Electric Drum Stacker for the Nuclear Industry

A leading UK nuclear facility required a safer, more controlled method of lifting, transporting and stacking heavy 205-litre steel drums. Their existing approach used traditional gripping mechanisms that relied on the drum's weight to keep the clamp engaged. This posed an unnecessary risk in a sector where even minor handling issues can have significant safety implications.

STS was approached to engineer a fully electric drum stacker that would exceed the stringent safety and operational standards of the nuclear industry. Our design delivers total confidence during drum handling, particularly during stacking operations and movements across uneven flooring.

Safety was the foremost priority. Nuclear operators must mitigate every foreseeable risk, especially during manual handling processes that involve hazardous or sensitive materials. To address these requirements, STS developed a bespoke dual-gripper head assembly powered by a hydraulic system.

Dual Redundant Hydraulic Grippers

The stacker features two independent hydraulic grippers. Each one maintains its own clamping pressure, meaning:

• If one gripper were to fail, the second continues to hold the drum securely.
• The drum remains safely clamped even during travel over rough or uneven floors.
• Unlike weight-dependent grippers, clamping force is actively maintained at all times and can be monitored via the clamp pressure gauge.

This redundancy gives Health and Safety Managers absolute assurance that the drum will remain secure during every stage of handling.

The lift and clamp functions are fully powered; however, the unit itself is manually pushed and pulled around the facility. This approach keeps operations simple and predictable while still allowing stable, controlled drum handling. Operators can move drums between process areas and position them accurately without strain or risk. A powered-drive version is also available if required. 

Key Performance Benefits

• Precise positioning when stacking drums vertically.
• Smooth, controlled travel, even across imperfect flooring.
• Consistent clamping pressure regardless of drum weight.
• Reduced operator effort, improving ergonomics and limiting manual handling risk.

This drum stacker was engineered from the ground up to align with the nuclear sector’s high expectations for safety and reliability. Throughout the design and manufacturing process, STS incorporated:

• A comprehensive understanding of nuclear facility workflows.
• Safety-led design decisions backed by decades of drum handling experience.

The result is one of the safest drum lifting systems available, offering unmatched protection against accidental release.

Outcome

The nuclear facility now benefits from:

• Significantly reduced manual handling risk.
• Greater confidence during drum stacking and transport.
• A future-proofed solution tailored to their strict environment.

The electric drum stacker demonstrates how precise engineering and safety-led design can transform high-risk drum handling tasks.