Overhead EMS, Light Rails, Conveyors & Transfer Carts

Material Handling & Logistics

Nextech manufactures turnkey material handling ecosystems: Electric Monorail Systems (EMS), EEPOS modular aluminum crane tracks, powered roller conveyors, and 40-ton automated transfer carts.

40 Ton

Max Cart Payload

50 m/min

EMS Rapid Travel

2,200mm

Low Headroom Profile

0 dB

Ultra-Quiet EEPOS

Division overview

Turnkey engineering & manufacturing

Synchronized shopfloor intralogistics that move heavy payloads smoothly between warehouse, machining bays, and final assembly lines.

Custom track layout simulations and load cycle throughput modeling
Pre-assembled modular rail sections for rapid weekend plant installations
Integrated anti-collision wireless sensors and emergency drop brake mechanisms

Engineered systems

Specialized equipment & sub-systems catalog

Explore detailed technical capabilities, cycle metrics, and specifications for each specialized sub-system within Material Handling.

Electric Monorail Systems (EMS)

Automated overhead rapid transfer systems for automotive chassis and engine transport

Rapid point-to-point overhead transfer linking storage bays directly to assembly stations while keeping the main floor completely unobstructed.

Travel Speed: Up to 50 m/min
Headroom: Fits 2,200 mm

Autonomous motorized trolleys traveling at speeds up to 50 m/min on suspended tracks
Engineered low-headroom clearance designed for plants with tight 2,200 mm clearances
Lifting capacities from 1 Ton to 2 Ton with fail-safe mechanical brake locks
Wireless optical collision avoidance sensors and multi-station indexing control

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EEPOS Light Crane Rails (XY Tracks)

Ergonomic modular anodized aluminum ceiling-hung crane systems

Allows operators to manually float and position tools, hoists, and heavy workpieces across entire workstations with near-zero friction.

Effort Reduction: 90% Less Push Force
Profile: Modular Anodized Al

Extruded anodized aluminum profiles providing smooth, ultra-low rolling resistance
Modular XY bridge layouts covering entire assembly cells without floor support posts
Integrated busbar power conductor lines and articulated pneumatic spiral hoses
High strength-to-weight ratio; simple clamp mounting to existing roof trusses

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Assembly & Powered Conveyors

Heavy-duty roller, slat, modular belt, and accumulation conveyor lines

Provides continuous controlled transportation of engine blocks, axles, and pallets between manual workcells and robotic stations.

Standard Lengths: 2m / 2.5m / 3m Modules
Load Capacity: Up to 3,000 kg/m

Heavy-duty powered roller conveyors with zero-pressure accumulation zones
Heavy steel slat conveyors designed for harsh engine and transmission assembly
Variable Frequency Drive (VFD) speed regulation with reversible bi-directional travel
Pneumatic pop-up stops, transfer turntables, and cross-bay diverters

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Chassis & Cabin Transfer Systems

Automotive vehicle body indexing and inter-bay dollies

Synchronizes vehicle cabin and chassis movements between welding fixtures, paint prep bays, and final trim assembly lines.

Application: BIW Cabin & Chassis
Guidance: Mechanical & Optical

Heavy-duty structural guided carriages with dual polyurethane drive wheels
Automatic optical line tracking and RFID station recognition
Pneumatic mechanical latching securing vehicle sub-frames during transit
Integrated emergency bump bars and 360-degree safety scanner beacons

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Flow Racks & Logistics Trolleys

Custom line-side FIFO gravity flow racks and kitting tugger carts

Organizes parts presentation at assembly workstations, streamlining line feeding and eliminating part searching.

Principle: Lean FIFO Kitting
Mobility: Tugger Train Ready

First-In, First-Out (FIFO) gravity roller tracks with adjustable guide lanes
Heavy-duty towable kitting trolleys with central directional steering casters
Laser-cut custom protective foam dunnage safeguarding Class-A painted surfaces
Ergonomic hand-brake releases and quick-link train hitch couplers

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Performance & compliance specifications

Material Handling technical matrix

Parameter	Engineered capability	Compliance / standard
Maximum Single Load	Up to 40 Metric Tons on custom transfer carts	IS 807 / FEM 1.001
EMS Maximum Speed	50 m/min with frequency-inverter smooth acceleration	DIN 15018
Track Profiles	EEPOS Anodized Aluminum profiles & Heavy I-Beam Steel	EN 13155
Control Protocols	Optical barcode positional guidance & RFID tag tracking	PROFINET / Safety
Safety Systems	360° LiDAR area scanners & mechanical fail-safe drop locks	EN ISO 3691-4

Execution methodology

Material Handling project lifecycle

Every custom automated machine and material handling line follows our 4-stage engineering lifecycle to ensure zero downtime and seamless plant handover.

01
Concept & 3D CAD Simulation
Translating client takt times, payload limits, and footprint constraints into full parametric models using SolidWorks and CATIA before cutting steel.
- Cycle time study
- 3D kinematic simulation
- Footprint GA drawing
02
In-House Machining & Fabrication
Precision CNC machining on VMCs, heavy plate cutting, and certified structural MIG/TIG welding at our Bagroda and Pithampur facilities.
- CNC milled tooling
- Stress-relieved weldments
- Ultrasonic NDT inspection
03
Electrical Automation & PLC Logic
In-house panel engineering, servo drive integration, safety interlock programming, and HMI design on Siemens, Allen-Bradley, and Mitsubishi platforms.
- E-Plan schematics
- PLC & Safety ladder logic
- MES SCADA integration
04
Factory FAT & Site Commissioning
Rigorous Factory Acceptance Testing (FAT) with actual prototype parts, followed by turn-key installation, ramp-up support, and team training.
- 100% FAT sign-off
- On-site installation
- O&M documentation

Explore other engineering disciplines

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Turnkey engineering RFQ

Have a custom material handling project requirement?

Share your layout drawings, cycle time constraints, or component specifications. Our senior engineering team will evaluate technical feasibility and return a detailed concept proposal.

Request technical RFQ Contact engineering team

Material Handling & Logistics

Turnkey engineering & manufacturing

Specialized equipment & sub-systems catalog

Electric Monorail Systems (EMS)

EEPOS Light Crane Rails (XY Tracks)

Assembly & Powered Conveyors

Chassis & Cabin Transfer Systems

Flow Racks & Logistics Trolleys

Material Handling technical matrix

Material Handling project lifecycle

Concept & 3D CAD Simulation

In-House Machining & Fabrication

Electrical Automation & PLC Logic

Factory FAT & Site Commissioning

Explore other engineering disciplines

Industrial Automation & SPMs

Lifting Solutions & Industrial Cranes

Battery Assembly Automation

Welding and Heavy Fabrication

Have a custom material handling project requirement?