As a manual transport device for effortless, safe and ergonomic handling of cardboard boxes, drinks crates, barrels or storage boxes, the EXPRESSO hand truck has a firm place in logistics and intralogistics. Its many variants have proven themselves in the supply chains of many industries around the world. The continued success of this single-axle ‘short-distance trolley’ is based not only on its high-quality workmanship, but also on the further development of the product idea into a modular system that offers more and more scope for the realisation of customer-, industry- and country-specific solutions. Based on the strict quality assurance of the assembly processes at its main factory in Kassel/Germany and in view of the durability of its hand trucks, the German manufacturer recently decided to take an unusual step: since January of this year, many standard hand trucks have had an extended warranty period of ten years! ‘This forward-looking promise of quality not only expresses our own confidence in the high reliability of our transport system, but is also a carefree package that offers the customer a considerable degree of added value,’ says Karsten Grötecke, who heads the hand trucks business unit at EXPRESSO. The new super warranty covers all material and manufacturing defects and applies to the majority of the hand trucks from the company’s wide range of models.

Investment security and availability

The customer benefits from the extended warranty period in several ways. They not only safeguard their investment decision, but also reduce their financial risk to a moderate minimum. This is because they are exempt from the costs of repairs and spare parts for a full decade in the event of production-related defects. Karsten Grötecke also explains: ‘To ensure the high availability of the hand trucks, we have set up a clearly structured process for the rapid rectification of production and material faults, which supports the rapid elimination of defects. Our partner network with many certified suppliers in the region is also a great advantage here.’ EXPRESSO has also included the costs for the delivery of repaired or replaced products to the original delivery address in the new warranty. Excluded from the ten-year warranty, however, are – as is generally the case – accessories and wearing parts as well as protective profiles (e.g. skids, tyres, lashing straps, protectors). The customer is still entitled to all statutory warranty rights in this respect.

EXPRESSO’s extended warranty period should also send a signal to all those companies that want to organise their supply chains according to sustainability criteria. Apart from the fundamentally high product quality of the hand trucks, it makes it clear that these ‘Made in Germany’ transport devices are designed for a very long service life. As their product life cycle can be refreshed again and again with spare parts or modules, it often takes many decades before an EXPRESSO hand truck becomes obsolete. Karsten Grötecke also emphasises that ‘ecological aspects are included in all product development considerations right from the start. We continuously optimise the use of energy and raw materials in order to protect the environment in the long term.’

Premium through and through

The high level of quality that EXPRESSO achieves with its hand truck is reflected in many details of the design. For example, the carcass structure of the pneumatic wheels guarantees maximum load capacity with minimum rolling resistance. In addition, all wheels are odourless and run on waterproof and dustproof deep groove ball bearings. ‘We have an Airlex wheel in our programme as a ‘non-flat’ solution. It is made of polyurethane, contains thousands of microcellular air bubbles and offers a service life that is 5 times longer. All wheel types have very good shock absorption on uneven surfaces and are extremely directionally stable,’ explains Karsten Grötecke. Worth mentioning here: All wheels with a diameter of 260 mm have the curved axle typical of EXPRESSO hand trucks as standard. This makes tipping easier, even with heavy loads, and prevents the user’s feet from slipping.

For the frame of its hand trucks, EXPRESSO uses aluminium elliptical tubes made from a high-strength special alloy that is 50 percent lighter than steel, yet still meets high standards in terms of stability and load-bearing capacity. Glass fibre reinforced, permanently protected angle connectors and double stainless steel clamps are also used in the main load areas. All cross connections are also GRP-reinforced and positively connected to the rail. The anti-slip profiles made of high-quality Exlan plastic protect the aluminium inclined runners when negotiating steps. When the integrated red centre of their wear indicator appears, it is time to replace the profiles. This is done quickly thanks to a clip system. The spade blade of the hand truck, precision-milled from a special alloy, is tightly profiled and prevents the load from slipping sideways. ‘All spare and wear parts can be ordered via our service centre or web shop. They ensure that an EXPRESSO hand truck can always be kept in top condition and will serve its user faithfully for many years – accompanied by the new super guarantee,’ says Karten Grötecke.

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With its world of ideas centred around the lift2move mobile handling system, EXPRESSO offers process optimisers, plant managers and factory planners numerous options for increasing the efficiency of processes in assembly, production and warehousing. In view of the tense economic situation in many industries, the German company will not only be presenting various customer-specific complete solutions at LogiMAT (11-13 March 2025), but also a particularly cost-effective and smart system product: the new lift2move selective and the matching portfolio of load supports. ‘We are thus offering a price-optimised and quickly available lifting, conveying and positioning system that covers a wide range of standard tasks in almost all areas of intralogistics,’ emphasises Oliver Stauch-Vaupel, Head of EXPRESSO’s Powered Handling and Transport Equipment business unit.

Premiere for payloads up to 200 kg

At its stand 7F41 in hall 7, EXPRESSO will be exhibiting the new lift2move selective in versions for payloads of up to 125 kg and 200 kg. They are offered with various electrically operated lift masts as standard. While the 125 version provides the user with strokes of 1,150 mm, 1,500 mm and 1,850 mm, the 200 version has strokes of 1,320 mm, 1,670 mm and 2,020 mm. As the smart feed unit can also be equipped with ten different load supports, it can be customised for a wide range of handling tasks. In addition to platforms with and without rollers and a rotating V-block, there is a roller mandrel, a roller turner, a fork for plastic boxes, a clamping fork for sheet metal and Schäfer crates, a short and a long jib and a prism for picking up round parts. Thanks to the three different lifting paths and the choice of load supports, the lift2move selective proves to be an extremely versatile handling system that can be adapted to changing operational requirements in just a few simple steps. And as with all EXPRESSO system products, this also applies here: All components of the lift are made in Germany and the supply of original spare parts is guaranteed in the long term.

‘In order to be able to provide the lift2move selective at an attractive entry-level price and with short delivery times, we have made some simplifications that have no impact on the technical and ergonomic quality of the mobile lift,’ says Oliver Stauch-Vaupel. In concrete terms, this means that the customer does not have to do without the low-maintenance spindle operation of the lifting mechanism, the sensor-controlled safety system or the height adjustability of the push bar. The same applies to the two lifting and lowering speeds of the lift mast, which are preset as standard and can be adjusted by remote control, the Powerpack battery pack (18 Ah), which can be changed without tools, and the central brake bracket with three operating modes for fixed braking, locking in the direction of travel and freewheeling. Its four swivel castors also make the lift2move selective an agile, manoeuvrable handling system that has an underride height of 88 mm thanks to its lowered front castors.

Promising prospects

EXPRESSO’s current trade fair programme will already include a lift2move 400 with double mast that can handle Euro pallets and a customised lift2move solution. The company will also be exhibiting a prototype lift in Stuttgart/Germany, for which it is currently seeking ISO cleanroom certification, and the eBalanceLift ARM load handling system as a swivelling column cantilever system. The company’s extensive consulting and engineering expertise is also likely to provide plenty to talk about at the EXPRESSO stand, with area sales managers and project managers as well as designers and service teams realising innovative intralogistics solutions whose performance sometimes far exceeds customer expectations.

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Online-on-site (OvO), omni-channeling or Retail 4.0 – the digitalization of retail now has many names. Karsten Grötecke, Head of the Smart Retail unit at EXPRESSO, has clear words on the subject: “The solutions that will establish themselves are those that are easiest to use, grow with store operators’ experience and offer them the best opportunities for individualization.” Visitors to EuroCIS, which takes place in Düsseldorf/Germany from February 18 to 20, 2025, will be able to see what this looks like in practice. Karsten Grötecke’s team will be presenting EXPRESSO’s new Smart Retail solutions for use in retail and wholesale stores as a world premiere at stand 10B50 in hall 10. As in the company’s other product worlds, everything here follows the principle of modularity. This means that store operators can choose between three system solutions called EO Smart, EO Go and SmartShopper^® EO Complete, with the latter including all SmartShopper^® models as well as the technologies of big data specialist CYREEN. “We serve up a rich Smart Retail buffet from which the customer can choose what meets their wishes and expectations. As consultants and system partners, we make sure that everything fits together perfectly,” says Karsten Grötecke.

Entry-level software or retrofit kit

With EO Smart, EXPRESSO offers store operators the easiest entry into the world of smart retail. The software solution is inexpensive, quick to install and quickly adapted to suit requirements – including the corporate design of a brand or promotion. Customers scan and pay via smartphone. “This reduces waiting times at the checkouts and gives shoppers a high degree of independence and flexibility,” says Karsten Grötecke. The system is suitable for all modern smartphones with a camera. Among other things, it enables the store operator to send targeted advertising messages and manage their staff more efficiently than before.

The EO Go retrofit system goes one step further, transforming the store operator’s shopping carts into smart shopping assistants. Customers use a barcode scanner on the cart to record their purchases, which saves them having to take their shopping off and put it back on the checkout conveyor belt and reduces waiting times. The system shows the customer the current status of their purchase on a touch display, allowing them to keep an eye on their spending. Staff freed up from checkout work can take on other tasks. The software used in EO Go can be customized and the system’s hardware can be adapted to all standard shopping carts.

Complete retail media solution

Finally, SmartShopper^® EO Complete is EXPRESSO’s all-in-one solution. It uses the company’s SmartShopper^® models as a system platform and can be expanded to include CYREEN’s retail media technology. “This means that the store operator can equip our digital shopping cart with a highly innovative and patent-protected Connecting Ad Impressions with Purchase (C.A.P.) solution in addition to its integrated scanning, sensor and display technology. It offers retailers considerable added value as it makes sales processes more transparent, more attractive and more profitable,” says Karsten Grötecke.

The SmartShopper^® features scanning and weighing of items, the display of shopping lists and cashless payment. For customers, this means shorter waiting times at the checkout and convenient shopping. The system supports store operators in optimizing their sales and personnel management: stock and inventory discrepancies as well as disruptions to automatic ordering routines are avoided; theft is virtually impossible, checkout staff can be flexibly deployed for other tasks and operating costs in the checkout area are reduced. “Experience shows that a SmartShopper^® EO Complete solution often pays for itself in less than a year,” says Karsten Grötecke.

At EuroCIS, EXPRESSO will be showcasing various SmartShopper^® models for use in food retail, beverage and drugstore chains, DIY and cash+carry stores and other markets. The company is also presenting a digital shopping cart with integrated retail media applications from CYREEN. “They provide retailers with extensive options for recording, measuring and evaluating the consumer behavior of their customers and for the targeted use of modern media for targeted campaigns,” explains Karsten Grötecke.

All Smart Retail solutions from EXPRESSO are GDPR-compliant and do not require access to sensitive ERP and POS data. They are also based on modern real-time data integration and do not require a constant internet connection. They are compatible with all common POS systems, have a largely modular design and can be easily integrated into existing system environments and various store organizations.

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‘We see this new cooperation as a catapult for the innovative expansion of the possibilities and capabilities of our SmartShopper^®,’ says Dr Alexander Bünz. As the CEO of EXPRESSO continues, the combination of CYREEN technology with the sensor, display and scanning system of the digital shopping cart creates ‘completely new perspectives for the development of pioneering retail media applications that offer retailers significant added value by making sales processes in stores more transparent, attractive and profitable.’

The C.A.P. solution from CYREEN is one of the pioneers of a new generation of data-driven retail media technologies that record, measure and evaluate consumer behaviour in the retail sector. Shoppers are provided with visual and audio information via monitors or other media that can be assigned to the receipts. This is all done in compliance with GDPR. ‘This creates a database that provides advertisers and market operators with precise and efficient analyses for product campaigns and content strategies – similar to measurement within e-commerce sites – as well as very precise insights into target group activities,’ explains Davide Scheidegger, Co-CEO of CYREEN.

EXPRESSO currently offers its SmartShopper^® in variants for food retailers, beverage and drugstore chains, DIY and cash+carry stores and other retail markets. These are complete mobile solutions with a hand scanner, display and load cells that check the goods selected by the customer to the exact gram. Network-compatible analysis software collates all the data. From the customer’s point of view, the SmartShopper^® simplifies shopping, prevents incorrect purchases and reduces waiting times at the checkout. This gives the store operator full transparency about trolley contents and demand trends. It also offers numerous opportunities to provide direct information about special offers and to optimise sales, checkout and inventory processes. Here, too, all processes are GDPR-compliant, as no personal data is requested from the customer.

The new cooperation with CYREEN now offers EXPRESSO the opportunity to enhance the SmartShopper^® with additional retail media capabilities through the integration of C.A.P. technology. This makes the digital shopping cart even more attractive for the store operator or branch manager, as it serves as a future-proof, multifunctional and multimedia control instrument for sales management. Davide Scheidegger explains: ‘They can integrate modern media, receive reliable information about their customers’ purchasing behaviour and, based on this, increase the efficiency of their own brand or product campaigns and those booked by advertisers, thereby significantly boosting the profitability of their store.’

Together with the big data experts from CYREEN, the specialists from EXPRESSO’s Smart Retail business unit have already started to develop specific retail media applications for the SmartShopper^® digital ecosystem. ‘We will probably be able to present the first results at the EuroCIS trade fair in February 2025,’ reports Dr Alexander Bünz.

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As a practical and safe premium solution for manually transporting cartons, beverage crates, and other goods, the EXPRESSO hand truck has proven its worth in many supply chains worldwide, particularly in the courier, express, and parcel logistics sectors. It differs from many similar products in one crucial aspect: it is designed as a highly flexible, weight-optimised, and ergonomic modular system that offers maximum freedom for functional adaptation to almost any industry, business, or product-specific task. “Whether it involves largely standardised or highly specialised requirements, in the end, it is always the specific logistics task of the customer that largely determines the design of our hand trucks. We also place particular emphasis on ensuring that all details are tailored to individual needs, aimed at providing the customer with an optimal and efficient solution for their transport challenge,” says Karsten Grötecke, who heads the business unit Manual Handling Equipment at EXPRESSO. Visitors to this year’s Parcel+Post EXPO, taking place from October 22 to 24 in Amsterdam, will be able to gain a tangible impression of this highly successful product concept. EXPRESSO will present itself in Hall 10 at Stand 10.123 as a premium manufacturer of modern transport solutions, showcasing various exhibits that demonstrate the possibilities of the modular system for postal and parcel hand trucks

Maximum modularity

At the Parcel+Post EXPO, CEP professionals will learn that the tubular footplates of EXPRESSO postal and parcel hand trucks – indispensable for transporting cartons, crates, and baskets – can be folded away to save space, are available in various lengths and widths, and come equipped with support feet that keep goods off the wet ground and dirt. Their optimised tilt angle secures the cargo in the parked position. Crossbars between the upright tubes prevent small packages from slipping through, and all EXPRESSO hand trucks can be fitted with additional crossbars to ensure that stacked cartons and crates are reliably supported against the frame. A rear-hung net provides safe storage for smaller parcels, and weatherproof accessory bags make it easy to deliver leaflets and magazines quickly. “Another important quality feature of our postal and parcel hand trucks is the loop handle, with its ergonomic, slip-resistant plastic coating. It allows for many different, ergonomically optimal gripping positions. Additionally, the upper crossbars of our hand trucks serve as extra handholds, ideal for safely navigating steps and stairs. Made of fibreglass-reinforced plastic, they have a curved design that provides a protective safety gap between the user’s hands and the load,” explains Karsten Grötecke.

These product features alone illustrate that the design of EXPRESSO hand trucks is thought out down to the last detail. To ensure the customer benefits from them for as long as possible, the company also guarantees long-term spare parts availability. Wear parts can be easily replaced, and every part of an EXPRESSO hand truck can be reordered later. With original spare parts and guided by the videos on the company’s YouTube channel, an experienced user can modernise a decades-old hand truck with just a few simple steps.

Over 2,000 variants to date

The now 70-year-long market success of the EXPRESSO hand truck can be traced back to a patent application filed by engineer and entrepreneur August Manss in July 1953. While the large skids were initially seen as an advantage, simplifying stair navigation, it was in 1967 that EXPRESSO’s engineers made the decision to turn the rigid truck design into a flexible aluminium modular system, unlocking the tremendous development potential of this manual transport device. “To date, over 2,000 variants of the EXPRESSO hand truck have emerged from this basis – and this trend continues. Today, we attach a triple quality promise to every customer-specific hand truck: Product excellence at the level of Made in Germany, optimal individualisation through constructive modularity, and longevity thanks to our spare parts guarantee,” emphasises Karsten Grötecke.

According to the business unit head, the future of the EXPRESSO hand truck is currently shaped by the perfection of the modular system, adherence to high-quality standards, and the expansion of service offerings. The company’s engineers continually receive suggestions for technical improvements, additional modules, or new accessories from users and sales partners. “These are valuable innovation impulses for the further development of our hand truck as an ergonomic, safe, and economical transport tool for the CEP industries,” says Karsten Grötecke.

By the way: The EXPRESSO hand truck is not only in use millions of times worldwide, but it has also become a part of Germany’s “Brands of the Century.”

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In many industries, rolls, coils, slit strips, wire rings, and drums are standard forms for semi-finished, intermediate, and finished products. The way they are handled throughout internal material flow – from goods receipt to processing and storage – significantly impacts process efficiency, workplace safety, and product protection. “Our product managers, engineers, and consultants are familiar with the specific issues related to handling such quasi-cylindrical objects from numerous projects,” says Oliver Stauch-Vaupel, who heads the Powered Handling and Transport Systems unit at EXPRESSO. He and his team continually develop and implement innovative complete solutions for roll and coil handling, based on the multifunctional floor transporter lift2move, the servo-motorized E-BalanceLift, and extensive in-house expertise in load-handling engineering. A crucial factor that currently sets EXPRESSO apart from many other market providers is the high quality and intensity of the consultation before, during, and after the project phase. The specialists from the German company will explain the methods, tools, and procedures they use at this year’s Fachpack in Nürnberg/Germany (24-26 September 2024) in Hall 7 at booth 650.

Custom tailored

For example, EXPRESSO is showcasing a lift2move of the latest generation, equipped with Industry 4.0 interfaces and lightweight battery packs (Li-Ion) for operating its electric lifting mast. To safely handle rolls weighing up to 100 kg with internal core diameters between 50 mm and 76 mm, the mobile lift-and-lower device can be fitted with a pick-up mandrel, a roll mandrel with top-mounted guide rollers, or a roll turner. Alternatively, a V-block is available for lifting cylindrical parts with diameters up to 600 mm and lowering them flush with the floor. “All these standard systems for roll and coil handling can be adapted in various ways to the requirements of different customers or industries. In addition, we can always develop special customized solutions tailored to specific on-site conditions,” emphasizes Oliver Stauch-Vaupel.

All EXPRESSO handling and transport systems are extensively modularized to inherently provide the necessary variability for customization. What the modular concept does not cover is then taken over by the company’s engineering team. “Whether we configure a standard system for a specific application or start a completely new development, we always immerse ourselves deeply in our customers’ processes and create highly individualized solutions based on our engineering know-how and the interdisciplinary consulting expertise of our area sales managers, project managers, designers, and service teams,” says Oliver Stauch-Vaupel. For visitors to EXPRESSO’s Fachpack stand, this means they can not only inspect the latest versions of the lift2move and the E-BalanceLift but also gain deep insights into the consulting methodology used in developing customer-specific system solutions.

It’s important to note that there are currently hardly any ready-to-use or certified handling devices for roll or coil handling available on the market. Therefore, it is crucial to start the realization of such a solution with an on-site visit from a knowledgeable consultant to analyze the customer’s specific requirements. This involves examining issues with the current state, special requirements of the quasi-cylindrical objects, aspects of ergonomics, route optimization, and more. Often, this initial analysis leads to the first sketches of the future roll and coil handling system. Accompanying this process, configurator apps and the company’s know-how database, featuring over 300 videos showcasing various application examples, are also used.

Delivery and after-sales service

Following the analysis work, EXPRESSO prepares a detailed technical description and calculates the project costs. “At this point, it often becomes evident that we can arrive at very economical solutions surprisingly quickly due to the depth of our consultation,” says Oliver Stauch-Vaupel. The implementation phase then involves providing a pilot device, with which the customer can already conduct practical trials. These test runs may yield further pointers for fine-tuning the future handling solution. The provisional final phase consists of the customer’s acceptance of the finished system and its commissioning. This includes training the operating personnel and final adjustments, usually taking place at EXPRESSO in Kassel. In some cases, acceptance can also occur directly at the installation site.

EXPRESSO’s complete offering also includes regular visits to the customer as part of after-sales support. This serves both as an opportunity for experience exchange with the on-site production and operations managers and to renew the company’s quality promise. “With each service appointment, we work with the customer to develop further perspectives for fine-tuning processes, improving ergonomics, or optimizing MRO services through our technicians and consultants,” reports Oliver Stauch-Vaupel. This high level of customer focus has led many clients to see EXPRESSO as a reliable competence partner who can be consulted whenever there are issues in intralogistics.

During its presence at Fachpack, the company is also offering a range of activities from which customers and interested parties can significantly benefit. For instance, it is hosting an online webinar on roll and coil handling on 6 September at 11:00 am. The webinar will be live, allowing the EXPRESSO experts Maximilian Kühn and Henning Petersen to answer participants’ questions directly. The webinar will focus on case studies that address specific challenges and solutions in industrial roll and coil handling. Shortly thereafter, the company will offer a white paper on this topic for download on its website. Additionally, at the trade fair, it invites experts in material flow, conveyor, or assembly technology to a presentation at the “Innovation Box Forum” in Hall 2 (Stand 208/210).

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