A long-time client in the conveyor belt services industry approached I&M Solutions with a clear request: build a small but powerful winch that one person could control with ease. Their existing equipment was bulky, inefficient and required two operators, which drove up labour costs and slowed down routine maintenance.
Our solution? A fully customised 3-tonne electric winch with a compact footprint, intuitive controls and a built-in clutch mechanism that slashed operating time and manpower.
Project Snapshot
- Industry: Conveyor Belt Maintenance / Bulk Materials Handling.
- Project: 3-Tonne Electric Winch.
- Key Features: Compact design, 200m rope capacity, clutch for single-operator use.
- Result: Faster wire payout, reduced labour, increased operational efficiency.
The challenge
The client needed a purpose-built electric winch for belt lapping and splicing tasks in tight spaces—something portable, powerful and easy for one technician to operate.
Their current winches were oversized and underwhelming, requiring two people just to manage basic rope payout. This slowed down maintenance and added unnecessary cost.
They turned to I&M Solutions for a smarter, more efficient solution—one that could meet their operational needs without compromising power or control.
The solution
I&M Solutions designed and fabricated a fully custom 3-tonne electric winch built around three critical client requirements: compactness, precise control and true single-person operation.
The team engineered a solution that would streamline belt maintenance workflows without sacrificing performance or safety. Key specifications included:
- Compact footprint (~1.1m x 800mm): Designed to fit tight workspaces and simplify transport, the compact chassis allowed for flexible deployment in the field without sacrificing pulling power or rope capacity.
- Right-angle gearbox configuration: To keep the unit compact while still accommodating a 200m rope drum and electric motor, I&M sourced a custom right-angle gearbox. This critical design choice made the entire build possible without increasing the frame size.
- 200-metre wire rope capacity: The system was engineered to support extended operations without the need for constant re-rigging. This enabled longer, uninterrupted pulls during splicing work.
- Variable speed electric drive: Delivered precise control over line tension and speed, giving operators the ability to fine-tune movements depending on the task and environment.
- Mechanical clutch mechanism: A standout feature, the clutch allowed one operator to manually walk out the rope with minimal resistance. This removed the need for a second operator during payout, cutting labour demands in half.
I&M’s engineering and production teams handled all design, fabrication and assembly work in-house. This ensured complete oversight on quality, performance and delivery timelines.
Project delivery & execution
The biggest engineering challenge was identifying a gearbox that could deliver the required torque and speed while fitting into the client’s tight dimensional brief. After extensive sourcing, we integrated a right-angle gearbox that met both mechanical and spatial requirements.
The project timeline from initial brief to delivery was approximately four months, with I&M managing every phase internally to control lead times and ensure quality.
No additional services were required for commissioning or training—the system was designed to be intuitive, low-maintenance, and immediately usable.
Results & outcomes
The winch delivered measurable improvements from day one, solving key operational challenges and streamlining the client’s maintenance workflow.
- Labour reduced from two operators to one, thanks to the manual clutch system that allowed easy rope payout without needing a second person on standby.
- Faster, more controlled rope payout, enabling quicker setup and reduced downtime during belt maintenance operations.
- Smoother, more efficient lapping and splicing, with improved operator control and fewer handling issues.
- Lower operating costs through decreased manpower requirements and reduced time spent on each job site.
The results spoke for themselves, with the client placing two additional orders for the same winch shortly after delivery—a strong endorsement of the value, performance, and fit-for-purpose design I&M delivered.
Why it matters
This project showcases I&M Solutions’ ability to respond to specific, niche operational challenges with tailored equipment.
By delivering a compact, high-performing winch system that integrated advanced features like a mechanical clutch and variable speed control, we helped the client achieve safer, faster, and more cost-effective conveyor belt maintenance.
It’s another example of how smart design and in-house engineering can transform everyday operations. Moreover, it shows why businesses in mining, bulk handling and industrial maintenance continue to trust I&M Solutions with their most demanding equipment needs. If you, too, require a custom-engineered solution, contact I&M Solutions today to discuss how we can design equipment tailored to your exact requirements.