Ganz Transformers is a Hungarian manufacturer with a rich history in electrical engineering. They are known for designing and producing large power transformers.
Their facility handles daily movement of transformers weighing up to 400 tons. When their outdated internal transport system started causing downtime and safety risks, they needed a smarter, more reliable solution.
Thanks to the new control system, a single operator can now move 400-ton transformers precisely and safely.
Automation removed the risk of manual errors and improved safety across the production process.
New air casters with protective coating extend lifespan significantly, even in demanding conditions.
The retrofit eliminated recurring disruptions, improving both productivity and operator satisfaction.
Ganz’s legacy transport system relied on manual handling and deteriorated air casters—industrial “balloons” that could no longer keep up with production demands. Pressure had to be regulated manually, which introduced human error and caused regular downtime. The system no longer met modern safety standards, and a full replacement would have been too disruptive. Ganz needed a reliable retrofit that preserved the core process while eliminating risk and inefficiency.
Aerofilm Systems offered a tailored retrofit approach: a new, intuitive control unit and upgraded air casters formed the backbone of the solution.
The new control system allowed one-person operation with precise regulation, removing the need for manual adjustments. Custom air casters were developed with a special protective layer to resist the aggressive transformer oil used by Ganz—solving a recurring durability issue.
The project was delivered in close collaboration with the Ganz team, ensuring a perfect fit with their workflow and safety requirements.
“We were looking for a solution to the many problems with manual handling, manual pressure regulation and poor quality balloons.”
The modernized air caster system transformed Ganz’s internal logistics. Heavy transformers can now be moved daily with ease, precision, and complete control—by just one person.
The oil-resistant air casters drastically reduce wear and tear, lowering maintenance costs and future-proofing the system. For Ganz, the solution was not just an upgrade—it was a strategic investment in long-term operational excellence.
The full case study includes more figures, project timeline and operator feedback.
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