Overhead and Gantry Cranes for Solar PV Module Industry
Choosing the Right Crane (0.5–20 Tons) for Safe, Efficient Module Handling

Capacity: 5–20 tons

Best For: Heavy stacks of modules, laminators, and large PV production equipment

Double girder overhead cranes are more robust and widely used in full-scale PV module production. The dual-girder design allows for longer spans and higher lifting capacities. They are perfect when you need to handle heavier modules or lift multiple items at once using a dual-trolley setup.

Advantages:

• Greater stability and longer spans – can cover large factory areas.
• Supports dual-trolley operation – allows two lifts at the same time.
• Smooth operation – wire rope hoists reduce sway and give precise control.
• Better for heavier production equipment – like laminators and automated stacking systems.

Considerations:

• Higher upfront cost compared to single girder cranes.
• Requires a robust building structure or runway support.
• Slightly more complex installation and maintenance.

When handling solar modules, safety and precision are just as important as lifting capacity. Certain crane features can make a huge difference in avoiding module damage and improving workflow.

Key Features to Consider:

• Anti-sway hoists – reduce swinging during lifting and placement.
• Soft load handling – prevents cracking or scratching on glass and thin-film modules.
• Adjustable lifting speeds – allow for precise module placement, especially on assembly lines.
• Custom spreader bars or vacuum lifters – useful when lifting multiple stacked modules at once without risk.

These features are particularly valuable in modern PV factories, where module sizes and formats vary, and efficiency is closely linked to careful material handling.

Capacity: 2–10 tons

Best For: Medium-weight loads in limited spaces, indoor or outdoor use

Semi-gantry cranes are a hybrid solution. One side of the crane runs on a rail, while the other is supported by a leg. This design reduces the need for a full outdoor rail system while still providing lifting capability for medium loads. They're flexible enough for growing PV factories or areas where space is partially constrained.

Advantages:

• Cost-effective alternative to full gantry cranes.
• Flexible layout options – works well in both indoor and outdoor areas.
• Adaptable – can be installed incrementally as production expands.

Considerations:

• Span is limited compared to full gantry cranes.
• Lifting capacity is moderate; may not suit heavy stack handling.
• Requires some floor or partial runway support.

Capacity: 0.5–5 tons

Best For: Small workshops, maintenance tasks, or flexible layouts

Portable or mobile gantry cranes are lightweight and can be moved between workstations or locations as needed. They're ideal for small-scale PV module assembly, repair tasks, or temporary installation sites. Because of their mobility, they provide quick solutions for changing production needs without requiring permanent infrastructure.

Advantages:

• Easily movable between different areas of the facility.
• Low cost and flexible – ideal for small-scale production.
• Quick setup – doesn't require permanent rails or building modifications.

Considerations:

• Limited lifting capacity and height.
• Less precise than fixed gantry cranes for repeated operations.
• Best suited for lighter loads and short-term use.

Your facility layout and workflow determine the crane type. Indoor assembly lines usually use overhead cranes, while outdoor yards or flexible areas often require gantry cranes.

Key Points:

• Map your material flow from raw materials to finished modules.
• Identify locations where fixed path lifting or mobile lifting is needed.
• Consider combining crane types for mixed indoor and outdoor operations.
• Make sure crane span and height match your floor layout and storage racks.

Not all PV modules are equal in strength. Frequent handling of fragile modules requires precise, controlled lifting to avoid damage.

Key Points:

• Use anti-sway hoists to stabilize delicate modules.
• For repeated lifts, electric wire rope hoists are preferable for smooth operation.
• Plan maintenance schedules to avoid downtime during peak production.
• Check for variable speed controls to adjust lifting speed as needed.

Solar PV facilities often grow over time. Cranes should be selected not just for today's requirements, but also for future production lines or heavier equipment.

Key Points:

• Choose cranes that allow capacity upgrades or modular expansions.
• Consider flexible designs that adapt to changing layouts or new assembly lines.
• Ensure runway systems or foundations can handle heavier loads in the future.

Safety is critical for PV module handling. Modules are expensive and fragile, and workers need protection from accidents.

Must-Have Safety Features:

• Anti-sway systems – prevent swinging during lifts.
• Spreader bars – evenly distribute weight on stacked modules.
• Vacuum lifters – lift glass modules without scratching or pressure points.
• Emergency stop functions and limit switches for height and travel.

The crane supplier's experience in the solar PV industry is just as important as the equipment itself. Experienced suppliers understand module handling, production flow, and required features.

Key Points:

• Request references or case studies from PV module factories.
• Confirm warranty, spare parts availability, and maintenance support.
• Ensure the supplier can provide custom solutions for unique module sizes or lifting requirements.

A well-chosen crane ensures your PV modules are handled safely, efficiently, and with minimal risk of damage. Matching the crane's type, capacity, and features to your workflow, module sizes, and future growth makes day-to-day operations smoother and reduces long-term costs.

The hoist is the heart of any crane. For PV modules, precision and smooth operation are crucial to prevent damage.

Key Points:

• Prefer electric wire rope hoists for smooth, controlled lifts.
• Check for variable speed controls for accurate placement.
• Ensure the hoist can handle frequent lifting cycles without excessive wear.
• Confirm reliability with manufacturer certifications and test reports.

Even the best crane won't help if it doesn't fit your facility or is too costly to maintain. Consider both current and future needs.

Key Points:

• Review installation requirements, including runway supports or foundations.
• Estimate ongoing maintenance costs and availability of spare parts.
• Check space constraints: ceiling height, aisle width, and floor load limits.
• Consider the impact on workflow and storage layout.

Not every PV facility has standard-sized modules or linear workflows. Custom solutions can maximize efficiency and safety.

Key Points:

• Ask for special spreader bars, vacuum lifters, or adjustable hooks.
• Consider dual-trolley or modular designs for unusual layouts.
• Verify the crane can handle stacked or oversized modules safely.

Modern PV facilities benefit from cranes that are not just functional, but also efficient and quiet, improving working conditions and reducing operational costs.

Key Points:

• Look for energy-efficient motors that lower electricity costs.
• Choose low-noise systems for indoor production areas.
• Check durability and expected lifespan—long-term reliability saves money.
• Factor in environmental exposure if cranes are used outdoors.

For PV module buyers, it's not just about the crane's capacity—it's about supplier experience, hoist precision, facility fit, customization, and efficiency. Following these practical tips helps ensure your crane investment delivers safe, reliable, and long-term performance.

A: PV modules are usually fragile and vary in size, so lifting capacity must account for module weight plus stacking:

• Small modules or single-panel lifts: 0.5–5 tons (portable or single girder cranes).
• Medium-sized modules or stacked bundles: 2–10 tons (semi-gantry or single girder cranes).
• Large modules, laminators, or heavy production equipment: 5–20 tons (double girder or full gantry cranes).

Tip: Always include a 20–30% safety margin on top of the maximum expected load for stacked modules.

A: The right crane depends on where modules are handled and how often:

• Indoor assembly lines: Overhead cranes (single or double girder) provide precise, controlled lifting along fixed paths.
• Outdoor yards or flexible areas: Gantry cranes (full, semi, or portable) allow wide coverage without relying on building support.
• Mixed indoor and outdoor workflows: Use a combination of overhead and gantry cranes for efficiency.

Other factors to consider:

• Frequency of lifting
• Fragility of modules
• Space constraints and building height
• Potential future expansion or layout changes

A: Handling PV modules safely requires more than lifting capacity:

• Anti-sway hoists: Reduce module swinging during lifts.
• Soft load handling: Prevents cracks or scratches on glass and thin-film modules.
• Adjustable lifting speeds: Helps precise placement in assembly lines.
• Spreader bars or vacuum lifters: Distribute weight evenly and handle stacked modules safely.
• Limit switches and emergency stop functions: Provide extra safety for operators and modules.

Tip: Work with suppliers experienced in the PV module industry—they can recommend the right attachments for your workflow.