The rise of digitalisation is everywhere, in every industry, and the hoist industry is no exception. Traditionally, the lifting industry has relied on mechanical designs that often relied on human input, but over time this has developed with electric and hydraulic hoists introducing new levels of efficacy and safety. Digitalisation is the next leap forward, turning hoists into intelligent lifting machines that are capable of collecting data, adapting and operating with minimal human intervention.
From artificial intelligence, real-time monitoring to automation and remote-control system, the integration of smart technologies is changing the hoist industry for the better. “Digitalisation has progressively increased within the hoist industry as emerging technologies continue to evolve,” explains Marc Premont, chief product officer for Kito Crosby. “The incorporation of Variable Frequency Drives (VFDs) into powered hoists marked a significant milestone, transforming hoists into intelligent machines capable of managing specific operational functions and providing user feedback. Subsequently, advancements in VFD technology have enabled manufacturers to implement enhanced features such as improved power management and connectivity.”
As digitalisation in the hoist industry has advanced, the integration of Industry 4.0 technologies have enabled networked systems and AI-driven automation, and the subsequent development of intelligent software, predictive maintenance and the creation of digital inspection and maintenance tools. “Digitalisation is transforming the lifting industry, reshaping the way we approach safety, efficiency and compliance,” explains Leanne Whitehurst-Maiden, national digitalisation manager at RSS.
Across the industry, there are several projects and product that showcase the impact of digitalisation strategies. This ranges from sensorenabled hoists that continuously monitor loads, usage and component wear, such as the integrated sensors in Demag’s DCBS chain hoist, which automatically pre-tensions suspended load in load pick-up mode to then lift it.
In other areas of the industry, companies are using remote connectivity to allow workers to oversee lifting operations from a control room, across multiple sites, for example, Konecranes’ TRUCONNECT Remote Monitoring. Incorporating predictive maintenance, it collects the condition, usage and operating data from sensors on a crane that can be used with inspection and maintenance information to provide a full overview of an equipment’s maintenance requirements and performance. With 24/7 access across the globe to experts, the TRUCONNECT’s Remote Support offering also enables troubleshoot support to reduce downtime and corrections.
Staying compliant
Another emerging strategy is the consolidation of digital services under one single user interface, uniting compliance and inspection tools into one platform, simplifying the customer experience while expanding the scope of digital solutions available. And at RSS, explains Whitehurst-Maiden, this is at the heart of its strategy. “Our live365 platform brings together all of our digital initiatives, standing as a cornerstone of our current offering.”
The platform integrates digital inspection services with data analysis software to examine safety trends, demonstrating the importance of maintaining and accessing safety documents, while also helping companies with equipment compliance and maintenance. According to RSS, access to critical safety documentation is essential to ensuring regulation compliance. The platform prioritises this, while also making sure its customers can access their certification at any time and in any place through the digitalisation of lifting equipment inspections. Through the platforms data analysis, it offers important insight into safety data trends to prevent potential accidents before they happen, as well as providing patterns of misuse and potential training faults by analysing failure rates across sites.
Another element of RSS’s live365 is its Pre-Use Check App, which enables on-site personnel to access inspection data and record pre-use check via an app, dubbing it the first line of defence in accident prevention. The checks allow for visibility that correct any procedures being followed and provide evidence to companies of compliance. The platform also offers a range of RFID tags depending on the application and equipment as well as near field communication (NFC) enabled RFID tags, offering increased precision in identifying equipment when recording preuse checks.
“Looking ahead, we’re expanding our compliance services, with the ambition of uniting them under a single user interface. We’re also exploring collaborations that will broaden the scope of features we can deliver, offering customers an even wider range of digital tools.”
As digitalisation strategies and technologies become the norm, the hoist industry is undoubtedly moving towards greater levels of intelligence, connectivity and safety. One development generating particular excitement is the rise of digital twins, a virtual, real-time model of hoisting equipment and process that can be used for simulation, predictive maintenance and optimising performance. These systems enable enhanced safety, operational efficiency by allowing for simulation of complex scenarios to aide training and offer predictive analytics for risks such as equipment failure or damage, reducing downtime and improving decision-making for operators. Operators can predict performance, test upgrades and schedule maintenance with better accuracy by mirroring real-word hoist and lifting equipment. It’s clear that the growing role of technologies such as artificial intelligence and digital twins is transformative, offering insight and optimising processes across the sector, paving the way for a smarter and more connected industry.
Another method to overseeing lifting equipment is RFID tagging. These digital chips or SupraTags provide product traceability, inspection history, usage data – all of which can be accessed instantly. “Making use of digitalisation technologies like RFID (which is within the SupraTag) to digitalise inspection management systems and efficiently manage inventory is becoming important,” explains Amie Read, marketing executive at Tiger Lifting, a distributor of YOKE digital products and part of the RiConnect network that provides products with RFID digital functionality. “Having safe use instructions, certification, inspection information and checklists available digitally helps companies manage their environmental impact and reduces time for equipment to be put into service making for more efficient operations.”
Platforms such as RiConnect maximise the utilisation of RFID and streamlines communication, Read explains. “Tiger products now come with either a suitable SupraTag or embedded digital chip. RiConnect is an asset management tool which is controlled through cloud-based software. RiConnect provides not just a solution for asset management but also a platform for efficient and accurate information transaction between different parties along the supply chain, including product manufacturers, asset owners and inspection service providers,” continues Read. “It helps to maximise the utilisation of assets and optimise asset maintenance and inspection plans, while fulfilling the needs of all the stakeholders in the process.”
At Kito Crosby, Premont explains, they have introduced a new electric balancer to integrate with a collaborative robot (cobot) for complex lifting tasks in manufacturing operations. “The hoist is responsible for lifting loads, while the cobot positions them accordingly. This combination can be used as an alternative to manual labour traditionally performed by multiple workers.” Cobots can be combined with external hoist solutions, like Kito’s electric balancer, to increase their lifting capacity and vertical reach. The combination of hoist and cobots also have a smaller footprint than traditional industrial robots and equipment, making them more flexible as well as safer for people to work alongside them in many cases.
Artificial intelligence is expected to play a transformative role across countless sectors, including hoisting. Cobots represent one area of promise, as Premont highlights: “Digital ecosystems are developing where hoists interact with both humans and machines. As cobots become more affordable, their functionality can be extended by integrating intelligent hoists, enabling them to work together to carry out complex lifting operations.”
The customer is always right
The industry-wide benefits of these technologies are undeniable, but the strongest driver behind digitalisation is customer demand. “More than ever, clients want the benefits that digitalisation brings – whether it’s analysing failure rates to prevent potential accidents, comparing product lifespans to reduce costs or ensuring sustainability across projects. Just as importantly, digitalisation ensures that site personnel can access critical safety documentation anytime, anywhere,” explains Whitehurst-Maiden.
Premont agrees: “Customers consistently seek to advance safety, minimise operational costs and optimise the productivity of their hoist operations. The adoption of emerging hoist technologies – including artificial intelligence, real-time monitoring and automation – facilitates streamlined workflows, improved throughput and predictive maintenance capabilities.” Real-time, data-driven insights are also allowing operators to respond quickly to lifting anomalies, allocate resources more efficiently and make better strategic decisions.
Sustainability is another major benefit. “Quality, reliability and serviceability of products, increasing product life cycles, is essential. Emerging technologies help efficiency, safety and cost by eliminating paperwork,” adds Read. Tiger Lifting echoes this perspective: “At Tiger lifting, we think that anything that helps the many parties in the lifting equipment supply chain become more sustainable and efficient is a really positive step. The SupraTag is highly corrosion and impact resistant and when it (or other embedded RFID chips) are linked with the RiConnect system, digitalised product information relating to usability and traceability of a product is readily accessible.”
The rise of digitalisation is not without challenges, however. “Working with our distributors and end users, and assisting them with adopting digital passports and relevant data is a huge challenge for all involved. But, as the original equipment manufacturer, we see our role as leading the transition. Change is never easy, but our commitment to the longterm benefits for all is something we feel very strongly about,” says Read.
Others point to integration and platform complexity. “While challenges remain – particularly in the seamless integration of data – the appetite for solutions is clear,” explains Whitehurst-Maiden. Premont adds: “Given the abundance of available options, selecting the optimal platform will be challenging. Customers will grant access to their digital ecosystems only to brands they trust. While the value proposition is sometimes evident, some customers face difficulties in effectively leveraging emerging technologies to achieve measurable benefits.”
Another challenge to implementing digital strategies and technology is initial high costs and significant investment in infrastructure, hardware and software. Not to mention retrofitting can be a complex and expensive task. There is also a skill gap while the industry catches up in training workers to manage and operate new systems. Cybersecurity also presents a significant threat to the integration of smart technologies, as they can cause significant disruption to operations, compromise data and cause financial loss. To combat this, companies and manufacturers have to implement cybersecurity from the onset of the product or systems development. For instance, RSS is certified under Cyber Essentials, a UK government backed scheme that covers basic cybersecurity. Konecrane’s TRUCONNECT is also certified under ISO/IEC 27001:2022 as well as Cyber Essentials Plus for Konecranes Demag, covering Konecranes sites across the UK. The company is also certified under ISO/IEC 27001:2013 and ISO/IEC 62443.
It’s no surprise that equipment like manual chain hoists remain relevant despite the rise and impact of digitalisation on the industry. The cost-effectiveness, alongside the simplicity, reliability and independence from electric and digital solutions still make them both a sustainable and dependable choice for many.
Setting a new standard
Looking ahead, digitalisation is set to become the standard across the hoist industry. Greater adoption of AI-driven predictive maintenance, wider use of digital twins and deeper integration with Industry 4.0 ecosystems are expected to follow. As technologies mature, costs will fall, making smart hoists more accessible across industries. The result will be a new era of efficiency, safety and sustainability.
Read emphasises the role of continuous innovation: “To remain at the forefront, we’re committed to adapting our product range to meet new regulatory requirements while manufacturing a sustainable portfolio of lifting products. Our goal is to increase safety levels and value for money over extended life cycles, helping future generations to carry out lifting operations better than ever.”
For Whitehurst-Maiden, the real excitement lies in how manufacturers are embracing this shift: “Perhaps most exciting is the way manufacturers are embracing this digital shift. Their engagement opens the door to enhanced services and innovative possibilities across the industry.”
Premont sees an industry at the cusp of rapid change: “It’s an exciting time in our industry. Although the fundamental requirement to lift heavy objects safely and efficiently is expected to persist, methods and technologies in hoisting are rapidly evolving. By maintaining agility and attentiveness to customer requirements, we can remain leaders in a growing global hoist market regardless of future developments.”
The rising demand of digitalisation in the lifting industry is key in influencing what comes next, with greater demands for automation and more data available and visible to customers instigating new projects as well as retrofitting old ones.
Ultimately, the hoist industry is entering an era where intelligent solutions, smart data and advanced automation will not just lift loads, but raise industry standards to new heights.
