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Tag: doors

Completion of Warehouse Phase 1

Posted on by David Priestman

St. Modwen Logistics, one of the UK’s leading logistics developers and managers, has successfully completed Phase 1 of the development at St. Modwen Park Derby. The 67-acre industrial and logistics park, which is the largest brownfield regeneration site in Derby, was developed in partnership with Derby City Council and Network Rail. It occupies a prime position, strategically located off the A52 providing direct access to Derby City Centre and just five miles to Junction 25 of the M1.

Rated BREEAM ‘Excellent’, Phase 1 of the project sees the completion of four sustainable, high-quality warehouses, with Phase 2 of development on the site already underway, providing a further c.350,000 sq.ft of high-quality logistics and warehouse space.

As a preferred St. Modwen Logistics supplier, Hörmann UK worked closely with main contractor Winvic to supply full loading bay solutions together with safety and operational equipment including dock buffers, dock lights and traffic lights, plus sectional level access doors and fire exit doorsets.

Across the four buildings that make up the first phase of the site a total of 27 loading bays have been installed. Twenty-three standard height loading bays have been fitted with HLS-2 swing lip dock levellers, with four Eurodock bays being fitted with an HTL-2 dock leveller which features a 1 metre telescopic lip. This provides an optimal range loading platform enabling the precise bridging of a variety of vehicle types and a guarantee of fast, efficient, and most importantly safe loading and unloading. In addition, 23 ‘single bay’ and 4 DSS-G ‘double/euro bay’ scissor arm dock shelters have been installed to provide protection from the elements for both operatives and goods, helping to reduce heat loss during loading and unloading operations.

With the St. Modwen Logistics site achieving an impressive EPC ‘A’ rating, each loading and level access bay is fitted with a robust Hörmann SPU F42 sectional door. The doors feature double glazed vision panels and provide excellent thermal insulation with an impressive overall U-value of between 1.1 and 1.3 Wm2.K. Stucco textured profiles deliver a durable and resilient finish to withstand the external elements, while rubber draught seals to the edges of the leveller’s help minimise heat loss during loading and unloading operations.

Other elements of the Hörmann loading systems include reinforced dock buffers which are constructed from recycled tyre rubber with 15mm thick steel faceplates. The buffers are designed to minimise any potential damage to the bay in the event of a vehicle making direct contact with the building. Traffic lights and LED dock lights complete the loading bays offering the highest standards in safety and operational efficiency during the docking and loading processes.

A total of 23 Hörmann STU steel fire escape doorsets have also been installed throughout the 4 units, completing an impressive range of products supplied, all chosen for their quality construction and the impressive service offered by the company.

Phil Thorpe, Industrial Division Manager at Hörmann UK, comments “St. Modwen Park Derby is a landmark logistics development for Derby and Hörmann are proud to be working with St. Modwen Logistics and Winvic on the completion of the site. Our loading solutions have been designed to deliver unbeatable levels of safety and functionality, together with excellent thermal properties. At Hörmann we are committed to providing St. Modwen and their clients with first-class solutions and service to help streamline business needs and processes.”

High-Speed Roller Doors

Posted on by David Priestman

A roller doors case study from the world of manufacturing offers useful pointers in upgrading legacy warehouses that run fast-moving logistics scenarios.

Established 30 years ago in the buildings of a former concrete factory, Telford-based Hager UK Limited has transformed the site into a high-calibre modern manufacturing base. It is a leading provider of solutions and services for electrical installation in residential, commercial, and industrial building, with products ranging from power distribution, cable management and cabling accessories to building automation and security systems.

As the company grew, so the buildings needed to be modernised. The internal doors were also gradually replaced, but this did not bring the desired results. For this reason, the factory planners decided to assess an EFA-STT® high-speed spiral door from Efaflex.

The first door was installed in 2020, intended as a test to replace and upgrade the old roller doors at the factory. The test was an undoubted success. In addition to opening speeds of up to 3 m/s, the door offers maximum wind resistance and can be supplied in standard sizes of up to 8,000 mm in width to 7,800 mm in height.

Plenty of daylight

Thanks to slats made of crystal-clear acrylic glass, the door leaf of the EFA-STT® is more than 70 percent transparent and allows plenty of daylight into the production areas. The unobstructed view through the door brings decisive advantages: accidents are avoided, and smooth transport processes are guaranteed.

The door leaf of the EFA-STT® is kept at a distance in a spiral. Thanks to contact-free winding, the transparent slats remain virtually wear-free and ensure a clear view for years to come. Due to the individual design of the slats, the EFA-STT® can be adapted to the desired application. All visible sections of the door are made of PVC-free acrylic glass as standard. Any combination with grey coloured slats is also possible on request. A translucent lamella look is also optional. This allows full incidence of light and at the same time protects against prying eyes.

More orders announced

For Hager UK, the EFA-STT® was equipped with the EFA-TLG® door light grid, which monitors the closing level of the door up to a height of 2.5 metres. Infrared rays create an almost flat light grid that can detect even the smallest obstacles without contact and, in this case, stops the door movement immediately. The door light curtain was integrated into the factory’s existing safety equipment.
In 2021, due to the favourable experience with the first door, another was ordered from Efaflex UK. A heavily worn high-speed door with a textile curtain was to be replaced. For this application, the planners opted for an EFA-SST®-S high-speed spiral door. Thanks to the efficiency of the Efaflex technicians, the old door could be replaced and the new one handed over ready for operation within two days. Hager UK has also announced that it will order further systems for the exchange of old doors from Efaflex in the coming years.

Warehouse Energy Saving

Posted on by David Priestman

In the last year, global energy prices have risen by almost 30 per cent and energy saving in the warehouse has become paramount as a result. European energy prices have risen to historic levels and are expected to keep on rising well into 2023. Thorsten Mauritz offers some energy saving tips.

Warehouses and logistics facilities are vast spaces with heating, cooling, lighting, and goods moved by electric-powered forklift trucks. Not surprisingly, energy bills are typically 15 per cent of warehouse operating costs, and The Carbon Trust estimates that over 70 per cent of those energy costs are for lighting and heating alone. In the current economic climate, and with winter approaching, substantially reducing energy use is not just prudent; it could provide business resilience in these turbulent times.

Loading dock seals

As trucks or lorries arrive at the warehouse to load or unload goods destined for our high streets and homes, they back into a loading bay. Bay doors are essentially holes – somewhere between 8’x8’ to 10’x12’ large – in the wall of the warehouse, where cold air can rush in and warm air escape. Most loading dock shelters provide a seal along the top, bottom and sides of the truck to prevent snow, ice, rain and wintry air from streaming into the warehouse.

But getting a good seal all around the trailer can be a challenge. Corners are often problematic and can remain open. Unsealed hinge gaps can equal up to two and a half square feet of open air. For as long as the truck is loading or unloading, warm air escapes and is replaced by chilled air. Even the smallest gap can result in annual energy losses of £1,200 to £2,700 per loading bay. So, it’s important to have dock shelters with optimal sealing features such as weighted curtains and fitted corners, like those found in Rite Hite’s Eclipse shelter.

Destratification fans

When a lorry or truck pulls away from the bay doors, cold air rushes in from the outside, across the warehouse floor and forces warm air to rise rapidly towards the ceiling. The process is known as air stratification and can result in a floor temperature 30 degrees cooler than the roof. To keep employees warm, one solution is to turn up the thermostat. But every extra degree increases heating bills by eight per cent.

A better solution is to use HVLS fans to even out the temperature. HVLS fans have large, slow-moving blades which can propel air approximately 85ft in every direction. Multiple HVLS fans working together push these large volumes of air from one to the other and are extremely effective at mixing the air in large warehouses.

Warehouse energy saving

During the winter, HVLS fans can be run in reverse (clockwise vs counter-clockwise) to draw the cold air upwards and mix it with the hot air near the ceiling before it falls back down again. Rite-Hite’s HVLS fans can either be run in reverse, or if more airflow beneath the fans is needed, they can run at half speed or less.

Commercial HVLS ceiling fans can save up to 30 per cent in heating costs, consume less energy than traditional (faster) fans and will pay for themselves within a year.

FasTrax high-speed doors

Warehouses often have different temperature zones for warm and cold storage of various products. Supermarket warehouses, for instance, need to store goods at freezer, chiller or room temperature. Keeping cool rooms and warm rooms grouped together in zones helps reduce temperature leakage. But as forklifts and trucks move from one zone to another, high-speed doors are essential for keeping temperatures stable. Every second counts. And Rite-Hite insulated high-speed doors can open and close at speeds of 2.5m per second to save energy.

But whether it’s the loading dock, the chilling zones, or the fans overhead, inspecting and upgrading your warehouse climate control solutions should be a regular feature of your maintenance schedule. Rite-Hite’s experts in loading docks and indoor climate control can conduct a thorough on-site survey to help you find ways to close any energy gaps before winter.

Thorsten Mauritz is European Marketing Manager for Rite-Hite.

GHL rebrands to iDoor Solutions

Posted on by David Priestman

iDoor Solutions has been revealed as the new company name for GHL Industrial Doors. As well as a new name, the nationwide industrial doors installation, repair and maintenance specialist has unveiled a new logo and website as part of an extensive rebranding initiative.

Building on the company’s 13 years’ experience as a trusted supplier of bespoke solutions in the industrial doors, dock levellers, gates and barriers sector, the company says its new corporate image and identity are reflective of iDoor Solutions’ professional approach and unrivalled customer service.

Steve Shakespeare, Managing Director at iDoor Solutions, says: “The new brand perfectly illustrates our growing ambition, and provides a unique opportunity for iDoor Solutions to become synonymous with quality, service and professionalism in the industry.

“We take an uncompromising approach to health & safety through recognised quality standards, driving excellence through training and development, by promoting preventative maintenance we ensure compliance with the latest legislation. This industry is developing at great pace, and we are at the forefront of progress.”

The new website provides an enhanced online presence that showcases the company’s solutions and services, with easy navigation and strong branding.

Alongside the rebrand, a significant investment supports iDoor Solutions’ ambitious growth plans, with a focus on continued expansion across the UK, customer growth and promoting professionalism and health & safety across the industry. This investment includes a new fleet of vans equipped with MiTower One-Person Quick Build scaffold towers to allow iDoor Solutions‘ fully trained service engineers to work safely at height without the need for additional access support.

 

 

Hörmann runs loading bay seminars

Posted on by David Priestman

Hörmann UK is opening its doors for a series of events throughout 2023 to showcase its “concept to completion and beyond” solutions for the industrial market. With its recent acquisition of Fen-Bay and Transdek, Hörmann now offers a total solution for industrial customers with an ever-expanding portfolio of best-in-class products supported by nationwide, 24/7 service support.

Covering industrial doors, loading technology together with its service and maintenance support offering, the events will be held at the company’s Coalville headquarters. Featuring tailor-made presentations and live demonstrations, attendees will have the chance to meet with Hörmann’s product experts and discuss forthcoming projects.

Managing Director of Hörmann UK, Wolfgang Gorner, comments: “Hörmann are well known within the industrial market and are ideally placed to bring real value to any project. Not only are we a large, multi-national manufacturing business synonymous with quality products and engineering, but we also have the flexibility to work with customers to provide innovative, customised solutions. The launch of our seminar programme for 2023 enables us to create a unique opportunity for clients, specifiers, and customers to come to see for themselves the difference Hörmann can bring to a project.

“Our aim is to make each seminar as bespoke and interactive as possible, with key product demonstrations being available onsite. I would like to extend my personal invitation to come and join us to find out how Hörmann can support you from concept to completion and beyond.”

Hörmann has created a micro-site which provides more information regarding the seminar programme and available dates. This is available to view by clicking THIS LINK. Bookings for the seminars can also be made online via the microsite.

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UK Roadshow to Help Firms Get Set for New Customs System

 

Smooth docking at Evri superhub

Posted on by David Priestman

As one of the UK’s largest delivery companies, Evri sorts and delivers millions of parcels every day. With ambitions of adding greater capacity to its nationwide network and strengthening its regional operations, the company – formerly known as Hermes – committed to creating a third superhub.

Situated on a 42-acre site in Barnsley, the 340,000 sq ft facility is the largest of its kind in Europe and represents a £60m investment by the firm. Responding to the growing demand generated by online shopping, the automated parcel distribution hub will take Evri’s national capacity to 4.2 million parcels per day.

A key aspect of the building is the 163 docking bays; lining two sides of the superhub, they provide the entry and exit points for every one of the 1.1 million parcels making their way through the facility each day during peak periods. This high volume of parcel traffic makes the vehicle docks an integral component in smooth and efficient parcel distribution.

Efficient doors for Evri

To equip the superhub with the docking solutions it required, Evri turned to long-term partner Assa Abloy Entrance Systems for a range of expertly designed systems. Centred around the OH1042P Insulated Panel Door, the solution for each loading bay also benefits from a DS6060P Mechanical Curtain Dock Shelter and a DL6120T Telescopic Lip Dock Leveller.

Providing a reliable, robust and well-insulated operational entrance, the OH1042P Insulated Panel Sectional Doors used in each bay maximise free space by opening vertically, or up and over ceilings, conveyors or mezzanines as required. Paired with a hard-wearing twin-ram hydraulic Teledock which ensures an adjustable, ergonomic and seamless contact between vehicle and dock, Evri’s team can get to work loading and unloading vehicles at each dock quickly, safely and easily.

Surrounding each dock system is the Mechanical Shelter, which provides weather protection during the loading and unloading process. For staff, this creates a safer and more comfortable working environment internally, while adding greater protection to parcels, ultimately improving standards through Evri’s processes.

For a long-term solution, however, several variants needed to be considered. From everyday high-volume use through to differing trailer types which will be regularly docking in the bays, the experienced Assa Abloy Entrance Systems team tailored each product specifically to Evri’s requirements.

Reduced window size

On the doors themselves, window sizes were reduced to limit the potential of accidental impact damage; buffers were modified to provide more robust protection to the building fabric and docking equipment; and the levellers and shelters themselves were adapted to accommodate different trailer bed designs and those of varying heights and widths – a crucially important consideration at a time when new trailer types are being introduced to improve vehicle efficiency.

Elsewhere on Evri’s 42-acre site in Barnsley, a dedicated Vehicle Maintenance Unit is regularly servicing and maintaining the fleet which moves parcels between hubs. Here, Assa Abloy Entrance Systems provided the 1042P Sectional Doors in level access arrangement. As well as maximising the opening area for vehicles to drive through, the doors also house larger windows, allowing more natural light inside the building whilst enhancing visibility of the yard. Simple, practical solutions designed to create safer and more comfortable environments for the superhub’s maintenance engineers.

Future-proofing smooth operations

Now Evri’s super hub is fully operational, the next challenge lies in keeping every door system and dock operating smoothly. Afterall, they’re the start and end of each parcel’s journey through the facility and need to remain operational round the clock.

Besides ensuring precisely designed, crafted and installed engineered solutions, Assa Abloy Entrance Systems is delivering a service and maintenance programme. Combined, this approach reduces lifecycle cost over the complete operational life of each door system, cuts the potential for unforeseen downtime and equips Evri with entrance systems they can rely on day after day.

As part of the service and maintenance programme, Assa Abloy Entrance Systems says it takes a two-pronged approach. Firstly, it schedules planned preventative maintenance at set periods and will see every opening asset on site serviced to keep them operating as expected. Secondly, the company provides immediate hands-on support when the unexpected happens, ensuring any system faults are quickly resolved by expert engineers.

Philip Whiteley, of Assa Abloy Entrance Systems, said: “Through our work with Evri, we have helped them to fulfil their ambitions of creating a major element of their nationwide distribution infrastructure which is able to cope with significantly heightened capacity. With the latest entrance systems in place, they can process more parcels more quickly than ever.

“We’re excited to be continuing our work with Evri over the coming years as we provide regular servicing and maintenance which will keep things running smoothly and, ultimately, reduce costs over their entire service life.”

 

Spiral doors bring clear benefits

Posted on by David Priestman

Hörmann UK has launched two new transparent, high-speed spiral doors, the HS5040 TurboLux and Turbolux S. With a market-leading opening speed of up to 4m/s, Hörmann says the TurboLux range combines high speed operation with optimised transparency, strength, and durability, making them ideal for demanding applications where efficiency and visibility are key.

The TurboLux range offers a pleasingly symmetrical and compact design, with transparent door laths manufactured from a clear, high-grade polycarbonate which provides high impact and breakage resistance. Providing 90% transparency, the door has been designed to maximise light and visibility, helping to reduce accidents, ensure smooth and efficient transport processes, and provide brighter working environments to improve operator conditions.

With TurboLux doors providing impressive opening speeds of up to 4m/s and closing speeds of 1m/s, operator safety is paramount. Situated within the side panels of the door is a light grille which monitors the door closing zone up to a height of 2500mm whilst a gentle soft-stop function stops the door in the event of an obstacle being detected.

Standard door sizes of up to 5000mm x 5000mm are achievable and offer an optional wind load resistance of Class 4, speeds of up to 133km/h, making the Turbolux door suitable for both external and internal installation. Narrow side panels of 250mm result in a door that offers installation flexibility as it can be fitted into confined spaces, and to aid fast and efficient installation key components are supplied pre-assembled.

Commenting on the introduction of the TurboLux range, Phil Thorpe, Industrial Division Manager at Hörmann UK, says: “We are excited about the launch of the Hörmann TurboLux, our new high-speed, transparent spiral door – a door that has been designed using high-quality materials to ensure a long service life and the ability to stand up to the wear and tear of challenging working environments.

“Together with industry-leading opening speeds and maximum visibility, TurboLux offers the market the chance to further speed-up workflow processes and reduce energy costs. Once again Hörmann are supplying the market with a real difference, and we think we have produced a clear winner.”

 

Union Industries increases stock levels

Posted on by David Priestman

Union Industries, the Leeds, UK-based manufacturer of high-speed industrial doors, has increased its stock levels even further to allow minimal lead times for production of its door range and replacement parts.

The driver behind this has been the 12% increase Union has seen in orders from companies looking to replace foreign-made doors.

A common problem with some manufacturers of fast rolling shutter doors is the lack of spare or replacement parts with many having particularly long lead times – one recent customer citing 21 weeks for spares to arrive into the UK from Germany. This problem has been increasing in recent years due to factors such as Brexit with some doors installed in the UK manufactured in Europe, it leads to both new and replacement parts being harder to source.

However, Union Industries prides itself on its low lead time and ensures there are sufficiently high stock levels to manufacture a minimum of 25 doors at any one time. Stock is replenished daily and spare parts for standard door servicing are always readily available for immediate dispatch.

Union says parts that require more bespoke manufacturing can be entered into production within a matter of days, meaning that disruption can be kept to an absolute minimum.

Union’s Operations Director, Tony Metcalfe, said: “We have seen an increase in orders to replace foreign import doors in the UK which this is mainly down to the long lead times for spares and repairs, along with more demand for our reliable and British manufactured doors.

“We maintain high stock levels to ensure we have a consistently efficient service line and can deliver replacement parts to our customers within 24 hours of the initial order in many cases.”

Alan Hirst, Sales Director, Union Industries, said: “Our business has always tailored itself to the needs of our customer base. We pride ourselves on listening to what our customers’ challenges are and helping them with the right solution, so this is a fantastic example of how Union Industries is yet again leading the way in the supply chain.

“We are proud to be a British manufacturer of robust and reliable industrial rapid roller doors that have the most minimal downtime due to the quality of the design and build as well as our ability to service and replace parts rapidly.”

 

Saving costs with intelligent door opening system

Posted on by David Priestman

Wherever high-speed doors are installed in production and goods distribution centres, customers will benefit from the new Door Control module offered as part of Linde Material Handling’s (MH) innovative Safety Guard assistance system. The intelligent control system enables communication between industrial trucks and infrastructure, thus avoiding above all, high costs due to collision damage.

High-speed doors can be found in businesses of all sizes and in all industrial sectors. They enable the rapid passage from indoor to outdoor areas and at the same time help to maintain constant temperatures in production and logistics buildings, protect workers from unhealthy drafts, deter the entry of birds and unauthorised persons and prevent contamination.

However, the positive effects of high-speed doors are partially diminished by the fact that they are repeatedly subject to damaging incidents, including those involving industrial trucks. One example in this context is the collisions that occur when the roller shutters are not yet fully open at the time that entry is attempted. In most cases, this only leads to property damage, but these instances can add up to considerable costs if rolling doors and forklifts are in need of repair or transported goods are damaged.

“A single accident can quickly result in costs in the five-digit euro range,” Fabian Zimmermann, Product Manager Safety Solutions, recalls from practical experience. “Drivers are often under pressure to meet deadlines or their minds are simply elsewhere and therefore not paying attention,” says the expert, citing possible causes of collision damage.

“Using the Safety Guard Door Control, our customers can now effectively defuse this accident-prone area and thus avoid costs and disruptions to their operations,” says Zimmermann, describing the benefits of the new safety feature.

Forklift speed is adjusted as needed

Like the Linde Safety Guard assistance system, the new Door Control function is based on ultra-wideband (UWB) technology. The truck communicates with the building infrastructure via high-frequency radio waves. When a truck approaches a rolling door, its travel speed is gradually reduced and the door opens automatically. To accomplish this, the intelligent system determines the distance between the permanently installed units on the forklift and the high-speed door to within 10cm. After passing, the door closes again and the forklift driver can continue on at the usual speed.

To prevent the door from being triggered by passing forklifts or to prevent neighbouring doors from opening, the size and shape of the zones around it (spherical or rectangular) can be adjusted to suit the specific needs. Yet another advantage of this technology is that the doors are only open for as long as necessary.

EFAFLEX unveils new IoT door solution

Posted on by Keith McKinley

With the innovative system EFA-SmartConnect, high-speed door manufacturer EFAFLEX says is sets new standards in the intelligent networking of door systems. The module enables both the operation and the planning of customer service and maintenance processes in their own, protected WLAN network.

All parameters can be conveniently controlled and visualised regardless of location and without contact. The user is always connected to the network via the app and benefits from numerous individually adjustable features for efficient, cost-saving real-time door management.

In times of ever-increasing digital change, not only future-proof technologies, but also reliable data security systems are essential in order to make work processes efficient, scalable, sustainable and competitive. EFA-SmartConnect meets the increasing demands of this modern corporate world with the consistently digital handling of door operation in its own, protected WLAN network.

The IoT solution is operated via the EFA smartphone app, compatible with the common operating systems iOS and Android, the functions of which include the visualisation of the current door status, the parameterisation of essential door settings such as open time and the display of maintenance data, error memory and current error messages including descriptions and root cause analysis. Thanks to the smart network with the manufacturer, users can also send service reports directly to EFAFLEX if they wish.

These properties contribute to streamlining processes on the user side and thus creating new space for efficiency and productivity increases and ensuring maximum smooth door operation. Thanks to in-depth analysis and clear visualisation, the time required for function checks, service requests and troubleshooting in the event of a fault is reduced considerably.

In addition, users can precisely calculate the exchange of spare parts, among other things. This in turn prevents and reduces costly downtimes and reduces the cost of customer service. The fact that EFA-SmartConnect is not only intuitive to use, but also works independently of additional IT programs, for example for cloud services, makes handling particularly easy.

Doors communicate in a network

Several doors equipped with the smart system can be connected to each other within a network and subsequently communicate with each other and with the app. If a particularly high number of gates is to be integrated into the management, for example in large halls, this is also possible because several networks can be operated in parallel. The module continuously forwards the current status report of each individual door to the app, from which the user can forward relevant data to the manufacturer if required.

As the operator of the door systems, they decide which of the available information they make available to EFAFLEX for further steps, such as reports on status, faults or maintenance issues. Depending on the needs they have assessed themselves, the app user can supplement this with free text information, for example with explanations or the request of IT support or a technician. In addition, the messages to be sent can be illustrated with photos.

Effective immediately, EFAFLEX will install the module in selected door controls. In order to be able to record and operate doors already in operation with EFA-SmartConnect, an additional board is integrated into the existing system, provided with a QR code, a serial number and access data. Older door systems can also be easily added to the network via the app, so that operators can also take advantage of the innovative module.

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