1. Project Background

A logistics and distribution center operated a rail-guided trolley system for palletized cargo movement within a large warehouse.
The system required quiet, floor-friendly, and low-maintenance wheels capable of handling moderate loads on fixed guide rails.

The original rubber wheels showed:

• Rapid wear under load

• Poor dimensional stability

• Inconsistent rolling behavior on rails

The customer approached Kingrail for a more durable and reliable solution.

2. Application Challenges

The key challenges included:

• Continuous operation across long warehouse shifts

• Moderate load per trolley with frequent starts and stops

• Requirement for low noise and low vibration

• Compatibility with existing rail track geometry

• Need for long service intervals to reduce maintenance labor

3. Kingrail Solution

Kingrail supplied Polyurethane Railroad Wheels specifically designed for warehouse rail trolley applications.

The solution included:

• High-wear-resistance polyurethane tread

• Rigid metal core for dimensional stability

• Carefully selected PU hardness to prevent deformation

• Sealed bearings to protect against dust and debris

Custom sizing ensured:

• Proper rail contact

• Smooth guidance without derailment risk

• Stable operation under full load conditions

4. Performance After Installation

Following commissioning, the Kingrail wheels delivered consistent results:

• Smooth rolling with minimal rolling resistance

• Noticeably quieter operation than rubber wheels

• No visible tread cracking or deformation after extended use

• Stable guidance along rails even during frequent direction changes

Maintenance inspections confirmed:

• Lower wear rate compared to previous wheel types

• Extended replacement intervals

5. Customer Benefits

The customer gained multiple operational advantages:

• Improved reliability of the rail trolley system

• Reduced wheel replacement frequency

• Lower maintenance costs

• Enhanced overall efficiency of warehouse material flow

Kingrail polyurethane railroad wheels successfully met the operational demands of modern logistics environments where noise control, durability, and stability are essential.