Lagor Srl

Lagor Srl is an Italian pioneer in transformer core production, with decades of expertise in handling extremely heavy steel assemblies.

Following a factory expansion, the company needed to rethink its internal logistics. Specifically how to move transformer cores weighing up to 200 tons without production delays or weather risks.

Impact

Heavy cores are now moved safely and reliably. No longer once a week, but every day.

All assembly now takes place indoors, regardless of external conditions.

No structural building changes were needed, thanks to the flexible air caster setup.

Fewer people are required to move even the heaviest units, reducing risk and physical strain.

The challenge

As Lagor Srl scaled up its transformer core production, the internal logistics system reached its limits. With cores weighing up to 200 tons, traditional transport options—like overhead cranes or rails—lacked the flexibility to navigate the evolving factory layout.

Outdoor assembly became increasingly impractical due to rust risk: just a few minutes of unexpected rain could delay entire projects. Cranes worked for small components, but not for massive units. The team needed a solution that could scale with core sizes, reduce weather dependency, and operate safely without a complete redesign of their facility.

“Because of the logistical improvement with help of our air caster systems, we can now offer a better service for our customers and grow further as a company.”

Mauro Ivaldi – Technical R&D Manager

Our approach

We designed a custom Air caster system tailored to Lagor’s complex workflow. For heavy transformer cores, cranes were replaced by Air caster transporters that effortlessly moved up to 200 tons indoors.

We provided on-site training to Lagor’s operators, ensuring safe and confident handling from day one.
The Air caster systems were implemented within days—no changes to the building were required.
The technology eliminated the need for rail or crane infrastructure and enabled omnidirectional movement in tight spaces.
Lagor’s team was also trained to perform basic maintenance independently, increasing their operational self-reliance.

The result

Lagor Srl’s production floor was transformed. Internal logistics became flexible, daily operations smoother and delivery timelines more predictable. With indoor assembly now standard, downtime caused by weather was eliminated.

The ability to move cores daily—rather than weekly—meant Lagor could offer faster service and better planning to customers. Operator safety improved thanks to intuitive controls and less manual labor. And although spare parts were stocked, the air casters required virtually no replacements.

With this solution, Lagor not only solved a complex logistical problem. They strengthened their reputation for precision, flexibility and customer reliability.