ZOOMRY
Heavy truck unloading methods can be divided into three categories: manual unloading, self-dumping, and unloading via mobile truck unloader. Manual unloading relies on workers using tools like shovels or grabs to manually move materials. Its advantages include lower short-term investment costs and flexibility for handling special cargo (e.g., oversized or sensitive materials). However, its drawbacks are significant: unloading a 40-ton truck requires 6-8 workers and over 2 hours, with labor costs as high as $15-20/ton (per OSHA statistics). Additionally, dust exposure increases workers’ respiratory disease risks by 12%, and collapse-related injury rates exceed 8%. This method is only recommended for small sites with daily handling <200 tons or temporary emergencies.
Self-dumping trucks rely on hydraulic systems to lift the cargo bed and unload via gravity. While they reduce manual labor, their inefficiencies include 15-30 minutes per unloading cycle, repeated vehicle repositioning, and 5%-10% material residue due to insufficient cargo bed tilt angles (typically <55°), leading to wasted resources and added labor costs.
Mobile truck unloaders revolutionize workflows by integrating a belt conveyor system: Trucks park at fixed positions, and materials are dumped onto the conveyor platform via self-dumping or mechanical assistance. High-speed belts (0.8-3.15 m/s) then transport materials directly to storage yards or downstream equipment without manual intervention. Key advantages include zero human intervention, 8-12-minute unloading cycles, and near-zero safety risks. Compared to self-dumping trucks, mobile truck unloaders reduce unloading time by 67% (300% efficiency gain), eliminate repositioning needs, and avoid hydraulic system wear, cutting annual maintenance costs by 40%-50% while extending equipment lifespan by 3-5 years.
| Metric | Manual Unloading | Self-Dumping Trucks | Mobile Truck Unloader |
|---|---|---|---|
| Unloading Time (40 tons) | 2 hours | 15-30 minutes | 8-12 minutes |
| Labor Required | 6-8 workers | 1-2 operators | 0-1 operator (fully automated) |
| Operational Constraints | Materials confined to truck vicinity | Requires repeated repositioning | Fixed-position omnidirectional unloading |
| Safety Risks | High (collapse, injuries) | Moderate (tipping, hydraulic failures) | Near-zero risks |
What Is a Mobile Truck Unloader?
Zoomry’s mobile truck unloader is an integrated bulk material transfer system. Its core function is to receive materials directly from trucks via Conveyor Belts and transport them to storage or downstream processes without requiring vehicle movement. Deployed at fixed unloading zones, the system uses self-dumping mechanisms (e.g., tipping beds or bottom gates) to deposit materials like coal or ore onto a conveyor platform. The enclosed belt (1.2-1.8m width, 0.8-3.15m/s speed) then transports materials continuously, with direction adjustable via telescopic stackers (up to 30m reach) to cover multiple storage areas.
Key components include a crawler/wheeled chassis (±90° steering flexibility), 5-10m³ hopper, high-speed conveyor, and intelligent positioning systems. During operation, trucks park in designated areas and dump materials into the hopper, which feeds the conveyor. Frequency-converted speed regulation adapts to material flow rates, maintaining dust leakage below 0.1%. Unloading cycles are compressed to 8-12 minutes, achieving dual breakthroughs in efficiency and safety.
Core Models & Specifications
| Model | ZRLS-TU1400 | ZRLS-TU1800 | ZRLD-TU1800 (Crawler) |
|---|---|---|---|
| Belt Width | 1400mm | 1800mm | 1800mm |
| Capacity | 200-1000 t/h | 600-1800 t/h | 200-1800 t/h |
| Truck Ramps | 2/4 lanes | 4 hydraulic lanes | 2 manual/hydraulic lanes |
| Power System | 2×22kW electric | Hybrid electric/diesel | Full electric + wireless control |
| Conveying Height | 6.3m | 6.3m | 6.3m |
| Applications | Ports, granaries | Mines, steel mills | Rough terrain, steep slopes |
For inquiries about using mobile truck unloaders to unload heavy trucks, visit: What does a truck unloader do or contact us:
- Zoomry Official Website
- +86 131-6401-6717
- oversea@zoomry.cn
Core Advantages of Mobile Truck Unloaders
Efficiency Boost
Mobile truck unloaders streamline workflows through fully automated conveyor systems. After trucks park, materials are dumped onto the conveyor platform, and high-speed belts (3.15 m/s) with telescopic stackers enable continuous transport, eliminating vehicle repositioning and manual handling.
South Africa’s Durban Port deployment of the ZRLS-TU1800 increased daily coal throughput from 12,000 to 36,000 tons (200% efficiency gain) while cutting labor costs by 70%, saving over $2 million annually. Australian iron ore mine applications reduced 40-ton truck unloading time from 25 to 10 minutes and daily cycles from 20 to 50.
| Metric | Manual Unloading | Self-Dumping Trucks | Mobile Truck Unloader |
|---|---|---|---|
| Unloading Time (40 tons) | 120 minutes | 25 minutes | 10 minutes |
| Daily Cycles | 4 cycles | 20 cycles | 50 cycles |
| Workflow | Manual labor | Repositioning required | Fixed-position automation |
Safety Assurance
Mobile truck unloaders eliminate tipping risks associated with self-dumping trucks. Their intelligent monitoring system uses tilt sensors and pressure feedback to detect material blockages, uneven loads, or terrain instability (>5° slope), triggering automatic shutdowns. With redundant hydraulic brakes, failure rates are <0.5 incidents/1,000 hours—98% lower than traditional methods.
Eco-Friendly Operation
A fully enclosed conveyor and pulse dust removal system maintain PM2.5 levels below 5mg/m³ (meeting EU CE standards). Precision scrapers (±0.1mm clearance) and V-shaped idlers reduce material residue to <2% and extend belt life by 30%, ensuring compliance with global environmental regulations.
Operational Flexibility
Crawler-type units (25° slope capability) handle rugged mining terrain, while wheeled versions (6m turning radius) maneuver in tight port spaces. Modular interfaces connect to telescopic stackers (18m height/50m range) or mobile ship loaders(4,000 t/h), enabling end-to-end automation from unloading to storage or vessel loading.
Why Choose Zoomry?
- Extended Lifespan: Critical components (e.g., rollers, idlers) use wear-resistant alloy steel, lasting 150,000 hours—2.3× industry average—reducing lifecycle costs by 35%.
- Rapid Delivery: Modular design and digital factories enable 1-2-month standard delivery, with emergency orders shipped globally in 30 days (60% faster than competitors).
- Custom Solutions: Pre-sales 3D simulations and efficiency forecasts tailor equipment parameters to material properties (e.g., coal angle of repose, grain moisture), ensuring <5% capacity deviation.
- Global Support: 24/7 multilingual tech support (English/Spanish/French/Russian/etc.), 95% spare parts stocked locally overseas, and <48-hour fault response time (72% faster than peers).
- Patented Tech: 100+ patents (including adaptive speed control and dust suppression) deliver 40%-60% higher efficiency.
- Certification Training: Zoomry ACCP certification covers intelligent controls and fault diagnostics, enabling teams to master operations within 3 weeks.
Case Study
Malaysia’s Lumut Port, a global hub for palm kernel (PKS) exports, faced chronic inefficiencies and severe dust pollution due to outdated wheeled unloading equipment. Its original ship loader, with a maximum boom length of 42 meters, could not reach deep cargo holds of 50,000-ton vessels, resulting in berthing delays exceeding 36 hours per ship and an annual material loss rate of 1.2%, amounting to over $3 million in direct losses. Port General Manager Hassan worked amidst swirling palm debris until Zoomry Heavy Industry transformed operations with four crawler-type mobile truck unloaders and a 52-meter-boom mobile ship loader.
The solution centered on a fully enclosed conveyor system: 1400mm-wide belts combined with magnetic seals reduced PKS dust leakage to 0.03% throughout the unloading, conveying, and loading processes. The crawler-type unloaders enabled bidirectional four-lane operations through automatic lane-switching technology, cutting truck dwell time by 70%. Equipped with independent power generators, the system maintained 48-hour uninterrupted operation during outages and demonstrated stormproof stability even in typhoon conditions.
When the "Emerald Princess" returned, the telescopic ship loader’s chute extended 52 meters into the vessel’s deepest holds, slashing loading time from 36 to 12 hours—a 200% efficiency improvement. Post-upgrade metrics include daily throughput surging to 36,000 tons (annual capacity surpassing 10 million tons), material loss rate plummeting from 1.2% to 0.03% (saving $2.8 million/year), and dust control achieving EU CE certification, establishing Lumut as Southeast Asia’s first ISCC-certified sustainable palm port.
Featured on The Star’s front page under the headline "The Smart Port Era Begins," the project received special recognition from the Prime Minister’s Office. Today, Lumut’s crawler unloaders—with three times the slope grip of wheeled equipment—operate relentlessly through monsoons, enabling Hassan’s "365-day uptime" pledge. Replicated at Indonesia’s Tanjung Priok Port, Zoomry’s innovation continues to redefine global palm logistics as Lumut’s steel giants carve automated port futures where starlight meets storm surges.
