
Case Studies

Our expert solutions staff has more than a century of combined experience in the caster and material handling industry, making Caster Connection a prime source for help and advice regarding all caster and material handling needs. We work with our clients to understand their needs for every application and provide the correct solution the first time, providing the proof our clients need to feel confident in our recommendations. Peruse below some examples of solutions we've provided our clients.


Use Case Study: Transforming Efficiency and Cost Savings for a Load Bank Manufacturer
A U.S.-based load bank manufacturer slashed costs by more than $400,000 annually after switching to Caster Connection, gaining tailored solutions at a 52% pric…

Case Study: Eliminating Downtime and Boosting Efficiency in Manufacturing with Caster Connection
A boat manufacturer was losing 5–6 hours of productivity per week due to failing casters in a fiberglass-heavy production environment. Swivel casters were seiz…

CC Apex Extended Lead Simplifies Handling for Manufacturer
A manufacturing facility in Kentucky was struggling with material handling challenges while transporting automotive components on their heavy-duty carts, which…

Manufacturer of Heating Equipment Finds Success with CC Apex HD
When a leading manufacturer of heating equipment faced costly floor damage and frequent caster breakdowns, they turned to Caster Connection for a solution. Kee…

Leading Electric Truck Manufacturer Reduces Downtime with CC Apex HD Outrigger Casters
In this case study, an industry-leading electric truck manufacturer faced caster failures that caused production line disruptions. Seeking a customized solutio…

Customized and Streamlined Caster Solutions for an Automation and Robotics Company
Casters for automated guided vehicles (AGVs) and automated guided carts (AVCs), critically affect overall performance. Noise, ergonomics, weight capacity, cust…

Case Study: Enhancing AGV Performance with CC Nexus Casters
A leading provider of adaptive material handling systems faced challenges with their 7000 lbs AGV units. Initially, the AGVs utilized a 4 swivel caster system …

CC Apex Improves Ergonomic Performance and Operational Efficiency for Tier 1 Automotive Manufacturer
This case study provides a detailed overview of the client's challenges, the collaborative solution provided by Caster Connection, and the resulting benefits a…

Internationally-Known Tire Manufacturer Has Ergonomic, Green Rubber Retention, and Noise Issues
An internationally-well-known tire manufacturer was experiencing several issues in their facility that could all be remedied by using different, more appropria…

Tire Manufacturing: The Perfect Casters
Most of our clients work with us because they have a specific issue they need to solve. However, as we begin working with them, we often discover that they hav…

CC Apex HD Optimizes Material Handling Efficiency at Tire Manufacturing Facility
This case study explores how a strategic solution was implemented to address various challenges related to material handling at a tire manufacturing facility. …

Toyota Material Handling's Transition to CC Nexus Casters
Our team recently conducted a site visit to Toyota Material Handling's production facility, where they showcased our product to the engineers and material hand…

How the CC Stark Has Performed for Top Agricultural Equipment Manufacturer
Have you ever bought a product that claimed to be durable and high-performing, but then you found out how fragile and poor-quality it was? We’ve seen it dozens…

Tier 1 Automotive Manufacturer Sees Ergonomic Performance and Operational Efficiency Improvements With CC Apex
This case study provides a detailed overview of the client's challenges, the collaborative solution provided by Caster Connection, and the resulting benefits a…

The CC Nylex Defies Expectations of One Manufacturer of Industrial Farm Equipment
Many of our clients don’t even think about casters until there has been a problem. In one instance, a facility for an industry-leading manufacturer of agricult…

CC Peak Rig Dramatically Improves Ergonomic & Towline Performance Agricultural Equipment Manufacturer
A well-known agricultural equipment manufacturer in the Midwest moves tens of thousands of parts each month, moving throughout main buildings and from one buil…

On-Time Solutions: Caster Connection Saves the Day
Owners of a storefront were worried they had to delay the grand opening of a new location due to an inability to get a set of casters on time. They were using …

The Value of CC Apex Casters
No company is the exact same, but over the years, we’ve found that our tens of thousands of clients have to answer one main question, “What value do these cast…

CC Apex Maintenance-Free Casters Reduce Push/Pull by 40% for Industrial Farm Equipment Manufacturer
When an industry-leading farm equipment manufacturer faced significant ergonomic issues that were jeopardizing the safety of their workers and hampering produc…

CC Nexus Improves Ergonomic Performance and Operational Efficiency at Midwest Automotive Plant
This case study examines how an American automotive company with an engine plant in the Midwest successfully addressed ergonomic challenges in their assembly p…

CC Apex HD Dramatically Reduces Push/Pull for Leading Manufacturer of Industrial Agricultural Equipment
When an industry-leading farm equipment manufacturer faced significant ergonomic push/pull issues that were jeopardizing the safety of their workers and hamper…

Caster Connection Reduces Noise by 20% for Ford Engine Plant
Before working with Caster Connection, a Ford Engine plant was experiencing excessive noise while using a urethane-tread wheel recommended to them by another c…

Casters and Wheels for Buick Restoration
A former carpenter found that he needed to build a “body dolly” that could hold the body of his 1941 Buick Century Sedanette during its restoration.

Cart Manufacturing Partner Reduces Automaker's Noise by 20%
In environments like automotive manufacturing, it's important to take measures to reduce noise levels as much as possible for the safety of employees. Casters …

Caster Connection Implements Casters for Ford’s Harshest Uses
Before meeting with Caster Connection, a Ford Truck plant was having issues with 8” x 3” and 10” x 3” casters from a couple of other caster companies. These in…

Caster Connection Solves Split-Tread Caster Problem for General Motors
Before working with Caster Connection on this issue, a GM automotive Assembly Plant in Kentucky was experiencing ergonomic problems while using a popular caste…

Caster Connection Helps Ford with Ergonomic and Durable Casters
Before working with Caster Connection, a Ford Assembly plant was originally using casters with a 250mm diameter that were recommended by another caster company…

Caster Connection Provides Organization and Tracking for Midwest GM Facility
A General Motors Supply Warehouse in the Midwest was experiencing issues with keeping track of all the types of casters they were using in their various carts …

Caster Connection Reduces Push/Pull for GM Plant’s Engine Side
Before working with Caster Connection, a Michigan General Motors Plant’s Engine Side was experiencing ergonomic issues with another caster company’s urethane o…

Caster Connection Reduces Noise by 20% for Ford Engine Plant
Before working with Caster Connection, a Ford Engine plant was experiencing excessive noise while using a urethane-tread wheel recommended to them by another c…

Responsive and Expert Solutions for a Multinational Manufacturer
A multinational conglomerate involved in a variety of industries had several caster-related problems at one of their manufacturing facilities.

Top Social Media Data Center Gets Customized ESD Caster Treatment
Over the years, it’s become very apparent that each one of our clients has unique needs and preferences. We’ve designed our casters to cover most of the issues…

The Birth of the CC Apex ESD (Electrostatic Dissipative) Caster Wheel
A large auto manufacturing client of Caster Connection brought a new challenge to the table: they needed a solution for an electrostatic discharge-safe area. T…

Runaway Casters Cause Problems in National Home Improvement Retailer
A national retailer that caters to do-it-yourselfers and construction professionals was having an issue with runaway carts. In their distribution centers, they…

A Custom Caster Solution Solves 3 Problems at a Ford High-Velocity Center
The Ford High-Velocity Center in Princeton, IN, provides wholesale distribution of motor vehicle supplies, accessories, tools and equipment. Prior to wor…

Caster Connection and CC Apex Reduce Downtime at a Chewy.com Distribution Facility
Chewy.com is an online pet food retailer whose distribution center operates 24 hours a day, 7 days a week. The company had a problem fulfilling orders in a tim…

CC Apex: Improving on an Industry Standard
Caster Connection’s focus on ensuring that our clients implement the right product for their needs the first time around separates us from the competition. Aft…

CC Apex Wheels: Making Hospital Carts Quieter and More Ergonomic
Hospitals constantly look for new ways to improve their patients’ comfort level. One aspect of patients’ comfort is the noise level of their environment. Hospi…

CC Apex Wheels: Ergonomics and Noise Reduction in the Medical Environment
The maintenance department of a hospital uses carts that encounter various types of floor environments, requiring casters that are durable, quiet and easy to p…

Casters with Neoprene Wheels: Protecting Hospital Floors
Hospitals pride themselves in keeping their floors and seating areas clean and unmarked. One hospital found that their rolling chairs and tables (which were fi…

CC Vintage Casters: The Perfect Touch for a Steel and Reclaimed Wood Coffee Table
It's awesome to see how our line of CC Vintage and other DIY-project casters and wheels can add the perfect touch to someone's home or office. Caster Connecti…

CC Vintage: Safe Enough For Wood Floors
A furniture maker was tasked with finding an aesthetically pleasing, vintage looking caster for a large, special project. They were having problems finding the…

CC Apex Wheels: An End to Damaged Flooring, Downtime and Noise
A Machine Shop client of Caster Connection was approached by a client of theirs that used multiple racks in their facility and had a floor surface covered in m…

Casters and Wheels in Automotive Manufacturing
Automotive plants are subject to strict safety testing in order to ensure the protection of their products and workers. Some examples of safety testing include…

CC Apex Wheels: Dispelling Debris, Increasing Ergonomic Performance
Manufacturing seats for the automotive industry creates an environment that can be very hostile to most caster wheels - an environment in which a great amount …

Blickle Casters and Brakes: Security and Ergonomics
Road cases often carry extremely valuable equipment, which is often substantially heavy. While a great deal of importance is placed on the design of the case i…

Importance of Proper Metric Conversion for Wheels and Casters
After a competitor of Caster Connection recommended a nylon wheel that was an incorrect fit for its meat mixing machine, a food packaging company quickly began…

The Delrin Bearing Succeeds in Food Processing
Bearings are an unsung component of casters that play a huge part in casters’ performance. Ensuring that the correct bearing is implemented for the application…

Pricing and Flexibility: Its Importance for a Caster and Wheel Supplier
High volume manufacturing and distribution requires flexibility and swiftness from all suppliers. Caster Connection strives to fulfill this nearly universal re…

CC Apex: Ergonomic Casters & Wheels in Industrial Manufacturing
The applications of many industrial manufacturing plants require the use of manually operated, hand-pushed carts. These carts are essential in carrying equipme…

CC Apex Casters Meet Auto Manufacturing Safety Standards
The equipment used in automotive manufacturing has to meet strict safety standards in order to be approved for use. Equipment that does not meet these standard…

The CC Apex Keeps Quiet in the Hospital Environment
Hospitals are designed to work around the patients’ needs and to keep them comfortable. It is sometimes easy to forget how big of an impact small details can h…

Blickle Casters: Taking the Shock out of Light-Rail Systems
A design and build contractor for one of the United States’ leading light-rail systems was encountering problems with static shock in one of their projects. Th…

Ideal-Stop Caster Brake Prevents Injuries and Damage
Manufacturers often face the problem of choosing brakes that are effective and ergonomic for the carts in their facilities. A major manufacturer had trouble fi…

CC Apex: Saving Time at a Clock and Furniture Manufacturer
A major manufacturer of clocks and furniture was in the midst of introducing a new product into their lineup. With the added stress of this new product on thei…

Material Handling Flexibility for an Auto Parts Maker
When purchasing casters and wheels, the quality of the sellers’ client service is often as important of a factor as the quality of the products being purchased…

Value in Caster Consolidation and Ergonomic Improvement
Casters and wheels are easy to overlook unless there is a glaring problem with them. However, sometimes there are some not so obvious problems with casters and…

Reducing Worker Stress with the CC Apex
When material needs to be moved and space is limited, manually pushed and pulled carts are typically used as mobility tools. Using manual carts instead of moto…

CC Apex Reduces Push/Pull Force for Ice Cream Cone Maker
A family-owned and operated ice cream cone and cup manufacturer was experiencing difficulty in manually pushing and pulling their 1,500 lb. batter bowls.

Providing Stronger Casters for Users of Industrial Magnets
End users of industrial magnets such as railroad yards, steel yards and warehouses use casters and wheels on their yard trucks to move the magnets throughout t…

CC Apex: A Client's Request Leads to Reduced Metal Chip Retention
Caster Connection received this message from a now-client in the manufacturing & design industry who found our website in hopes of finding a solution to their …

CC Peak: An Industry Breakthrough in Ergonomics
A large automotive manufacturing client of Caster Connection is clearly aware of why selecting the right caster is vitally important to keeping business in mot…

CC Stout HD: The Performance Enhancer
A material handling company was using a 6” x 3” polyurethane wheel that was continually failing and retaining large amounts of debris. This made the company’s …

CC Apex: Noise Reducer Extraordinaire
A poultry producer was using a very hard 4” x 1-1/4” polyolefin wheel for their feed carts. The wheels were very noisy, and broke after only a few months of us…

CC Apex Wheels Perform on Debris-Heavy Floors with Spectacular Results
An auto manufacturer had a series of carts that operated in an area with lots of metal chips and debris on the floor. The application currently had in use poly…

CC Nylex Saves Time & Money in Dough Making Facility
A large baking facility was having problems with carts carrying heavy amounts of dough. The carts were using phenolic wheels with roller bearings. The phenolic…

Ideal-Stop Caster Brake
You may have already experienced high-quality ergonomic casters (casters that protect you from debilitating back injury). Possibly, you’ve used high-quality ca…

Bodyweld: The Right Wheel for the Application
Automotive plants are one of the toughest environments when it comes to operating truck carts, WIP carts, tugger carts and other material handling systems. Au…

Automotive OEM VLE Casters Case Study
For more than 30 years, we’ve seen a lot of different facilities and unique challenges. At times, there are multiple casters that will solve the problem, but i…

Auto Manufacturer Mistakes Orange Wheel for CC Apex
Due to the success and recognizable orange color of Caster Connection's CC Apex caster wheel, numerous manufacturers have come out with their inferior version …

A Kingpinless Solution for Window Manufacturing
A company that manufactures windows was having a difficult time moving carts using 8” x 2” phenolic rigid and swivel casters. The phenolic wheels were picking …