Cape Town, South Africa — October 2025. Powercon Handling Systems has completed its second project for Ceres at their Pack house in Cape Town. The new installation – an overhead monorail conveyor (CR45 system)—distributes cartons from the carton store to multiple pack stations, improving flow, freeing floor space and reducing manual handling.
The challenge
Pack lines depend on a steady supply of cartons, and floor‑level congestion can quickly lead to starved stations. Ceres needed a compact, low‑disruption way to move empty cartons from a central store to numerous points of use, without adding traffic from forklifts or trolleys.
The solution: CR45 overhead monorail
Powercon’s CR45 uses roof‑mounted track and carton support hangers to route cartons directly above the pack area and feed each station as required. By taking movement overhead, the system keeps aisles clear, shortens travel paths, and gives supervisors a clear view of line conditions. The layout makes it straightforward to serve multiple destinations and balance demand across lines.
System overview (new installation)
- Two lines: 204 m and 195 m
- Carton support hangers: 99 on the 204 m line, 57 on the 195 m line (156 total)
- Variable speed drives: 6–18 m/min on both lines to match shift demand
- Construction: Fully galvanised for durability
- Mounting: Suspended over the pack area for clear, free floor space
- Design: Modular bolt structure for ease of assembly on site
Second system, same trusted partner
This project marks the second Powercon installation for Ceres, underscoring a strong working partnership. The CR45’s modular design allowed installation to take place in just 2 weeks, commissioned in October 2025 with minimal disruption to day‑to‑day operations.
Operational benefits
- Reliable flow to the line: Stations receive cartons as needed, helping maintain productivity.
- More usable floor space: Overhead routing removes carts and ad‑hoc staging from aisles.
- Fewer manual touches: Less walking and lifting for operators, supporting ergonomics and safety.
- Scalable and serviceable: Modular track and accessible components simplify expansion and maintenance.
“By taking carton distribution overhead with the CR45, Ceres can keep operators focused on packing—not fetching. Two lines, variable speed, and a galvanised build give the site the capacity and durability it needs.”
— Bennie Jordaan, Powercon Handling Systems
