Not every machine is needed permanently. In some cases, an old machine has to be stored temporarily so that it remains of interest to buyers. Sometimes the machine should remain quickly available for future peaks in demand. When machines need to be stored, there are various variables to consider and questions to answer. We show you point by point what is important.
1. how relevant is the topic of ageing?
Technical systems, especially mechanical systems, wear out not only through use, but also through material ageing processes of various kinds. An example of the latter is the rusting of steel components or the hardening of seals, hoses and other flexible plastics.
How quickly and to what extent such ageing processes occur and have an effect is often directly related to the storage conditions. In this respect, it must first be checked to what extent the current condition of the machine must be maintained during storage.
The extremes here range from unprotected storage in the open air to storage in which the machine is wrapped in vacuum film and stored in a climate-controlled environment – heated, cooled and in some cases with monitored humidity. Decisive factors for the selection are
- Value,
- Condition,
- Age,
- future use and
- Sensitivity
A different approach is required for the interim storage of an old machine until it is collected by a recycler than for the storage of a machine that is subsequently to be ready for use again.
2. how quickly or frequently must outsourcing be possible?
The reason for storage and what is to be done with a machine in the medium to long term is related to almost all storage conditions. In this respect, it must also be clear how often or quickly it will be necessary to take the machine out of storage.
One example of this is a fleet of forklift trucks: surplus industrial trucks are often stored temporarily in order to be able to quickly absorb peaks in demand that are difficult to plan. Accordingly, the forklift trucks must not only be kept in good technical condition during storage, it must also be possible to have the equipment back on the company premises ready for use as quickly as possible. In addition to qualitative requirements, storage must meet the following criteria:
- Easily accessible storage so that, for example, other machines do not have to be moved aside before removal.
- Relatively close to the location and with good transport connections.
- At least during business hours and rather spontaneously accessible.
The length of the storage period also plays a role here. The longer it is, the less relevant the last two points in particular become.
3. is there sufficient space in your own company?
Just to park a disused machine so that the recycler can transport it away without any problems, there must be a suitable space on the company premises. Even if only ten forklifts are to be parked safely for a certain number of months, a rainproof hall is required.
In addition to space requirements, other criteria must also be reconciled. In the context of this chapter, this primarily means
- the required minimum area
- a design appropriate to the storage conditions
- Accessibility as part of further transportation measures
4. how mobile is the machine?
If the ten forklifts from the previous example are to be stored in a hall on the factory premises, the procedure is quite simple: they are driven to their storage location and parked. In addition to any measures such as removing/disconnecting the batteries, hardly anything needs to be done.
However, if the same forklift trucks are to be stored only a few kilometers away, transport is already necessary if the industrial trucks are not approved for public road traffic.
It becomes even more complex when it comes to machines that cannot be moved without technical aids.
5. how expensive is external transportation?
A conventional low-loader is often sufficient to transport forklifts or various other machines to an external warehouse. If you do not have your own, you will need to find a suitable company to transport it. A special transport vehicle is also required for various larger machines such as excavators or wheel loaders.
Production systems and other non-mobile machines sometimes have to be dismantled in order to achieve transportable dimensions and component weights. The following should also be noted:
- It needs to be clarified who can take over the dismantling – depending on the future usability.
- Cranes and similar systems may be required to move, load and transport the machine from the factory.
- Special transport vehicles may be required because the machine is too large and/or too heavy for conventional equipment.
Furthermore, it must be clarified for each of these points who is professionally qualified to do this – and what costs are involved.
6. how important is protection against theft and vandalism?
Every machine that is needed again or is intended to generate new funds through sale is an asset. This also applies in cases of disposal if there is a relevant material value.
Accordingly, the machines must be housed securely enough in certain cases and the warehouse must offer protection:
- from vandalism due to boredom or a desire to destroy
- against theft of parts or the entire machine, for example due to its value
- against theft of information about the machine in the context of economic/industrial espionage
In practice, the latter may only apply to very special machines that are not (yet) available on the open market.
The necessary protection for a machine therefore also depends on the situation in question. Even simple measures such as fencing, lighting and access control can make a big difference.
7. is special technology required at the storage location?
For some machines, it makes sense to have a power connection available at the storage location. When storing vehicles such as heavy wheel loaders over the winter, for example, the heavy starter battery does not have to be removed. Instead, you can connect the machines to a trickle charger directly on site.
For other appliances, special conditions may be necessary for the accommodation – for example with regard to climatic conditions. In this case, special climate control systems may be important.
Depending on the storage location, a permanently installed crane system can also be helpful to store machines more efficiently – i.e. to save space – and make transportation within a hall easier.
8. are the machines particularly heavy?
The weight of the machine is an important factor – both for the transportation itself and in terms of the load capacity of the appropriate storage location. In practice, heavy machines pose several challenges:
- When moving it from its previous location: If a heavy production machine was previously standing on a special concrete foundation, it must be checked whether the ground on the company premises is strong enough to support the machine – especially if the weight of a crane is added.
- At the storage location itself. It must be able to bear the load for at least the planned period without, for example, subsidence and similar problems occurring.
In both cases, the ground pressure per unit area is important. If, for example, a 50-ton production machine stands on six fairly small feet, the subfloor must be able to withstand significantly greater loads than if the same machine were to rest on the entire surface. The weight is then distributed over a much larger area. Prior static calculations may be required at the storage location.
Preparing machines for storage
If a machine is only stored temporarily for a few days, suitable weather protection is often sufficient. However, if the machine is to be stored over the winter, further preparations are necessary to protect it adequately
The detailed procedure differs from machine to machine. In addition, the manufacturer’s specifications always apply. For many systems, however, it boils down to the following steps – possibly modified for specific machines:
- Cleaning: Dirt of any kind should never be left on for long periods of time. For example, because it can act as a sponge for humidity and thus promote corrosion – or because it is a breeding ground for mold, bacteria and similar organisms.
Before storage, each machine should therefore be emptied inside and out and then cleaned. The techniques and cleaning agents used depend on the sensitivity. This also includes rinsing out pipes if they are not permanently filled.
- Protect metal: During storage, ferrous metals in particular and all moving parts should never be left “bare”. Depending on the component, treatment with paint, oil or grease is therefore necessary. If there are grease nipples on the machine, a comprehensive lubrication service must be carried out to ensure that all bearing points are protected.
- treat fuel: This applies in particular to diesel fuels. Due to the mandatory admixture of biodiesel, these can typically only be stored for around six months before there is a risk of bacterial infestation – the so-called diesel plague. The following steps are necessary to prevent this:
- If the vehicle is stored over the winter and cold temperatures are expected, the fuel may need to be drained and replaced with winter diesel.
- The machine should be fully fueled so that there is as little oxygen in the system as possible (also to protect the inside of metal tanks).
- A suitable diesel biocide in the right quantity for the filling quantity provides additional protection.
- Finally, the engine should be left running so that the biocide mixture is distributed throughout the entire fuel system.
- Seal openings: Depending on the storage conditions, they can attract animals and other unwanted inhabitants. All openings must therefore be sealed with plugs or adhesive tape at the latest at the final storage location.
- Prepare the electrical system: This primarily includes protecting electrical contacts from oxidation. Various contact sprays are suitable for this. The work also includes the appropriate treatment of batteries. They must at least be charged or, in the case of starter batteries, connected to appropriate chargers during storage – regardless of whether they are installed or removed.
- Check antifreeze: For machines with liquid cooling, where it could freeze during storage, the antifreeze level must be checked and brought to an appropriate level. For combustion engines, -25°C should be the minimum. Alternatively, drain the coolant completely.
- Inflate tires: Existing tires should be inflated to their maximum pressure. However, heavy machines should not stand on them the entire time. Alternatives should be chosen here, such as jacking up. In other cases, it makes sense to store the machine without the tires fitted.
In driver’s cabs and similar closed cavities (i.e. not exposed to air flow), it can also be useful to take measures to protect against moisture and mold infestation. A whole range of moisture-absorbing aids are available for this purpose – such as various silica-based drying agents.
Important 1: The measures mentioned here are intended for storage over a period of several months. If a machine is to be stored for significantly longer, more complex approaches are required. These include, for example, draining hydraulic fluids and filling the system with inert gas.
Important 2: Even during storage, machines should be checked at least once a month – for leaks or animal infestation, for example.
Image sources:
- adobe.com © Fabio Sasso
- adobe.com © Philipp Berezhnoy
- adobe.com © Kirill Gorlov
- adobe.com © Nattawit
- adobe.com © Bself
- adobe.com © Kaspars
