A transfer trolley (also known as a rail-less transfer cart or battery-powered transfer cart) is widely used in industries that require the safe movement of heavy loads, such as steel manufacturing, shipyards, mold manufacturing, transformer production, and heavy machinery factories.
The standard load capacity of a rail-less transfer trolley usually ranges from 1 ton to 150 tons. However, the trolley can be fully customized according to the customer’s requirements, including platform dimensions, steering method, wheel type, power system, and operating environment.
The maximum load capacity depends on several key components and working conditions:
The gear reducer directly affects the trolley’s pulling force and load capacity. An oversized reducer increases the equipment cost, while an undersized reducer may cause overload operation and reduce service life.
Battery capacity is critical for battery-powered transfer trolleys. A larger load requires more power support. Higher-capacity batteries provide longer operating time and stable performance during heavy-duty transportation
The electrical system is designed according to the trolley’s rated load. The control program, motor protection, and operating parameters are customized based on different tonnage requirements.
Different load capacities require different wheel designs. For heavy-duty applications, more wheels and stronger materials are used to distribute the load and improve stability.
The working surface has a direct impact on trolley performance. Uneven, rough, or high-friction floors require stronger drive systems and higher safety margins.
Harsh environments, such as steel plants, shipyards, or dusty industrial areas, may increase resistance and require customized components to ensure reliable operation.
| Load Capacity | Battery | Wheels | Reducer |
| 1-5 tons | Battery | Wheels | Reducer |
| 6-10 tons | 24V/48V Li-ion or Lead-acid Battery Capacity: 100-200Ah | Polyurethane (PU) / Rubber solid wheels Diameter: φ250-300mm Qty: 4 wheels (2 drive + 2 follower) | Planetary reducer Ratio: 1:10~1:20 Motor power: 0.5-1.5kW |
| 11-15 tons | 48V Lead-acid / Li-ion Battery Capacity: 200-300Ah | Rubber / Nylon wheels Diameter: φ300-400mm Qty: 4-6 wheels (2 drive + 2/4 follower) | Planetary reducer Ratio: 1:15~1:30 Motor power: 1.5-3.0kW |
| 16-20 tons | 48V Li-ion Battery Capacity: 300-400Ah | Nylon / Rubber-coated steel wheels Diameter: φ350-400mm Qty: 4-6 wheels (2 drive + 2/4 follower) | Planetary reducer Ratio: 1:20~1:40 Motor power: 3.0-5.0kW |
| 21-30 tons | 48V/72V High-capacity Li-ion Battery Capacity: 500-600Ah | Steel wheels / Crane-specific wheels Diameter: φ500mm Qty: 8 wheels (4 drive + 4 follower) | Planetary / Heavy-duty reducer Ratio: 1:30~1:60 Motor power: 7.5-10kW |
| 31-40 tons | 72V Li-ion Battery Pack Capacity: 600-800Ah | Steel wheels (ZG55 cast steel) Diameter: φ500-600mm Qty: 8-12 wheels (multi-drive) | Heavy-duty planetary / Worm gear reducer Ratio: 1:40~1:80 Motor power: 10-15kW |
| 41-70 tons | 72V High-capacity Li-ion Battery or Auxiliary External Power Capacity: 800-1000Ah | Crane-specific steel wheels Diameter: φ600-800mm Qty: 8-16 wheels (multi-drive + multi-follower) | Heavy-duty / RV reducer Ratio: 1:50~1:100 Motor power: 15-30kW |
| 71-100 tons | 72V Ultra-high-capacity Battery Pack or Diesel Hybrid Capacity: 1000Ah+ | Extra-large diameter steel wheels Diameter: φ800-1000mm Qty: 12-16 wheels (distributed drive) | Ultra-high-torque reducer / Custom drive unit Ratio: 1:60~1:150 Motor power: 30-50kW+ |
Our customer is a power company in Malaysia. Their workshop has a concrete floor and they needed to transport 18-ton semi-finished products between production areas. Based on the working environment and material requirements, we designed a customized 20-ton heavy-duty rail-less transfer trolley.
20 tons (maximum capacity 23 tons with safety factor calculation)
– Platform size: 4000mm × 3000mm
Solid polyurethane wheels designed for indoor concrete floors, protecting the ground while providing excellent traction
– Steering: Rail-less free steering system
Customized lifting platform with 100mm lifting height for smooth connection with production lines
25 meters/minute for a balance between efficiency and safety
Reinforced frame with six auxiliary support structures to evenly distribute heavy loads and prevent deformation
Does the transfer trolley include a charger?
Yes. The charger is supplied together with the transfer trolley as a complete system.
Do you provide after-sales service?
Yes. We provide a 2-year warranty for the complete transfer trolley.
How long does delivery take?
Delivery time depends on the destination country. Standard production time is approximately 15 days after order confirmation.
Do you have stock available?
No. Our transfer trolleys are customized according to customer requirements, but production is fast.
Can you provide certifications?
Yes. We can provide relevant certification documents according to the requirements of different countries.
Conclusion
The load capacity of a transfer trolley depends on many factors, including battery capacity, drive system, wheel design, electrical control, floor conditions, and working environment. Choosing the correct configuration ensures safe operation, longer service life, and better transportation efficiency.
