Klug Avalon celebrates 25 years of innovation this year.
What key milestones have defined your journey so far?
Over the last 25 years,
Klug Avalon has consistently pushed boundaries in crane safety and sensing
technology. One of our early breakthroughs was the development of wireless
sensors and pressure-based safety solutions making crane operations safer,
smarter, and easier to manage.
A major milestone has been
building our own fully integrated manufacturing facility in Pune. From PCB
assembly and cable harnessing to load cell manufacturing and testing,
everything is done in-house. This helps us maintain high quality and deliver
faster.
Our journey also includes
steady global growth. Today, with over 38,000 systems active in 62 countries, a
world-class manufacturing setup, and a team of 140+ skilled professionals, we
continue to create user-friendly, reliable solutions that improve safety, save
time, and build trust across industries.
Engineering Precision
Your LMI/SLI/RCI systems
process real-time crane data. How does your team ensure accuracy and
reliability in such dynamic environments?
At Klug Avalon, precision
starts with complete control over our technology. We manufacture all key
components—like load cells, draw-wire sensors, and angle sensors—in-house. This
helps us maintain strict quality control and deliver products that are
consistent and dependable, even in tough site conditions.
Our systems are tested
under harsh environmental scenarios, including extreme temperatures, vibration,
dust, and electromagnetic interference. We also follow international safety and
durability standards like ATEX, IP ratings, and EMI-EMC certifications to
ensure the systems work reliably across different job sites.
The real-time processing is
handled by advanced electronics with noise filtering, signal conditioning, and
CANbus communication. This ensures data is processed accurately and without
delay. Each solution is also fine-tuned for specific crane types such as
mobile, crawler, or tower cranes ensuring it delivers optimal performance based
on the machine it’s installed on.
Customization at Scale
You offer highly customized safety solutions for different
crane types. How do you balance flexibility with scalability?
Customization is one of our
core strengths, and we’ve built our manufacturing system to support it at
scale. More than 80% of our production is done in-house from PCB design and
assembly to sensor calibration and wiring. This gives us the flexibility to
offer tailored solutions without slowing down our delivery timelines.
Our production lines are
designed to be flexible and work on a just-in-time model, which means we can
adapt quickly to new customer requirements or crane models. Whether it’s an OEM
needing a custom interface or a rental company looking for a specific
configuration, we can respond fast and efficiently.
On the design side, we
maintain a common software core across products. Only the working parameters
change depending on crane type and application. This allows us to keep the
systems simple to support and easy to scale, while still delivering the
customization that different users need.
Global Expansion
With 38,000+ systems in 62 countries, what have been the
biggest challenges in scaling global support and training?
As we continue to grow
globally, one of the key challenges has been ensuring high-quality support and
training across different geographies. To address this, we are building a
strong international dealer network. We provide our dealers with detailed
technical training, product manuals, and direct access to our engineering and
support teams so they can confidently install our systems and train their own
customers.
Our products are designed
with simplicity in mind. Installation is straightforward, and the user
interface is intuitive. This ease of deployment makes it easier for our
partners and customers worldwide to get started quickly, with minimal
dependency on factory support.
At the same time, we have a
robust service infrastructure within India, including 20 field service
engineers and 8 in-house experts who handle remote diagnostics, video support,
and repairs. We regularly conduct operator training sessions and support OEMs
and partners with first-level servicing, backed by a responsive back office for
recalibration and warranty handling. Together, this combination of global
enablement and local strength ensures consistent service, wherever our systems
are deployed.
Driving Safety Culture
Even small overloads can double stress. How are your
systems reshaping safety standards and operator behavior across industries?
Overloads, even small ones,
can cause serious damage over time. Our systems prevent this by giving
real-time safety guidance. They monitor load, angle, and radius, and display
safe working conditions directly to the operator removing guesswork and manual
load chart checks.
We’ve built in clear visual
and audio warnings well before unsafe conditions arise, and offer optional
lockouts to stop dangerous operations. Over time, this creates a culture of
safety, reducing accidents, downtime, and repair costs while making safety
compliance a routine habit on site.
The Future of Crane Tech
What role will AI, IoT, and predictive analytics play in
Klug Avalon’s next wave of innovations?
We see AI, IoT, and
predictive analytics playing a big role in the next stage of our growth.
Through IoT, our systems will be connected to the cloud allowing fleet owners,
OEMs, and rental companies to monitor crane health and performance remotely.
They’ll get real-time alerts, usage reports, and diagnostic data that help with
better planning and control.
Predictive analytics will
help us move from reactive to proactive maintenance. By logging stress cycles,
overload incidents, and usage history, our systems can generate early warnings
for component wear or calibration needs. This will reduce unplanned downtime
and help customers get more life from their equipment.
AI will bring smarter insights by analyzing usage patterns. It can detect risky behaviors, near-miss events, or inefficiencies and suggest safer, more effective ways to operate. These insights will help site managers and operators make better decisions, reduce risk, and improve overall job site performance.
