Hyster fine-tunes trucks to meet industry challenges

Businesses can now easily fine-tune a forklift to match their specific industry and application needs with the new scalable Hyster A Series lift truck series.

With A+ Logic, the Hyster lift trucks can be configured with a range of features to help overcome common materials handling challenges across industry, while delivering a low total cost of ownership.

“For example, in construction materials applications, lift trucks will often be used outside in dirty or dusty environments with poor ground conditions,” says Robert O’Donoghue, VP Marketing and Solutions EMEA for Hyster. “A+ Logic with the Hyster A Series lift trucks offers several adjustable features that can help optimise trucks everywhere, from concrete manufacturing operations to those handling bricks and blocks.”

Dust can result in wear to parts and components. The Hyster A Series features sealed electrical connectors to help manage this but selecting oil-immersed brakes, tilt cylinder boots, and mud guards may provide some applications with additional support. Heavy-duty air intake can also help reduce service intervention requirements.

Where debris is an issue, on-demand cooling includes a reversing fan feature to blow debris out of the engine bay, helping to minimise radiator and engine bay cleaning.  Debris on the floor can also be tackled by choosing a belly screen option and string cutter, helping to optimise uptime.

The Hyster A Series also provides a 2-year / 4000-hour warranty as standard in regulated EMEA markets, giving tough applications peace of mind.

Optimising driver awareness

“In finished metal goods applications, lift trucks will typically be operating indoors in production areas and warehouses,” says O’Donoghue. “In this environment, noise and other distractions can often represent a risk, especially if the truck is working in the vicinity of pedestrians.”

For these applications, a Hyster A Series lift truck can be built with features to support driver awareness. For instance, blue and red spotlights, red line awareness lights, and/or a visible alarm can be chosen to help indicate to pedestrians where a truck is, and that it is moving or working.

The Hyster A Series lift trucks also offer excellent all-round visibility, giving operators the ability to see their surroundings quickly and clearly. With a new mast design, the A series provides through-mast visibility to help improve awareness of the environment. Configurations with a cabin can also benefit from a high-strength laminated glass roof for an unobstructed upwards view. The truck can also be fine-tuned with mirror and camera options to meet application-specific needs.

The mast design also provides excellent fork tip visibility when handling loads, and a fork laser level line can help increase visibility and productivity further.

Operator comfort

Timber storage and distribution centres will commonly comprise in/out operations. For example, unloading a trailer parked in a yard and bringing the load inside, or moving loads from one building to another across a yard or outdoor area.

To maximise comfort for operators, wood applications can opt for their truck to be built with a suitable cabin option for hot or cold climates. For instance, a full weather-proof cabin may help keep operators comfortable and productive in outdoor areas in colder or wetter climates,” says O’Donoghue.

Full cab options include front, top, and rear screens as well as wipers and steel side doors, plus heating, air conditioning, or heated screen options. Sunshades can also be selected with A+ Logic.

Finally, to help meet environmental objectives in many different applications, the new Hyster A Series lift trucks also help deliver reduced emissions, leading to lower costs.  The H2.0-3.5A diesel trucks consume up to 13% less diesel than leading competitor models, and LPG trucks use up to 9% less fuel.

The first ‘Distinctly Hyster, built for you’ models available in the A Series are the H2.0-3.5A IC lift trucks, for handling loads up to 3.5 tonnes.

CLICK HERE to watch the A Series during an Extreme Environmental Conditions Test in Germany.

Interview: Baoli is growing in different markets

The industrial truck manufacturer Baoli EMEA, part of the KION Group, aims to become one of the top suppliers in the entry-level segment in all 53 countries where it is currently represented with its products. That is the plan. At present, however, the markets are still developing very differently.

While Baoli is already very prominent in Italy, its market share in France and Austria is still modest. Olivier Le Bozec, Baoli country manager in France, and his counterpart in Austria, Roman Tahetl, talk about how the brand is developing in their markets.

Q: How has the market in the entry-level forklift segment developed in your area of responsibility in the recent past?

Olivier Le Bozec (OLB): In France, this market in particular is growing very dynamically. According to my estimates, the entry-level industrial truck segment has at least doubled in the past 12 months.

Roman Tahetl (RT): In Austria, the total market for industrial trucks rose from 8,473 to 11,922 vehicles last year. The Asian suppliers, who mainly cover the market for entry-level industrial trucks, grew by around four percent last year.

Q: What do you estimate is Baoli’s percentage share of these markets?

OLB: We currently have a market share of around 0.5%. At first glance, that does not sound like a very significant share, but it is a very respectable figure for France. After all, Baoli has only been seriously in business there for four years and development is still in its early stages. But I am pretty sure that we will grow very quickly in France.

RT: In Austria, we will soon reach a market share of 1.5%. That is very impressive considering that we only entered the Austrian market with Baoli in January 2022. In just a few months, we were already able to demonstrate impressively that the “Baoli model” works very well in Austria.

Q: How has the Baoli dealer network in your country developed over the past 12 months?

OLB: We have acted very stringently in the past months and trained our dealers and their sales staff very intensively. Fortunately, we have succeeded in winning six new dealers for Baoli in France.

RT: We were also very successful in acquiring dealers in Austria and are now working successfully with eight dealers. After starting from scratch at the beginning of 2022, this positive development is very, very pleasing.

Q: How many new dealers do you want to acquire for Baoli in your country in the next 12 months?

OLB: We still have a great need, and I hope that at least 12 new dealers will join us in the next few months. Demand is very high, especially in the north of France. Benoit Pasquier, a new sales professional, is currently working on developing the material handling market for Baoli.

RT: We would like to start our business in Austria with 10 dealers to begin with – so we still need two more – and then to observe whether this will be sufficient. In addition, we will take a close look at the regions and analyse where we have further demand.

Q: In your opinion, what are the reasons for dealers in your country to decide to work with Baoli?

OLB: Baoli’s clear structures, loyalty and consistency are certainly the most important reasons for a positive decision.

RT: In Austria, all dealers want to have one brand under contract if possible. In this way, we gain small dealers in particular, who are enabled by this contract to build up their own fleet. But the price and discount structure are also important for this decision. All dealers receive the same discount from us and a sufficiently large sales area. As all dealers in Austria know each other very well and constantly exchange information, there is no significant competition or price war among them.

Q: Is it important for your dealers that Baoli is part of the international KION Group?

OLB: In my experience, the reputation of the KION Group plays an important role in the dealers’ decision to choose our company. For example, KION offers the guarantee that spare parts will be available for more than a decade. In addition, the umbrella organisation guarantees very comprehensive quality control.

RT: I can only confirm that: Being part of the KION Group is an important argument for most dealers to work with Baoli. There are corresponding guarantees – and that is a very important factor in my eyes.

Q: How do your dealers react to the new Baoli vehicles?

OLB: In France, the dealers are first positively surprised by the high-quality of the vehicles manufactured in China, and then very impressed by the trucks. They keep telling us that Baoli vehicles have a very good chance of being successful in our market – the entry-level industrial truck segment.

RT: Unfortunately, we are not yet that far along in Austria. Our dealers are still very cautious in their assessment of the vehicles and want to examine and test them extensively first. However, I am also firmly convinced that we will develop BAOLI into one of the leading brands in the entry-level segment in this country.

Q: So, your dealers are primarily convinced by the quality of the components installed?

OLB: They definitely are. Especially because we use proven components that are used by many forklift manufacturers. The Doosan engines which BAOLI installs, for example, underline the very high-quality standard of the brand. With these high-quality supplier products, our forklifts need to fear no comparison.

RT: Unfortunately, my answer to this question is not as clear as that of my French colleague. As we have only been active in the Austrian market for a few months, I think it is still too early to make a realistic statement here.

Q: Do you consider the current supply of Baoli vehicles to be sufficient?

OLB: At the moment, the range can certainly be expanded to cover all conceivable requirements. However, since Baoli is planning an extensive expansion of its product portfolio, this situation will quickly improve significantly.

RT: I would answer this question in exactly the same way. I, too, am of the opinion that the current range of vehicles will not be sufficient in the long run and should be supplemented – but that has already been planned.

Q: How do your dealers rate the price/performance ratio of Baoli vehicles?

OLB: Our prices have increased over the past year and a half due to the well-known import costs and raw material costs increase because of the worldwide economic situation. However, we must always keep one thing in mind – and we also communicate this to our customers: Baoli forklifts offer significantly more quality and service in the entry-level segment than other suppliers. Anyone who buys a Baoli forklift always buys a comprehensive after-sales service as well.

RT: In Austria, the price/performance ratio of Baoli forklifts is considered very positive according to my experience so far.

Q: Do you see any approaches to optimising cooperation with Baoli dealers?

OLB: Improvements are always possible. The Baoli vehicles could be presented more prominently in the showrooms of our partners in order to anchor our brand even more firmly in the minds of our customers.

Q: Mr. Le Bozec, Mr. Tahetl – thank you for this very interesting interview and for your assessment of the markets in which you operate.

Clark introduces mono-mast high-lift pallet truck

Clark has expanded its product range in the area of pallet trucks with another lift truck. The new WS10Mi is a high-lift truck with mono-mast and initial lift.

The WS10Mi is one of the entry-level models in the world of high-lift trucks. Thanks to its mono-lift mast and its maximum load capacity of up to 1000kg (1200kg initial lift), the areas of application of this nimble warehouse helper are many: The vehicle is suitable for transport over short distances, for stacking applications up to a lifting height of 1955mm or also as a mobile, ergonomic work table. The WS10Mi comes into its own especially when used on uneven floors, smaller ramps or weighing equipment, as the WS10Mi effortlessly overcomes inclines thanks to its initial lift (115mm).

The compact design of the high-lift truck also allows it to be used in space-critical work areas, for example in narrow racking aisles. The length of the truck including the back of the forks (l2) is just 600mm. Only a small amount of force is required to steer the manoeuvrable lift truck. This conserves the operator’s strength and relieves him of his workload. Due to the low vehicle weight of 520kg (including battery) and the resulting lower ground load, the vehicle can also be used on intermediate levels.

Safe and ergonomic load handling

The handle-optimised vehicle drawbar enables precise operation of all travel and lifting functions. In addition, the mono-lift frame offers the best possible view of the fork tips. The operator always keeps an overview and can position the unit safely and precisely as well as thread it unerringly into pallets. Like all models in the WS10 range, the WS10Mi has a low-slung vehicle frame to protect the operator’s feet and those around the vehicle.

The WS10Mi is equipped with maintenance-free block batteries and a built-in charger. This allows the battery to be recharged at any 230v socket. This increases availability and simplifies handling. The vehicle display informs the operator about the battery charge level as well as the operating hours driven.

 

Getting best value from fleet investment

With costs rising across the board, getting the most from your investment in fork lift trucks is more important than ever. As Stewart Gosling of RDD, the UK importer of Mitsubishi Forklift Trucks, explains, there are so many factors that can lead to savings over the lifetime of equipment.

“While the price of the truck itself and the fuel costs are the headline items when weighing up your options, there’s much more to it than that when looking at the wider picture. Safety, maintenance, downtime, and support are all factors that’ll affect your bottom line.

“Every Mitsubishi Forklift Trucks product that leaves the factory is built with the same vision behind it. It’s not just about being the best in terms of performance, it also has to be the safest, most reliable, and most fuel-efficient it can be. They’re designed for a long life of high performance and minimal downtime.”

Exceptional fuel economy has been a hallmark of the GRENDiA range of diesel and LPG counterbalance trucks since their inception. It’s a key part of the ‘green diamond’ concept. Low fuel use and low emissions paired with robust construction make for an economical and long-lasting truck that can serve as the backbone of your fleet.

When looking at long-term costs, over a typical 5-year span electric trucks can offer savings in the thousands compared to IC engine equivalents. The EDiA electric counterbalance range – including the award-winning 5.5-tonne EDiA XL – not only matches IC engine trucks in terms of performance but adds a host of cutting-edge advanced features.

Class-leading visibility is a staple of any Mitsubishi Forklift Trucks model. The better the operator can see the surrounding environment and the load, the less likely they’ll have an accident.

Combine this with smart, adaptive technology for speed, stability, and traction such as the Sensitive Drive System or patented DriveSteady system and there’s a greatly lowered risk of a scrape or collision, dropping something, damaging racking, or other incidents that lead to downtime which can eat into your profit margins.

Stewart adds: “Beyond the capabilities of the actual trucks, where you acquire them is also of huge importance. With Mitsubishi Forklift Trucks–authorised local dealers the benefits are twofold. Not only do you have a local point of contact who will understand your business and your specific requirements, but they also have the support of the UK Mitsubishi Forklift Trucks network.

“It means local, personal service backed with manufacturer resources. For example, this means any parts they don’t currently have in stock can be with you quickly from the central parts hub.

“Our dealers will also be able to provide a free site survey to ensure you not only have the correct equipment, but that you’re using it in the best possible space.

“Make sure you look at the whole picture when making your next investment in equipment as the initial outlay never tells the whole story.”

 

UniCarriers launches next-generation of ERGO stackers

Stand-in stackers are among the safest, most space-efficient and profitable handling equipment available. UniCarriers pioneered this technology and is now welcoming the next generation of the successful ERGO A series with the 2022 models.

The 2022 ERGO A series, comprising of the ASR125, ASR160, ASR200 (including initial lift models), is the latest evolution of an unprecedented success story in material handling, with improved operator functionality, new electrical architecture and even better performance. Since the launch of the very first stand-in stacker in 1961, pioneered by UniCarriers, the versatile, space-saving and safe design has provided its customers with World-Class ergonomics and efficiency.

Stand-in stackers guarantee a fast return on investment, regardless of the type of warehouse, warehouse utilisation or logistics strategy – by reducing operating costs to a minimum. Truck design around human needs makes people more productive and happier at work. The next-generation Stand-in stackers contribute to a low total cost of ownership (TCO), as a result of improved truck safety, ergonomics and design.

Safe operations, unmatched ergonomics

UniCarriers says the outstanding safety feature of the ERGO is its design. The central concept is that the driver stays inside the machine, regardless of driving position or operation. This in turn minimises the risk of accidents, while providing unlimited working positions. UniCarriers has developed the ergonomics further with the operator in mind, preventing operator fatigue and improving body position.

A new steering wheel design, adjustable in height and angle depending on driving direction; new presence control – an optical sensor instead of a pedal, which results in a more relaxed driving position in all driving directions; a new ergonomic handle, and multi-function display to support several options, such as weight and height indicator.

Additional features including sensitive power steering and cornering control, provide excellent stability when on the move, regardless of speed or load. As before, the unique ProVision mast design offers unrestricted all-round visibility; furthermore, the truck’s mast is outstandingly quieter than the previous generation.

Space- and cost-efficient

The ERGO is perfectly at home in tight and confined conditions, with its minimal dimensions and tight turning radius, and so it can make optimum use of expensive space for storage and retrieval. Because of its design, the ERGO can work in far narrower aisles than a platform truck. This adds up to a 10% saving in floor space in a normal warehouse. With lift heights of up to 7m, storage density and utilisation of floor space can be further optimized using higher racks which offer up to 43% better volume density than other stackers.

To increase residual capacity and improve stability, the trucks can be equipped with a new design of foldable stabilisers that allow them to lift heavy loads as high as a significantly more expensive reach truck. This considerably increases the profitability of an existing warehouse, and green-field facilities can be built smaller and so more environmentally cost-effective.

Powerful and effective

The ERGO is a particularly powerful machine. Fast drive speeds and excellent lift and lowering speeds enable best possible throughput and efficiency. Its fully integrated, high-performance batteries, paired with high energy efficiency and intelligent solutions for battery replacement, all make the ERGO the perfect solution for long, high-performance, multi-shift operation and intense 24/7 use. Customers now have the option to choose between energy efficient and maintenance free, built-in fully integrated Li-ion batteries for 24/7 operation with only quick opportunity charging, or traditional lead-acid for the ultra-compact Junior versions, while the larger Senior size is available with lead acid batteries.

With its overall performance, safety aspects and space saving design, the new ERGO stand-in stacker is the best choice when it comes to flexible transport or stacking in light to heavy duty operations, in warehousing, manufacturing or anywhere a safe and productive stacker is required. A new milestone for a technology that, after sixty years of continuous development, now fits the times and modern requirements for safety and efficiency better than ever before.

The new models are available for loads of 1.25, 1.6 and 2.0 tonnes.

Combilift launches two new models

Irish forklift manufacturer Combilift has added two more products to its now extensive range. The Combi-FSE (pictured) – an electric  four wheeled, two directional sideloader in both 5,000kg or 6,000kg lift capacity is joined by a new Swap Body Transporter – the Combi-SBT.

The Combi-FSE  electric sideloader

As part Combilift’s drive to help customers achieve their aims of more sustainable operations, over 60% of the company’s output is now electric. Recent models such as the Combi-XLE and now the Combi-FSE focus on heavier duty application for industry sectors such as timber, steel, tubes & pipes and builders merchants.  Thanks to Combilift’s immense engineering and design experience, the Combi-FSE delivers on all aspects of reliability, durability, powerful performance and ease of maintenance, combined of course with the quiet and emission free electric operation that more and more customers are demanding.

The patented traction system in this new product plays a major part in ensuring the optimum performance of the Combi-FSE in all weather conditions. Sensors in the front steering axle linked to the innovative Electronic Traction Control system enable the two independent 15kW drive motors on the rear axle to be controlled individually, with the speed of each wheel governed by the steer angle of the front wheels to provide improved steering control for the operator, better truck turning radius and reduced tyre wear.

This new technology, when combined with regenerative braking (which recaptures the truck’s kinetic energy during deceleration and can be used to recharge the batteries to extend battery life), makes for Combilift’s most advanced steering system on its four wheeled trucks to date.

The generous glazing of the cab, particularly the roof to floor windscreen, allows the operator to have an excellent field of vison of the load, the machine and the surroundings. Considerable engineering development to ensure optimum visibility for the driver saw the perfection of the under-deck battery system, with the power pack strategically placed at the rear of the truck between the drive motors – giving a clear line of sight to the rear and when reversing, and guaranteeing the best operator visibility of any comparable truck. This position also enables safe and easy battery removal from the low-level rear of the truck.

Maintenance time has been kept to a minimum due to key service features such as its quick interchangeable battery for shift work, centralised grease points on the front and rear of the load platform and removable panels for easy access to the motor.

Combilift CEO Martin McVicar commented: “We introduced our first 4-wheel sideloader around 10 years ago after initial requests from companies in the timber sector, and it has since become pretty much a standard solution for those who run intensive schedules which clock up many operational hours. The technological advancements in battery technology since then means that it was a natural progression to develop this electric model, which will help customers to drastically reduce their carbon footprint.”

Swap Body Transporter – the Combi-SBT

Combilift has collaborated with some of its customers in the concrete sector to come up with a newly developed product for the improved handling of what can be a problematic material to lift and move around. The attributes of this new model will also greatly benefit companies in other industries who deal with extremely oversized, heavy or bulky loads. Since Combilift was established 24 years ago it has always taken customer feedback on board when designing new products, and this has been a key component of the unparalleled growth of the company which now exports to over 85 countries.

The Combilift Swap Body Transporter – Combi-SBT – can transport of a wide variety of swap body containers ranging from standard container swap bodies to concrete wall panel swap bodies from production to storage. With a maximum lift capacity of 50,000kg, the machine is available with diesel or LPG power options. It has a 3-wheel design with 6 wheels for lower ground pressure. Its rear wheels are hydrostatically driven and are steered from the front, ensuring excellent manoeuvrability.

A pair of lifting platforms on the machine bed support the load during transportation. In-cab control of these ensures that the operator is in a safe, secure position when the load is being lifted and lowered. The platforms can also be lifted and lowered independently, enabling the machine to lift swap bodies that are not on level ground. The front platform is fitted with guides to suit standard ISO corner castings, with the rear platform having no guides. Having guides only on the front allows effortless loading of the swap body as the operator needs to align only two guides, which when in the correct position, guarantees the rear platform will also be in the correct lifting position.

In terms of safety and visibility the Combi-SBT offers numerous advantages compared to a shunt truck and trailer where you are driving “blind” with the load behind the driver. The cab is mounted at 90° on the machine and off-centre to the load which offers full 360° visibility and line of sight to all areas of the machine. With the addition of mirrors and a rear-view camera there are no blind spots, making the positioning the Combi-SBT under the swap body quick and easy as well as safer for the operator and surrounding personnel. The operator can also complete a full cycle without having to exit the ergonomically designed low level cabin.

The development of the Combi-SBT was, in part, customer-led, as is the case for many of Combilift’s new products. A major manufacturer of precast concrete had designed its facility for high levels of production, but the amount of finished concrete being stored around the factory floor was slowing down production and reducing the safe workable area. They contacted Combilift to see if the company could come up with a solution for quicker removal of products that could lift the concrete from underneath and operate in narrow confines and the Combi-SBT was the result.

Cycle times between casting have been reduced and workflow has increased to 50-70 batches per day at 24t each. The previous truck and trailer combination took two men about 15 minutes per load, whereas this is now a one-person job that takes as little as two minutes with the Combi-SBT which can be reversed under the swap body and quickly lift the product from ground to travel position. The three-wheel design also enables easy operation on areas with compacted gravel where a perfectly level surface cannot be guaranteed.

McVicar comments: “Combilift product development has always been solution-based and customer-led, and this new model is a prime example of successful collaboration between our customers who are experts in their field, and our engineers who have a wealth of experience. This results in machines that are not only 100% fit for specific customer requirements, but which often end up being used for other applications, for the benefit of customers in other industry sectors.

 

Yale showcases ‘Technology that moves’

Yale Europe Materials Handling made what it describes as a triumphant return to LogiMAT under the theme of ‘Technology that moves’. At the event, which was held at the Stuttgart Messe on 31 May – 2 June, visitors witnessed first-hand a variety of game-changing materials handling solutions on the Yale stand.

Yale, which has undergone a business transformation, brought its refreshed and recharged solutions to the international intralogistics event. Experts were on hand to explain how its technology is moving with the times and offering customers new materials handling solutions that meet changing industry demands. The latest Yale products combine technology and design to provide a customised solution to each and every customer.

“It was a real pleasure to be back at LogiMAT this year and have the opportunity to reunite with customers, dealers, partners and new visitors under one roof,” said Timo Antony, Area Business Director Central Europe at Yale. “There was a great atmosphere at the event, especially as Yale has undergone a hugely exciting business transformation including a new website and sales process designed to address customer needs with a focus on industries and solutions. We showcased our latest solution, the new Series N, which will offer a whole new way of configuring materials handling solutions and help keep businesses moving, even under constantly changing circumstances.”

Visitors at LogiMAT got to see the newest fleet on the block, the Yale Series N, in its very first public outing following its launch in May. The new product offers customers an easily configurable truck to match their unique requirements, raising the bar for success while offering operator comfort, safety and efficiency.

Yale’s lithium-ion battery partner, Sunlight Group, was also on hand at LogiMAT to meet visitors and showcase a warehouse reach truck powered by one of its lithium-ion solutions. The MR16 Reach Truck can lift up to 10.7 metres and has a maximum load capacity of 1,600kg. The robust mast design provides high residual capacities and stable load handling, which can enable faster put away and retrieval times. The reach truck has a spacious operator compartment and can manoeuvre in tight spaces, making it ideal for warehousing applications that need to maximise on storage space.

Yale recently strengthened its relationship with the Sunlight Group, having previously used its lead-acid batteries as an option for its product range. Yale now also offers the company’s lithium-ion batteries.

“It was a real joy to be joined by our new lithium-ion battery partner, Sunlight Group, at LogiMAT,” said Antony. “It’s one of the world’s top manufacturers of energy storage solutions, and we’ve long utilised their battery solutions in our products. We’ve expanded our partnership and we look forward to continue working with them to provide our customers with the very best power solutions to keep them moving.

“LogiMAT is just one chapter of an exciting period at Yale. It was the perfect opportunity to meet with our dealers, our customers old and new. There is more to come from Yale in the near future to better serve our dealers and customers and work with them to drive all our businesses forward. This is an exciting time for Yale as we embark on this shared journey with our trusted partners.”

Narrow margins deliver big returns

VNA systems deliver many benefits, but warehouse designers risk compromising safety and productivity if they place too much emphasis on simply achieving the narrowest aisleways, says John Maguire, managing director of Narrow Aisle Ltd.

With the fallout from the pandemic and Brexit continuing to impact on manufacturing and retail supply chains, UK warehouse space remains in short supply. In fact, the problem has become so acute in some places that one leading industrial property consultancy has forecast that parts of Britain could completely run out of empty storage facilities within the next 12 months.

So, warehouse managers and intralogistics professionals are under huge cost pressure to utilise every square foot of space available to them in the most effective way. At many sites this means reconfiguring the layout of the existing storage system around the narrowest aisleways.

With typical VNA – very narrow aisle – applications aisle widths can be reduced to between 1,600 and 1,800mm, which allow e-Fulfilment customer orders to be picked at ground level shelves and locations. Compared to traditional ‘wide aisles’ zone picking, which usually need around 3,000mm to allow two ‘low-level order pickers’ to pass one another, the space saving potential of VNA systems to e-Commerce companies is immediately obvious.

And, of course, better space utilisation means increased storage capacity – which, in turn, equals reduced storage costs per square foot. In some cases, it might also mean that additional storage space (if, indeed, any can be found) is not required or a costly extension to the existing warehouse (if you have room and can obtain planning permission) is avoided.

But before you begin ripping out your racking and narrowing your aisleways, be aware that VNA solutions in e-commerce applications have different requirements to traditional wide aisle zone picking systems and there a number of important factors to consider before concluding that VNA is the way ahead for your business.

For example, because older ‘guided’ VNA stacking aisles are only slightly wider than the materials handling equipment that serves them, a guidance system – wire or rail – will usually be required to ensure that lift trucks do not collide with the racking. These can be costly to install.

Another consideration is training of your forklift operators. Operating guided VNA machinery requires additional training to conventional reach or counterbalanced trucks and, at a time when qualified forklift operators are hard to find, if your lift truck drivers struggle with the demands of guided VNA materials handling equipment technology, it could be a problem.

With the type of specialist materials handling equipment often specified to operate within very narrow aisles – such as man-up Combi trucks and man-down VNA trucks – it is essential to assess the different technologies and their suitability to your operation’s unique needs before investing.

For example, because man-up Combi VNA trucks are physically big pieces of kit, storage schemes have to incorporate large transfer gangways at both ends of each aisle to allow these long trucks to switch aisles. This often means that the space savings achieved by reducing the aisle widths can be lost.

In addition, there are efficiency issues associated with the physical picking process when a Combi truck is used: quite simply, reaching out from a fixed cab to a pick carton placed on a pallet some distance away and then travelling between picking locations are neither ergonomic or throughput efficient.

In a lot of very narrow aisle applications, high lift Flexi Truck articulated forklift trucks have replaced VNA man-up machines. Flexi Truck articulated trucks have the same fixed space mast frame carriage technology as high lift Combi VNA and this – combined with operator vision system technology that enables a crystal clear picture of the highest pallets to be transmitted to the operator’s in-cab screen – enables pallets to be picked and put-away up to over 14 metres high using a Flexi Truck.

Flexi Trucks have other advantages over traditional VNA machinery too, not the least of which is the ability to operate safely and efficiently without wire or rail guidance systems. The Flexi Truck retains a fork tilt function and therefore does not require costly ‘super flat’ concrete floor specification.

It is technically feasible for Flexi Trucks to pick up and turn pallets in as narrow as 1,600mm wide aisles, the absence of guidance systems means that aisle widths ensure more clearance on either side. In applications where a high throughput and ground level order picking is required, it is possible to give a little extra aisle clearance to improve efficiency. Where 1,200mm deep Euro/ISO pallets are being stored, the optimum aisle width for a Flexi Truck is 2,000mm, which provides excellent operational clearance for stacking and picking functions.

So, while wire and rail-guided VNA forklifts can work in aisles as narrow as 1,600mm, with minimum clearance, the extra width required by Flexi Trucks is more than compensated for by the extra flexibility that the absence of guidance systems delivers while the fact that the Flexi Truck operator remains at ground level at all times means it is possible for pedestrian picking staff to carry out ground and low level picking operations within the aisle.

New VNA systems deliver many storage cost benefits, but warehouse designers risk compromising safety and productivity if they place too much emphasis on simply achieving the narrowest aisleways.

 

 

IFOY FINALIST FOCUS: SYNAOS IMS Vehicle Localization

Continuing with our run-through of each of the IFOY Award nominated finalists ahead of the winners announcement on 30th June at BMW World, we look at the SYNAOS IMS Vehicle Localization solution from SYNAOS.

IFOY Category: Special of the Year

Description

The seamless localization of transport vehicles is one of the most important steps towards fully digitized, highly efficient intralogistics. As soon as the position of every manually guided vehicle is known at all times, numerous new potentials arise: Important KPIs such as fleet utilization can be recorded, heat maps can be created and layouts can be optimized. In addition, drivers can be navigated optimally through production facilities and logistics centres, with delays being detected at an early stage. Furthermore, flexible, near real-time transport order planning can be realized. Also scan-free processes are made possible in this way, further simplifying workflows.

However, so far these and other use cases are not or only very rarely implemented – previous localization solutions are simply too expensive and it is not possible to achieve any savings. SYNAOS therefore pursues a modern approach: Intelligent software combined with cost-effective hardware allows precise and robust vehicle localization. For this purpose the sensor kit, which holds a stereo camera and a powerful embedded computer, is attached to the vehicles. This comparatively inexpensive combination enables the implementation of many use cases that were previously unprofitable.

Innovation
Current approaches for localizing vehicles in intralogistics are based on UWB (ultra wide band) or LIDAR (light detection and ranging). However, both techniques are associated with high costs – they require high and long-term investments. UWB requires a huge infrastructure investment and is very difficult to change or extend. In addition, the accuracy of localization depends on the illumination on site. LIDAR on the other side is achieving a very high accuracy. But this is not necessary for 95 percent of the applications in intralogistics. Another disadvantage is the high commissioning effort, because a map has to be created first.

SYNAOS IMS – Vehicle Localization, on the other hand, uses cameras and a technology called “visual odometry”. This technology is known from the fields of robotics and autonomous driving and is applied in logistics for the first time according to SYNAOS. In addition, SYNAOS uses simple markers at frequented locations in the hall so that the system has a global reference from time to time. This makes the installation of the system simple and commissioning uncomplicated, as no map has to be created. Only some markers are needed and the environment can change at any time without affecting the localization.

Market relevance
Every intralogistics vehicle providing power supply and a mounting option can be equipped with the SYNAOS IMS – Vehicle Localization, enabling precise localization in real time. Thereby, complete fleets can be digitized retrospectively. The system increases the efficiency of fleets and saves costs. The market for this solution is therefore huge: In 2020, about 1.5 million forklifts were produced. In addition, there is a correspondingly high number of already existing vehicles in the field. But very few of these vehicles already have their position recorded, nor are they digitally mapped.

Upgrading manual transport systems with the localization solution from SYNAOS is also highly relevant for the mixed operation of autonomous and manually guided vehicles. The entirety of transport orders for intralogistics can be controlled precisely and more efficiently. In addition, autonomous guided vehicles can be better controlled with known positions of the manually guided vehicles. For example, they can be slowed down when a forklift comes close, avoiding an emergency stop at an intersection. Enabling or improving the mixed operation of manual and autonomous vehicles also supports the gradual automation of intralogistics processes.

Main customer benefits
Customers benefit from easy-to-use, real-time localization for any intralogistics vehicle. However, SYNAOS IMS – Vehicle Localization is not only quickly installed, but also easy on the budget. Despite a comparatively low price, the solution achieves a very high accuracy. The position of the vehicle is calculated by strong computer vision algorithms from the images of the camera. Apart from an accelerometer, no other input sources are required. The complex creation of a map is also not necessary, since SYNAOS IMS – Vehicle Localization additionally uses simple markers for orientation, which are placed approximately every 100 meters in the environment. The solution is therefore extremely flexible and can be used in any intralogistics scenario.

All image processing takes place locally on the embedded computer – no sensitive data needs to be transferred to the cloud. The image data captured by the camera is immediately discarded after processing. Furthermore, communication is always transparent and future-proof thanks to compatibility with a standardized industrial interface.

Summary

The position of forklifts and other manually guided vehicles in intralogistics is usually unknown. This is now changing with SYNAOS IMS – Vehicle Localization: A camera-based sensor kit for the cost-efficient localization of manually guided intralogistics vehicles. SYNAOS uses state-of-the-art computer vision technology as enabler for its accurate and robust location system that is easy to install and scale.

CLICK HERE to watch a video.

IFOY TEST REPORT

What good is all the digitalisation if there are always “blind spots” in the company. One such blind spot is the fact that most of the forklift trucks that drive around in companies are still controlled manually and are therefore not digitised or only rudimentarily digitised. With the SYNAOS IMS – Vehicle Localisation system, a camera-based sensor kit ensures their cost-efficient localisation – using state-of-the-art computer vision technology.

SYNAOS is a software company, but has decided to build a small hardware. A small black box (19 x 12 x 6 centimetres) can be found at the demo set-up in Hall 3 of the Dortmund Trade Fair. It is screwed onto a child’s forklift and projects its images onto a screen.

The manufacturer has dedicated itself to eliminating the gaps in the localisation of manually controlled industrial trucks of all kinds: So it’s all about indoor localisation of industrial trucks. 95 per cent of companies have forklifts in use, but they are rarely well integrated into the value chain: Currently, only the transport order is digital; the forklifts themselves are not digitalised. As a result, there is no knowledge of where a forklift is located. There are forklift localisation technologies, but they are often not used. There is a reason for this: ultra-wideband or lidar technology are simply too expensive. Speaking of lidar: the system is already too accurate, as if one were shooting at sparrows with cannons.

With the new system from SYNAOS, which works with so-called “markers”, a Localisation-as-a-Service (LaaS) tool, it’s different: Everything is already included in the price and the detection comes to an accuracy of about 25 centimetres. So it’s not just about the “little box” on the test set. For 1,980 euros a year per truck, that would be relatively low costs for admittedly standardised electronic components that can easily be bought at electronics stores: But the intelligence is in the software – plug and play.

You can create transparency in a flash with SYNAOS IMS – Vehicle Localisation: Where in the warehouse is busy? What are the braking distances? Where are people driving around without a driving order? Even the truck that is always running late can now finally be pointed out. In short: you can observe the fleet utilisation exactly. And a very big USP compared to the conventional storage method is that the forklift only reports the position where it has driven a pallet; scanning the pallet or the products on it is no longer necessary.

SYNAOS expects CE certification in a few weeks. The already mentioned indoor accuracy of 25 centimetres is achieved with markers every 100 metres. The “little black box” operates with a power consumption of 7 watts and transmits its camera data – 15 images per second – via WiFi for evaluation using computer vision algorithms. Apart from an acceleration sensor, no other input sources are required. In times of increasingly important cybersecurity, this is perhaps not entirely unimportant: the entire image processing of the system takes place locally on the embedded computer; no sensitive data need to be transferred to a cloud. After the camera’s image data has been processed, it is immediately discarded.

IFOY Test Verdict

The simple real-time localisation of all types of industrial trucks with the help of this very convincing localisation system helps customers on their way to the complete digitalisation of intralogistics. It is very easy to record fleet utilisation, but also to create heat maps for critical points in the warehouse or optimise warehouse layouts. The basic tenor: inexpensive hardware works together with intelligent software. Every industrial truck with a power supply and a mounting option can be equipped with the SYNAOS IMS – Vehicle Localisation sensor kit – a huge market.

IFOY INNOVATION CHECK

Market relevance: The localisation system was developed in order to retrofit forklifts with a sufficiently accurate, cost-effective and scalable solution for position tracking and to integrate it into digital control processes. With an annual production of approximately 1.5 million forklift trucks and a minimum service life of 10 years, there is a very large market with a high demand for digitalisation of all players in the warehouse, also driven by the trend towards mixed operation with AGVs.

Customer benefit: Users benefit from the fast set-up, almost without adapting the infrastructure, as well as the easy usability of the system. As a result, the solution scales from quantity 1 without significant investment costs, as it is offered as Localisation-as-a-Service at a reasonable price. In use, SYNAOS enables the user to perform statistical analyses for fleet utilisation and process optimisation, digital order control and monitoring, optimised driving behaviour of AGVs in mixed operation, navigation of forklifts in the warehouse as well as automatic scanning processes for goods booking. Unlike compact UWB (ultra-wideband) systems, however, SYNAOS can only locate vehicles, not people.

Novelty: The localisation of intralogistic vehicles on the basis of visual odometry, i.e. relative localisation via stereo vision with occasional absolute referencing via markers, is a novelty in the industry. However, the technology itself is not completely new and has already proven itself in autonomous driving. Advantages over the usual laser scanner-based methods with a map are the lower costs as well as the simplicity and robustness of the approach even in highly dynamic environments. Compared to UWB-based solutions, the advantage lies in the low need for adaptation of the infrastructure and the low investment costs. The innovation value consists in a solution that is appropriately balanced between localisation accuracy (approx. 25 centimetres) and costs.

Functionality / type of implementation: The solid test setup of the sensor kit with integrated computing unit convincingly demonstrated the functionality of the system. The energy-efficient retrofit kit requires only a power supply and can be integrated via the WiFi infrastructure. SYNAOS offers its own order and fleet management, but can also connect to other systems via VDA 5050. The operating interfaces are user-centred and the closed sensor system does not disclose any images to the outside for data protection reasons, but will enable new additional functions in the future. It is still not clear how much maintenance is required with regard to contamination of the camera sensors.

Verdict: The forklift market is a lucrative market for SYNAOS in the long term. The customer benefit is high due to improved order status information, statistics and optimised traffic flow guidance. The novelty of the reliably and robustly implemented plug&play system is given in logistics.

market relevance ++
customer benefit +
novelty +
functionality / type of implementation ++
[++ very good / + good / Ø balanced / – less / – – not available]

For an overview of all the finalists, visit www.ifoy.org

CLICK HERE to find out more about SYNAOS.

BYD Forklift unveils advanced products at LogiMAT

BYD, a world-leading manufacturer of New Energy Vehicles (NEVs), is using the occasion of this week’s LogiMAT trade fair to introduce new products to its range of zero-emission forklifts. A highlight is the European premiere of the heavy-duty BYD ECB70/80 counterbalance forklift. Additionally, BYD is demonstrating an expanded range of industry-leading robust material handling equipment, all powered by the patented BYD Iron-Phosphate Battery.

Since the previous staging of LogiMAT in 2019, BYD Forklift has significantly expanded its range of award-winning forklifts. The new heavy-duty BYD ECB 70/80 is BYD’s highest-capacity counterbalance forklift to date, and is being displayed in an outside area (between halls 9 and 10) to reflect its suitability for use both inside the warehouse and outside in the yard. Representing a breakthrough in a sector dominated by diesel- and lead acid-powered trucks, the BYD ECB70/80 can operate for up to nine hours on one charge. BYD’s advanced charging intelligence means with just one hour of charging, its range can be extended a further two to three hours, making it an attractive proposition for high-intensity operations in sectors such as manufacturing, beverage and building products.

LogiMAT visitors are also among the first in Europe to see the BYD ECB20S, a three-wheel counterbalance with a 2-tonne capacity that ensures BYD offers a complete product range to meet every customer’s needs. Originally scheduled to make its public debut at the cancelled 2020 staging of LogiMAT, the all-purpose BYD ECB20S has attracted considerable attention from busy logistics operations thanks partly to its flexible zero-maintenance battery options that offer the highest-possible levels of availability.

Making their European debuts are a pair of powered pallet trucks from BYD each offering lifting capacities up to 2 tonnes. The BYD PTP20P features a fixed ride-on platform and side panels, and has been optimised in virtually every area to improve operator safety and ergonomics, as well as manoeuvrability and energy efficiency. The new BYD PTW20Si, designed for use in retail, supermarket and stores for easier picking and transportation tasks, boasts a compact design, light weight and the ability to lift up to 750mm.

As well as introducing models into existing ranges that offer greater choice of capacities, BYD has launched the SEF range of counterbalance trucks, which have been designed to bring a cost-effective forklift to low-level users who may previously have believed the advantages of a lithium solution were beyond their reach. Visitors to BYD’s stand have the opportunity to see at close quarters the new BYD SEF35 for the first time, which has been carefully configured to deliver similar driving and performance characteristics as a diesel forklift with an equivalent capacity.

As a global leader in NEVs, BYD is renowned for making significant advancements in charging technology, and takes the opportunity at LogiMAT to display a number of its smart chargers. As well as a continuous drive to extract the greatest performance using the lowest-possible energy consumption, BYD offers a new smart charger with flexible charging configurations that optimise energy use for any material handling application. Uniquely, BYD manufactures its efficient next-generation chargers and batteries in-house, making it the only manufacturer with the ability to ensure its forklifts are fitted with a tailored battery solution.

The line-up of BYD products at LogiMAT are completed by further Iron-Phosphate Battery-powered zero-emission models from its extensive range. Demonstrating it has a truck for every purpose, BYD is showing the rugged BYD ECB50 with a 5-tonne lifting capacity, and the BYD EPS14Pi, a manual stacker with a capacity of 1,400kg and lifting heights of up to 5,400mm.

Finally, BYD is unveiling tools that help fleet managers keep tabs on their vehicles whilst also helping them to optimise remotely their energy use and battery management.

“Since we were last at LogiMAT in 2019, we have driven advancement in areas such as active safety, telematic solutions and charging technology at a rapid pace,” says Blade Feng, Forklift Business Unit Director, BYD Europe B.V. “As a specialist in lithium technology, we are looking forward to speaking with visitors to LogiMAT who are interested to explore the improved flexibility and potential total cost of ownership savings offered by a switch to BYD.

“We are particularly excited to launch to the European market our new models, including the heavy-duty BYD ECB70/80, a true ‘diesel killer’ that finally brings a zero-emission solution with no compromise on performance to a sector that has relied for too long on polluting IC engines.”

Feng concludes: “We would also like to use our presence at LogiMAT to speak with potential new dealers seeking to offer a complete lithium solution to their customers. Also, we encourage operators to get up-close to our forklifts, to see the build quality for themselves and to acknowledge the high comfort and visibility levels from the cabin.”

BYD Iron-Phosphate Batteries come with the most advance design, highest levels of safety and an industry-leading 8-year (or 10,000-hour) warranty, offering its customers a safe, reliable, and long-term materials handling equipment partner supported by a growing network of local dealers.

 

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