Rescuing a Theatre Hoist OEM’s Supply Chain Through Domestic Manufacturing

A North American manufacturer of theatre and opera house hoists faced mounting operational risk after its European brake supplier became unreliable. Lead times exceeded 14 weeks, and costs were climbing due to tariffs and consecutive price increases. The OEM needed a reliable domestic partner capable of meeting stringent acoustic and safety requirements.

KEB America delivered a customized, US-built solution that cut lead times by more than 70% and reduced total cost of ownership.

The Challenge: Unworkable Lead Times and Rising Costs

This theatre hoist manufacturer operates entirely on a project basis. Professional theatre clients demand installations that work around demanding performance schedules, with work carried out strictly between seasons to avoid disrupting productions.

The company also serves school theatres, where most installations must be completed during the summer construction window, a narrow period when students are out, and facilities are accessible.

Against this backdrop of rigid scheduling, their long-standing European brake supplier had become a liability:

• Logistical Gridlock: Lead times reached 14+ weeks, making it impossible to respond to new project bids.
• Rising Costs: Ongoing price increases, compounded by a significant tariff in 2025, reduced the OEM’s margins.
• Specific Technical Barriers: The application required a specialized “theatre-grade” brake. The replacement had to meet three non-negotiables:

1) Silent Operation: Noise-reduced design so the brake could be used during live performances.

2) Safety Integration: An integrated microswitch to interface with the hoist’s safety controller.

3) Manual Hand Release: A reliable hand release mechanism for maintenance and emergency inspections.

The KEB Solution: Engineered and Assembled in the United States

KEB America has supported the theatre and stage industry with automation and motion control products for over 40 years. Its most popular brake solution for theatre applications includes load-brakes and spring-set brakes.

KEB spring-set brakes are electrically released, DC-actuated, and engineered for failsafe power-off engagement across the full range of stage machinery: deck winches, turntables, line shaft hoists, pilewind hoists, and orchestra lifts.

KEB America’s application engineers conducted a technical consultation to bridge the gap between the European spring-set brake design and a viable US-manufactured alternative. Through leveraging our core spring-set brake technology and customizing the assembly in Minnesota, KEB delivered a solution that met every technical requirement.

The Product: KEB 1000Nm Spring-Set Theatre Brake

• Noise Reduction: Engineered with specialized damping systems to ensure near-silent engagement/disengagement during quiet stage scenes.

• Safety & Maintenance: Factory-fitted with a precision microswitch and a durable manual hand release.

• Domestic Prototyping: Because engineering and assembly took place in the US, KEB delivered functional samples in just 2 weeks, made possible in part by 3D models available for immediate download from the KEB website.

“The ability to download a 3D model immediately from our website and get a 1000Nm brake into the customer’s hands for testing in 14 days completely changed their project trajectory,” said Jonathan Bullick. “We weren’t just a component vendor; we became the solution to their supply chain crisis.”

The Results: Supply Chain Resilience by the Numbers

By moving to KEB America, the OEM effectively decoupled itself from international shipping volatility and trade-related cost exposure.

Building on Success: Future Outlook

Following the successful integration of the 1000Nm brake, the customer is now working with KEB America to scale this success.

The next phase involves designing a 1500 Nm theatre brake for a larger, high-capacity hoist model. That brake will be paired with KEB’s K-style helical-bevel integral gearmotor, deepening the overall product and supply chain relationship.

KEB Delivers Full Automation Solutions for Theatre Applications

Is your supply chain exposed to long lead times or international cost pressure?

Contact KEB America’s engineering team to discuss your application or use the Gearmotor Selector Tool to find your next solution. With a standard lead time of four weeks or less, KEB can help you bid confidently on aggressive project timeframes.