fatal accidents involving cranes continue to be reported in workplaces every year.

LOW-RISK MATERIAL HANDLING ON RAILS

Self-propelled rail-guided trucks can be an efficient solution in certain industrial environments. Compared to wheeled self-propelled trolleys, the primary additional risk is the presence of rails within the working area, which may pose tripping hazards and create obstacles for smaller wheeled equipment.

However, a key safety advantage of rail-based systems is the predictability of movement. Loads travel along a fixed and clearly visible path within the plant, increasing operator awareness and reducing the risk of unexpected movements.

Self-propelled rail-guided trucks can be an efficient solution in certain industrial environments. Compared to wheeled self-propelled trolleys, the primary additional risk is the presence of rails within the working area, which may pose tripping hazards and create obstacles for smaller wheeled equipment.

However, a key safety advantage of rail-based systems is the predictability of movement. Loads travel along a fixed and clearly visible path within the plant, increasing operator awareness and reducing the risk of unexpected movements.

FORKLIFTS AND SAFETY CONSIDERATIONS FOR HEAVY LOADS

Forklifts are widely used in industrial material handling and, up to certain load limits, can represent a practical and flexible solution. However, when handling extremely heavy loads, the associated safety risks increase significantly.

Many of the safety limitations of forklifts can be eliminated by using self-propelled material handling equipment. Battery-powered trolleys address several critical issues commonly associated with forklift operations:

• Maneuverability and blind spots: Forklifts have limited turning radii at the front, while the rear swings outward during cornering. Transported loads can also obstruct the operator’s field of view.
• Load stability: Risks increase when operating on slopes, wet or oily floors, or uneven terrain.
• Speed-related hazards: Even at low speeds, a forklift carrying a heavy load can cause severe damage, comparable to a vehicle moving at much higher speed.
• Refueling risks: Diesel forklifts refueling introduces additional hazards related to fuel handling and emissions.

SAFETY FACTORS TO CONSIDER

Selecting the right solution for heavy-load material handling requires careful evaluation of multiple safety factors. Safety should always be the primary criterion when making this decision.

If you would like support in assessing your specific application or need guidance to make an informed and confident choice, please contact us. We will be pleased to assist you in identifying the safest and most effective solution for your operation.

Morello Customer Loyalty Team: Amedeo Morello, Luca Tibaldi, Stefano Rizzo.

The construction and decommissioning of hundreds of new nuclear power and research reactors necessitate substantial resources for material handling and logistics within the nuclear power sector. Decommissioning a nuclear power plant is a lengthy and costly process that requires exceptionally high levels of security, adhering to strict rules and standards for cleaning up radioactively contaminated infrastructure and safely removing radioactive fuel.

Since its founding, Morello has developed numerous projects utilizing customized heavy-duty industrial carts for nuclear energy decommissioning in various European countries. Given that stringent requirements and standards dictate that every aspect and detail of the equipment must be checked and documented, Morello is well-equipped to provide all necessary supporting services and documentation. Our structured project management goes beyond equipment design and construction.

Safety and security are paramount in the nuclear industry, a principle exemplified by our work on the decommissioning of the nuclear power plant in Latina, located in the Lazio region, in Italy. This plant, which operated from 1963 until 1987, is currently in the first phase of its decommissioning process, scheduled for completion in 2027. Morello submitted detailed proposals to Sogin, the company responsible for the decommissioning project, addressing two operational requirements for handling heavy materials.

The first requirement involves moving shell casings weighing 120 tons and measuring 5.6 x 3.4 meters from an external location to a purpose-built warehouse, where they will be cut and sectioned into smaller pieces for disposal. The second requirement concerns the movement of containers holding contaminated waste, weighing up to 20 tons, which need to be transported within the plant and lifted to higher floor levels.

The nuclear site in Latina is situated in a seismic zone, and Morello had to ensure that the heavy transportation equipment for nuclear energy could withstand potential earthquake tremors of varying intensities. To meet these stringent requirements, Morello proposed and constructed three heavy-duty industrial transfer carts.

For the transportation of shell casings, we designed a customized battery-powered transport cart on wheels, model SGAI-E VSP3. This cart features a unique configuration with 32 super-elastic wheels and equalizing mechanisms to ensure that all wheels maintain contact with the floor. This solution provides optimal weight distribution, supported by 4 electric traction motors that require no maintenance, along with a wheel steering mechanism designed to prevent wheel grinding during turns using Ackermann steering. This self-loading platform has a capacity of 130 tons and utilizes 8 cylinders integrated into the loading platform.

The SGAI model is equipped with laser scanners that ensure secure stopping when obstacles are detected in the cart’s path. Additionally, it features a steel chassis frame supported by four 10-ton weight supports, designed to lift and move once the shell casings are positioned on top.

Shell casing handling is accomplished using the battery-powered Rail Guided Transport Cart, model SBA, which has a load capacity of 130 tons and is supported by 8 double-edged rail wheels for precise positioning. A special rotating platform facilitates accurate positioning of the shell casings for cutting and sectioning.

Morello’s heavy-duty industrial transfer cart, model SBA-E, is specifically designed for handling contaminated materials in the nuclear energy sector. This customized rail cart is equipped with numerous sensors and safety controls to ensure maximum operational safety. It features a liftable platform that raises the containers using 4 cylinders equipped with position and pressure sensors.

The design of these 3 heavy-duty industrial transfer carts is engineered to withstand seismic shocks, as detailed in comprehensive supporting documentation and technical documents from Morello that exceed the general requirements for heavy industry operations within a nuclear energy setting.

Advanced diagnostics are available on the HMI (human-machine interface), and the integrated IoT capabilities allow Morello to provide ongoing remote assistance as needed. We ensure a high level of performance, security, and precision, which are crucial for material handling in the nuclear energy sector and power plants. Our experience and expertise equip multinational corporations in the energy sector with the support and solutions necessary for efficient and safe material handling.

Based in Turin in north-western Italy, Morello offers expertise in customization and production of industrial material handling trolleys for international market. With a solid portfolio of heavy-load handling challenges in a variety of industrial sectors, today Morello actively enhances international market. Handling of heavy loads up to 1000 tons for international companies is 60% of Morello business nowadays.

Producing heavy-duty transport trolleys, Morello blends unmatched quality, expert problem solving, advanced technologies and complex project management. Global companies such as Samsung, Siemens, General Electric, Tenaris, ABB, Saipem, Alstom, ArcelorMittal, Toyota, Hyundai, SKF and many more apply material handling solutions from Morello in their operations worldwide

Our team of engineers offers the most advanced technologies in the world regarding forklifts making multinational corporations and international companies chose Morello as reliable, well-organized and certified manufacturer of industrial self-propelled vehicles.

International Prospect

Before expanding to European market in France, Germany, Spain and UK, Morello original core business was based in Italy. Now our solutions are used in plant operations in nearly 20 different industries with specific operational requirements around the world.

Our presence in the United States involves reliable technical-commercial partner Prella Technologies supplying industrial trolleys for material handling and logistics in the variety of sectors. Blending advanced technologies, experience in the industrial sector together with rigorous quality and project management we challenge most severe logistical barriers for US customers.

Poland represents one more successful example of developing a foreign market. Partnership with TransTechnik, a company specializing in transport solutions for plant manufacturing sectors defined our further success in automation of material handling for local companies. Morello material handling trolleys are also present in the Asian and Middle Eastern markets with emphasis on energy sector.

Remote and Local Support in real-time technical support is one of key features for our international success. Morello collaborates with a network of technical-commercial partners in key markets. Our industrial trolleys for material handling can be equipped with on-board remote assistance technology providing immediate expert support and advanced diagnostics. We can also continuously monitor all equipment remotely and plan preventive maintenance.

Presence on international market

Supplying industrial self-propelled vehicles we care about each detail in customer demands covering complete range of industrial sectors around the world.

In Oil & Gas sector we work with companies from the United States, Australia, Malaysia, France, United Kingdom, Russia, Nigeria, Angola providing customized ATEX trolleys in line with individual requirements.

Nuclear power plants in Germany, France, Italy, Benelux, United Kingdom use Morello equipment for both functioning and decommissioning projects.

We have wind energy projects in France, Germany, Denmark, Spain, China, India solving unmatched cases of wind turbine handling.

In automotive industry we offer excellence in mold carrying trolley customization for companies from Mexico to the United States through all European markets to Eastern Europe also exploring new opportunities in India.

Handling heavy sheets, coils and pipes in steel and metalworking industries Morello trolleys are used on the markets of Middle East and Turkey, USA and Mexico, Russia and Eastern Europe as well as in all Western Europe.

For handling of large transformers, turbines, chillers and other equipment in Energy sector we are present in the United States, India, almost all European countries, the Middle East also opening new markets.

Construction industry is presented with unique tunneling case in the UK, handling of precast concrete in the US and Saudi Arabia and other large building projects.

Besides indicated industries Morello offer solid experience and rich case portfolio in sectors of defense, shipbuilding, chemical, solutions for asphalt mixing plants, large valves and radiators around the world.

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Morello Customer Loyalty Team: Amedeo Morello, Luca Tibaldi, Stefano Rizzo

We look forward to welcome you!

This project was born thanks to the mission of OceanX, a company based in the USA and founded by Ray Dalio and his son Mark Dalio. Their purpose is to explore the depths of the ocean, protect the sea and marine life, in order to educate, inspire and make people know the wonders of the underwater world through a gripping narrative. 

This mission could be fulfilled only with the ship OceanXplorer: the most advanced exploration and research vessel ever built. It was fabricated in Norway by the company Damen and is capable of exploring the most unreachable places on Earth. This ship can carry four submarines and will sail the ocean around the world pushing the limits of discovery until the maximum depth of 6000 meters.

OceanX proposed a demanding, but very stimulating, challenge to Morello in order to carry out the important mission of the ship OceanXplorer. For this project, Morello was expected to provide a special type of heavy-duty platform cart that could safely move highly sophisticated submarines on the deck and in the hold of the ship without any risk for the crew.   

Let’s see in detail this stimulating project.

Information about the customer:

The direct customer of Morello is the Norwegian shipbuilding company Damen, while the final customer is the ship OceanXplorer. It is an American vessel that will sail across all the oceans of the world to explore and protect the marine environment. For this mission, Morello dealt also with the submarine operator.

The challenge:   

Object

Two on-board submarines which, although small submarines, were very large relative to the size of the ship

The working environment:

Working Area	The implementation of shipboard operations can be very dangerous in narrow spaces, especially during the roll and the pitch of the ship or when the sea is really rough.
Space	The ship is relatively small with narrow spaces where the crew had to move the submarines.
Weather Conditions	Morello’s heavy-duty platform carts must operate on a ship during its journey across the ocean and withstand any weather condition.
Air Quality	Sea air, saltiness and adverse weather conditions can cause many problems to the equipment.
Floor Conditions	The floor of the ship is not suitable to withstand excessively heavy loads and for this reason the distribution of weight must be stable and balanced. Moreover, the floor is often wet and the risk of slipping during the roll and the pitch must be well evaluated and kept under control.
Place and Service	Even in the middle of the ocean there can be mechanical breakdowns and for this reason Morello’s transfer carts must be highly reliable. Possible breakdowns aren’t easily repairable and Morello’s experts can’t be available 24 hours a day in such a difficult environment.

The solution provided by Morello:

Vehicle	The ship OceanXplorer needed two heavy-duty platform carts to transport the submarines. They are battery-powered OMNI platform carts, equipped with electric engines in order not to pollute the environment. We used only IP certified electrical components, made of stainless steel and covered with C5-M certified marine varnish. Our carts were built to transport submarines and other equipment with a maximum weight of 20 tons.
Steering	Our heavy-duty platform carts are very flexible to drive in the narrow spaces of the ship OceanXplorer. Thanks to the multidirectional driving system, our carts can steer right and left 90 degrees, diagonally or rotate on their axis.
Mobility	A specific calculation of dynamic acceleration was done in order to ensure a uniform distribution of weight with all possible sea conditions and to avoid overload on a small portion of the surface. Moreover, the twelve wheels are equipped with individual engines and hydraulic suspensions to ensure an excellent stability and adhesion to the surface. In addition, a specific calculation to measure the friction between the floor and the wheels was done both in dry and wet conditions.
Enginees	Our transfer carts are equipped with alternating current brushless engines, that don’t need maintenance and don’t pollute.
Operational Control	Our platform carts are driven with a remote-controlled potentiometer. The operational software has been developed and improved by Morello over the years and now is used all around the world.
Technical Support	All the components that were used don’t need maintenance and all the possible risks of breakage were identified and minimized. In case of emergency, specific procedures were established and spare parts were provided in order to ensure the maximum level of efficiency. An advanced interface was installed to diagnose all the possible mechanical problems of the vehicle. Moreover, remote assistance was activated through the use of an on-board monitoring software.
Project Management	Morello’s team has many years of experience in the supply of technical solutions to carry out important and challenging projects such as the one related to the ship OceanXplorer. This project was very stimulating due to the adverse ocean and weather conditions that the ship had to face during its journey.

https://youtu.be/PtknhQ2UZnE?t=8

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Morello’s expert team: Amedeo Morello, Luca Tibaldi, Stefano Rizzo.

Contact us: we are glad to help you!

Today Morello is the company focused on international market offering material handling expertise and professional approach to companies across diverse industrial sectors.  The very nature of the business is in providing bespoke heavy duty carts, each individually constructed and customized to the specifications agreed with a client by our professionals in Client Engagement team. This complex make-to-order material handling transportation system must go through a well-defined project definition phase. Moreover Morello has a constant flow of new clients arriving on a monthly basis and it is critical to engage efficiently and propose the right solution and technology for each individual project.

Pre-project research and project definition are critical steps as well as subsequent project design and build phase ensuring Morello heavy duty carts are employed to transport extremely heavy loads in extremely different environments followed by strict Risk management. Our structured approach applied over a short time frame to engage Client Problem Solving in 8 steps to engage the client and provide effective project offer.    The first phase is the initial Client Engagement during which a client will give a general outline of its specific material handling requirements. The team has great experience in discussing the management of heavy loads across multiple industrial sectors.

Step 1 starts with initial client engagement during when client gives a general outline of its specific material handling requirements. Our team of professionals offers solid experience in heavy-load handling research and management in various industrial sectors.

Step 2 follows initial contact when Client Engagement team provides information about Morello approach to customization, project management and company credentials.

Step 3 is data collection stage to make our offer: we gather a series of data regarding load, environment, operating conditions, space, and technology considerations. RFQ document gathers all required data in a structured format while different industrial sectors face different challenges and all of these must be carefully assessed.

Step 4 is data analysis to assess and integrate client requirements with any additional information required and evaluate the most suitable solution developed by  Client Engagement team together with Morello Technical Department.

Step 5 initiates Technical Information meeting which may be held either at the client’s site, at Morello premises or in conference call if required. Client Engagement team outlines the solutions and options also in follow-up meeting when required to provide further details.

In Step 6 Morello develops Commercial Proposal with all required technical details.

Step 7 includes final clarifications for client before we proceed to the Client Project Sign-Off and Purchase Order.

Step 8 is actually the project Start-Up launch involving Morello Project Technical Team based on project requirements with following definition of project milestones and master schedule.

Client Problem Solving creating an effective working relationship with the client senior management is key process of Morello international success. Our reputation, attention to details and excellent customer service define our client base growing every week.

Morello Customer Loyalty Team: Amedeo Morello, Luca Tibaldi, Stefano Rizzo

We look forward to welcome you!

We are proud to announced that Morello has produced two wind turbine blades self propelled modular transporters, powered by batteries, for the transport of the world’s longest wind turbine blade: 107 meters in length! In order to handle a blade of this length it was necessary to design 2 modular transporters, each with a capacity of 60 tons, that could operate in synchronized fashion over 80 meters apart!

Our software engineers took on an extremely challenging job to make sure that the two wind turbine blades self propelled modular transporters could communicate and automatically correct their trajectories at such a great distance and with such a flexible load.
Especially when you consider, among other things, that the two transporters are able to perform, both individually and when paired, many different type of maneuvers: rotation around their own axis, lateral movements, diagonal movements, etc.
Being omnidirectional, they are able to move the wind turbine blade with extreme efficiency, even in relatively tight spaces.
Both wind turbine blades self propelled modular transporters have raisable loading beds. This feature is fundamental in making sure that the transport of the blade, which rests on special supports, can be performed in a completely autonomous fashion, that is to say, without cranes or gantries. Thanks to these transporters it is possible to move the blade inside the factory, around the yard or at the shipping dock.

These transporters are also equipped with hydraulic suspension that can work over irregular terrain without damaging the transported load.
An important feature of these wind turbine blades self propelled modular transporters is their battery power supply. A clean, non-polluting energy source was one of the main requirements of this customer, who, working in the area of renewable energy, paid particular attention to the environmental aspect.

The turbine on which this blade will be mounted is the most powerful wind turbine in the world, to date. It is a 12 MW offshore turbine that will be built in the middle of the ocean.
This 12 MW wind turbine will be able to generate 67 GWh of clean energy per year, equivalent to the average requirement of 16,000 European homes.
You can find more information on this amazing technological innovation here:
GE – The World’s Largest Wind Turbine Blade Is Longer Than A Football Field
LM WIND POWER – World’s longest wind turbine blade sees first daylight

Morello is the leader in the production of customized transporters for moving heavy materials the world over: United States, Canada, South America, Europe and Asia.
The possibilities for customization are limitless! Here you can find some of our products: Battery powered transporters

N°2 OMNI-E-M DR
60 t + 60 t – 5,000 x 3,400 mm

Main features:
Capacity: 60 t + 60 t (up to over 1,000 tons on request)
Steering: omnidirectional
Power: battery
Traction motors: brushless AC
Steering motors: brushless AC
Size: 5,000 x 3,400 mm (other dimensions on request)
Speed: 20 m/min
Battery range: 4 km
Control: radio control
AGV: on request
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)

A diesel-electric hybrid truck designed for handling loads up to 20 tons in industrial plants

Morello has developed a diesel-electric hybrid truck that successfully combines all the key features required by manufacturers for material-handling operations:

• low maintenance requirements
• low environmental impact
• ability to operate both indoors and outdoors with the same vehicle
• extended operating autonomy

Hybrid power system and operational advantages

Morello’s diesel-electric hybrid truck can be equipped with a lithium battery, allowing operators to switch from diesel power to battery power at any time. This flexibility makes it possible to operate the vehicle with zero emissions whenever required. When powered by the diesel generator, the truck offers maximum autonomy, enabling continuous operation without interruptions.

Electric AC traction and steering motors ensure extremely low maintenance requirements, an essential factor when evaluating long-term operating costs and overall machine reliability.

Thanks to these characteristics, Morello’s diesel-electric hybrid truck stands out as one of the most versatile solutions for handling heavy loads in industrial applications.

Main features:

SGAI VSF – CABIN
20 t – 3,300 x 2,400 mm

• Capacity: 20 t (up to over 100 tons on request)
• Steering: front steering axle
• Power: diesel-electric
• Traction motors: AC
• Steering motors: AC
• Dimensions: 3,300 x 2,400 mm (custom sizes available on request)
• Speed: 10 km/h (up to 30 km/h on request)
• Control: driver’s cab
• AGV version: available on request

Customization and tailored solutions

But Morello goes even further! Our commitment to 100% customer satisfaction drives us to design solutions tailored to each specific need. Every application has unique requirements, and the most effective way to support our customers is to engineer a machine perfectly suited to their operations. For this reason, this diesel-electric hybrid truck can be fully customized in every aspect, including load capacity, speed, dimensions, loading deck design, and much more.

Contact us to discuss your requirements: we will be pleased to develop a custom-engineered solution tailored precisely to your needs. Morellos designs and manufactures diesel-electric hybrid trucks for customers worldwide.

Morello has designed and manufactured a laser-guided omnidirectional automated guided cart (LGV), with raisable loading bed, for a well-known company that makes machinery for the food and beverage sector.

The AGV is part of a larger project, an automated warehouse for the storage of materials of large weight and size.
The technology that allows this cart to travel with full autonomy is what we call “laser-guidance”. At a height of approximately 3 meters we install a special laser that, constantly rotating at high speed, intercepts reflectors stationed around the facility, allowing the software to triangulate the position and orientation of the omnidirectional automated guided cart on which the laser is mounted.

The software then plans the best course according to the task provided by the automatic warehouse management system.
Communication between the AGV cart and the management software installed on a PC on the ground is through Wi-Fi technology.
In spite of the large size of the cart and the load it carries, this Morello omnidirectional automated guided cart can move agilely about the plant thanks to its omnidirectional steering technology. All of the wheels are in fact indipendent and the cart can therefore move in standard fashion, at 90°, rotate about itself (carousel), move diagonally and travel around a point (compass).
The AGV is also equipped with a raisable loading bed with a 200 mm range in order to be able to load and deposit warehouse pallets onto suitable supports.

Thanks to its enormous experience in the battery powered electric cart sector, Morello has succeeded in achieving a positioning accuracy at loading/unloading stations of ±5 mm.
To achieve maximum efficiency the omnidirectional automated guided cart is powered by a high energy density lithium battery that is automatically fully recharged at available charging stations.
Morello produces customized AGV with all types of guidance technology, with all types of capacity, size and integration with customer systems. Check out some examples here: AGV

OMNI-E – AGV
15 t – 6,200 x 3,400 mm

Main features:
Capacity: 15 t (up to over 1,000 tons)
Steering: omnidirectional
Lifting loading bed: yes (range 200 mm)
Power: lithium battery (others on request)
Traction motors: AC
Steering motors: AC
Size: 6,200 x 3,400 mm
Battery range: 4 km
Battery charge: automatic with trickle charging
AGV technology: laser guidance (LGV)
Communication: WiFi
Command: customer warehouse management system (WMS)
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)

Morello, always in the vanguard of electric vehicle design, has manufactured 2 battery powered electric SPMTs for a major Indian multinational

 

Battery powered electric SPMTs are in growing demand by companies the world over who want to be able to move very large and heavy materials in an eco-friendly and cost-efficient manner. Electric batteries and full electric power render these modular SPMTs ideal for use both indoors and out, guaranteeing total flexibility. Aside from being non-polluting, battery powered electric SPMTs with electric motors are also extremely quiet and, above all, clean. Standard modular SPMTs today are manufactured with multiple hydraulic motors and hydrostatic transmissions. This complex hydraulic system is always the source of oil leaks around the plant, in addition to demanding constant, complicated maintenance.

The economic aspect also plays a role to carefully consider in the selection of these SMPTs. The electric motors are in fact much more efficient than their hydraulic counterparts, and therefore reduce power requirements. The cost of electricity is also much less than that of diesel. These factors make battery powered electric SPMTs more economical in the midterm than conventional SPMTs with diesel power and hydraulic motors.

Morello designs battery powered electric self-propelled modular transporters based on customer requirements. We are thus able to manufacture our SPMTs customizing them with the features required by the customer’s load. We can customize capacity, loading bed dimensions, speed, battery life, wheel type and many others. Our attention to the customer and their needs is without doubt the most important feature of our battery powered electric SPMTs.
Contact us for a free consultation where we can discuss your needs. Morello sells its battery powered electric SPMTs the world over!
Here you can find some of our products: Battery powered transporters

OMNI-E-M DP
25 t – 5,000 x 2,900 mm

Main features:
Capacity: 25 t (up to over 1,000 tons on request)
Steering: omnidirectional
Power: battery
Traction motors: brushless AC
Steering motors: brushless AC
Size: 5,000 x 2,900 mm (other dimensions on request)
Speed: 20 m/min
Battery range: 5 km
Control: radio control
AGV: on request
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)