Overview
A standard VRC moves material vertically. But loading, unloading, and safety gate operation still require manual effort at each level — and integrating a standalone VRC into an existing conveyor system often means sourcing separate gates, conveyors, and controls from different suppliers. The FlexLoader eliminates this complexity by delivering a single, turnkey system where the VRC, conveyors, and safety gates are designed, manufactured, and controlled together.
The result is a safer, more efficient, and more automated material lifting operation that connects all facility levels with flush-mounted conveyors — making it easy to load and unload with a standard pallet jack or forklift while keeping personnel protected behind interlocked overhead safety gates.
How the FlexLoader Works
The FlexLoader follows a repeatable automated sequence at each level:
- The operator raises the overhead safety gate, which guards the open shaft-way while allowing material to be loaded onto the flush-mounted roller conveyor
- Material is inducted onto the conveyor with a pallet jack or forklift
- The safety gate is manually closed, preventing personnel from entering the lift platform area
- The load is automatically delivered to the designated level by the Wildeck VRC
- The safety gate at the receiving level is opened to off-load the material
This sequence repeats at any level in C-load, Z-load, or H-loading patterns. Separate inbound and outbound conveyor lanes can be configured at each elevation for higher throughput.
Controls and Diagnostics
The FlexLoader ships with a comprehensive control package built for automation-duty operation.
- AutoSenz® D-Series overload detection system with full diagnostics and programmable service reminders
- Emergency stop buttons at each load point
- Full maintenance jog controls for horizontal and vertical movement on the main control panel
- Destination selector buttons at the infeed on multi-level systems
- Signaling system with lights and alarms for auto mode, manual mode, system status, and fault conditions
Safety Gates and Guarding
The FlexLoader integrates Wildeck overhead safety gates at every infeed and discharge point. These gates protect workers from the equipment and the shaft-way, and prevent loads from inadvertently being pushed into or down the shaft opening. All system components — VRC, safety gates, and perimeter guarding — are designed together for heavy automation duty with safety interlocks that prevent operation when gates are not properly positioned.
Flush-Mounted Conveyor Integration
The roller conveyors at each floor level are flush-mounted for easy loading and unloading with a standard pallet jack or forklift. Conveyors can be supplied by Wildeck or by the customer with Wildeck factory mounting. This flexibility allows the FlexLoader to integrate with existing conveyor infrastructure or to serve as a standalone system with its own dedicated conveyors at each level.
Applications
The FlexLoader serves distribution centers, manufacturing facilities, e-commerce fulfillment operations, and any multi-level facility that needs automated pallet transfer between floors without the cost, permitting complexity, and ongoing inspection requirements of a freight elevator. It is especially well suited for operations looking to increase throughput, reduce manual handling, and utilize overhead cubic space that is currently underused.