Application-specific drive solutions for material handling

The electrification trend is just taking off in mobile applications for material handling. Electric drives are dynamic, efficient, powerful and above all reliable. They are thus suitable for forklifts, automated guided vehicles (AGVs) and pallet trucks. ABM Greiffenberger supplies the appropriate motors, gearboxes and electronics developed and manufactured in-house – and adapted to the individual application. This makes the drive specialist from Marktredwitz a valuable partner for customers with diverse intralogistics applications.

Many things are moved in and around a logistics centre – and wherever this happens, drives are required. It starts with employees coming to work in electric buses. Lorries transport goods to the receiving point – drives for auxiliary units such as hydraulic pumps, compressors and fans are needed here. When the lorries drive up to the dock, rolling doors open and close so that the employees can load or unload. By means of pallet trucks, forklifts or AGVs, the goods are moved to pallet and accumulation roller conveyors, which bring them to the high-bay storage area. Ergonomic lift assists are used for goods handling and machines are used for cleaning the production floors.

“We supply suitable motors, gearboxes, brakes and inverters for all these applications – from a single source,” says Michael Lühmann, Head of Sales & Marketing at ABM Greiffenberger. “This makes us a systems supplier for the entire intralogistics field.”

The drive specialist offers ready-to-install plug-and-play systems available as modules within a platform concept for the mobile sector. “We can thus easily combine gear ratio and motor size with brakes and sensors and in this way optimise customer applications. The finished solutions can be integrated into the different vehicle types,” reports Lühmann. This is by no means always the case on the market.

ABM Greiffenberger can completely cover the functions of traction, lifting and steering with its solutions in the mobile sector. They comply with strict environmental and emission requirements, are particularly safe and are extremely responsive for precise movements even at low speeds. “With this we are responding to a growing market. Because electrification is advancing more and more in mobile applications in intralogistics,” says Lühmann. Electric drive systems are more sustainable and more efficient. They run reliably and smoothly, are dynamic and durable, and offer safety. For that reason it is only logical for electric drives to be increasingly employed in a number of applications.

Hub wheel drives with electric steering

The drive specialist offers three gearbox types for mobile applications – including the robust TDH series hub wheel drives. This type of drive is extremely compact because the drive components are integrated into the drive wheel. The user profits from high static and dynamic wheel loads. Thanks to high wheel torques at low speeds, the user can precisely manoeuvre and drive up inclines with, for example, pallet jacks, aerial work platforms, AGVs or sweeper/scrubbers.

“We also offer the hub wheel drive with electric steering,” says Dipl. Ing. Mayk Krüger, Head of Mobile Drive Technology. With its low installation height, this version is ideal for forklifts and automated guided vehicles. The user benefits with the hub wheel drive with electric steering from a precisely controllable and efficient AC motor technology. It brings a torque of up to 300Nm to the wheel and has a drive torque of 360Nm. The redundant steering sensors provide for precise steering. Moreover, the drive is durable, maintenance-free and highly loadable.

Bevel Gearbox Drive Units: Innovative platform concept

With the bevel gearbox drive units in the TDB series for wheel diameters of 230 to 254mm, the systems supplier has efficient components featuring high performance and low energy consumption in its portfolio. The ready-to-install systems are modularly designed and are available as a platform concept. The complete solution comprising the motor, gearbox and sensors can easily be integrated into different vehicle types. In industrial trucks the TDB series bevel gearbox drive units provide high climbing performance and acceleration. They offer responsive and dynamic steering over the entire speed range.

The bevel gearbox drive unit is available in three versions – for example, with an integrated steering drive. The traction motor is vertically mounted in the fixed version. The operator profits from, amongst other things, redundant steering monitoring, maximum integration and excellent ride comfort with high safety.

ABM Greiffenberger also supplies the bevel gearbox drive unit for manual steering. The vertical mount of the traction motor in the rotating version is designed for direct drawbar mounting. This robust and durable solution features space-saving installation.

“Application-specific steering is also possible; customers can also combine the TDB bevel gearbox drive units with their own steering drives,” says Krüger. They are thus suitable for electric power steering systems and can be controlled via spur gear. A zero position sensor can optionally be attached for calibration of the steering positions.

Speed recording in this series is done via an incremental encoder with up to 64 pulses per revolution. There is also an option to use the AC technology with regeneration capability. An electromechanical holding brake is integrated for parking and emergency stopping.

Parallel shaft gears: Quiet and efficient

The TDF series helical gearbox drive units offer an especially high efficiency, low wear and quiet running even at high loads. “We achieve this via the high-contact-ratio helical gear technology,” explains Lühmann. The gearboxes are suitable for use in pallet jacks and three-wheel forklifts, for example. ABM manufactures the gearboxes from die-cast aluminium. Thus customer-oriented solutions can be provided at a good price-to-performance ratio. The design and the matching of the material to the application make sizes 200mm and 230mm light and stable. Speed recording is done via an incremental encoder with up to 64 pulses per revolution.

Systems supplier with high level of development expertise

ABM Greiffenberger scores points both with its extensive know-how and experience in the development of application- and customer-specific drives and with its platform concept, which ensures that customers quickly receive cost-optimised solutions. “However, we can also specifically address customer requirements,” says Krüger. “Thus we are not a standard supplier and offer our customers a measurable added value.”

One example of an individual development is an electric differential axle for forklift trucks and transport systems. Precisely adapted to the application, the differential axle has optimised interfaces and can thus easily be implemented into the vehicle.

ABM supplies all products, including motors and gearboxes as well as suitable electronics, from a single source. Even complex prototypes can be produced at short notice with additive manufacturing.

“Our drives offer high performance and system availability,” stresses Lühmann. This is especially important in material handling because the vehicles are often used in two- or three-shift operations. Reliability is extremely relevant here. Operators therefore rely on drives that are maintenance-free, robust and durable. “We consistently pursue our goal of not only delivering high-quality drive solutions, but also supporting our customers in the capacity of a partner with engineering and manufacturing expertise,” says Lühmann.

 

Narrow Aisle invests in Scotland

Narrow Aisle Ltd – the manufacturer of the iconic Flexi Truck articulated warehouse truck range – has extended its warranty, service and parts operation in Scotland.

Dedicated to meeting the requirements of Flexi Truck users north of the border, the new investment will see coverage extended to the whole country and will enable rapid response to call-outs across Scotland to ensure that Flexi Truck customers’ performance is optimised.

In addition, Narrow Aisle intralogistics specialists will operate in Scotland to provide warehouse storage design, fleet management and power source guidance. The warehouse design and storage system configuration advice offered to Flexi Truck users will ensure that maximum space utilisation and throughput efficiency benefits are derived from all of their trucks. It will also allow companies to begin to plan their operations around the latest cobotic e-commerce customer order picking technology and processes.

John Maguire, managing director of Narrow Aisle Ltd, commented: “The Scottish market is extremely important to us and Flexi Truck sales across the country continue to grow year-on-year. The territory brings its own challenges – not the least of which are some logistical difficulties in reaching certain customer sites in the wider region of the Highlands, so we feel it is absolutely essential to have a long-term presence within the market.

“The new Scottish investment will enable us to strengthen relationships with our clients and deliver the highest levels of support to Flexi Truck users throughout the country.”

Narrow Aisle Ltd has supplied more than 15,000 Flexi articulated forklift trucks to users throughout the world and has a global network of over 70 authorised distributors.

Flexi highlights sustainability goals to distributors

Narrow Aisle Ltd – the VNA materials handling solutions specialist – recently hosted a series of distributor open days at its UK Flexi Truck manufacturing plant in Great Bridge, West Midlands.

Attended by some 150 visitors, the three open days gave guests the opportunity to see some of the recent additions to the Flexi Truck range of articulated warehouse trucks and hear how the latest generation of Flexi Truck models are helping today’s logistics operations meet their sustainability goals.

In an address to guests, John Maguire, Narrow Aisle Ltd.’s managing director, explained that the company is focusing on the further development of environmentally conscious battery-powered trucks with renewed emphasis on lithium-ion technology which, he said, is ideally suited to the needs of some modern, 24/7 logistics and e-fulfilment hubs.

“Over the last three years or so there has been a major change in attitudes to forklift power sources. Lithium-ion battery technology has come of age at precisely the right time to meet the market’s environmental, productivity and safety demands,” Maguire, commented.

“The radically different on-demand charging regime that lithium-ion offers is ideally suited to interface with on-site ‘solar’ power generation systems, as the demand is spread across the working day rather than concentrated at one time and drawn from the costly mains supply.

“Of course, lead acid batteries remain a highly efficient option for electric forklifts and many electric Flexi Truck lift trucks still feature this type of battery. But lithium-ion technology is now regarded as ideally suited to the needs of modern, 24/7 logistics and e-fulfilment operations.”

Narrow Aisle’s Flexi LiTHiON range of lithium-ion powered articulated warehouse trucks require zero maintenance and deliver extended multi-shift availability – making the trucks the ideal ‘green’ energy solution for modern order fulfilment operations, retail warehouses, temperature controlled stores, chemical stores and automotive manufacturing facilities.

Maguire added: “We see it as essential that our product offering constantly evolves and, of course, sustainability drives much of our research and development thinking. More and more customers are targeting zero emissions across their business so it is critical that Narrow Aisle has a range that helps them to achieve their sustainability goals.”

In addition an example of the new generation of automated picking robot technology that can help ecommerce operators increase productivity by up to 50% was presented to demonstrate the ease with which these Cobotic picking machines can interface with Flexi Trucks in a very narrow aisle storage system.

The robots and pickers work alongside Flexi Trucks safely in VNA aisles assembling customer orders. This functionality is not available in traditional VNA warehouses because it is deemed unsafe for low level order pickers to work in the same aisleway as guided man-up VNA order picking machines.

After enjoying a barbecue lunch and entertainment, guests toured Narrow Aisle’s Flexi Truck production facility. Capacity at the Black Country site, which Narrow Aisle has occupied since the mid-1980s, continues to be increased to enable the growing demand for Flexi Trucks – both from within the UK and worldwide – to be met.

Maguire concluded: “Our customers need to trust that we are able to provide Flexi trucks on fast lead times when they require them and, as sales of trucks in the Flexi Truck range continue to grow, we have to ensure that our production facilities are able to keep pace with demand. This means that we need to keep investing in our UK manufacturing site to support the dedicated work of our hugely skilled engineering teams.”

 

Heavy-duty mast for Linde reach trucks

Intralogistics specialist Linde Material Handling (MH) is now equipping its R14 HD to R25 reach trucks for payloads of 1.4 to 2.5 tonnes with a new heavy-duty mast. It offers operators a better view of the load and the surroundings as well as greater residual load capacities, enabling them to move pallets quickly and safely at lift heights of up to 15m.

In order to accommodate more goods and a larger range of products, warehouses and racking systems are growing ever higher. This places increasing demands on the reach trucks used, because the loads need to be stored and retrieved quickly and safely up to the top shelf levels. And that’s not all: While the vehicles are able to reach higher and higher with the mast extended, they must also be able to pass through gates and racking without any problems with the mast retracted.

At the same time, the vehicle must not become longer in size. Every centimetre counts so that the equipment can remain as manoeuvrable as possible, be able to cope with narrow aisle widths and make optimal use of storage areas. Last but not least, solutions are needed for the mast vibrations that occur with increasing lift height and for the increasingly limited visibility conditions.

Visibility-optimised mast

The best possible view of the load and surroundings is the basic prerequisite for the safe use of reach trucks. With the new heavy-duty mast, this is achieved in two ways: For one, it is much wider than previous models, and secondly, the developers were able to dispense with the cross struts previously required. This results in significantly larger viewing windows between the mast sections, which significantly improves the view of the forks. Depending on the type and design, the driver’s field of vision is extended by up to 27%.

The optimised design of the head cross beam also extends the upward visibility, allowing the operator to better see and thus control the forks when storing and retrieving at high lift levels. But it is not only the view upwards that is improved. The new mast also enables an optimised view of the horizontal working environment, as it is mounted on the vehicle in a more advantageous position. In this way, the driver can look past the loaded mast without leaning to the side.

With a maximum lift height of up to 15m, the new mast reaches a full two meters higher than the masts previously installed. It also has a higher residual load capacity, so that the vehicles can handle significantly more load weight than before when the mast is fully extended. To ensure that the reach trucks with the new mast can safely pass through warehouse passages, Linde MH has further optimised the ratio between lift height and overall height. As a result, the new 15m mast is even lower when retracted than the corresponding 13m version of the predecessor model.

Robust and service-friendly

Even greater stability of the mast is provided by more robust mast profiles with staggered reinforcements that additionally stiffen the reach mast and minimise deflection of the individual components. This results in lower mast vibrations during storage and retrieval at great lift heights, which not only saves the driver the waiting time until swinging out, but also avoids collisions between the mast and racking, which often cause severe damage to the load and infrastructure. Even more mast stability at great heights can be achieved with the optional Dynamic Mast Control (DMC) driver assistance system: a sensor-controlled electric thrust actuator compensates for mast vibrations and deflections through targeted and highly precise counter-movements.

The vehicle length has remained unchanged so that the reach trucks can manoeuvre in narrow warehouse aisles as usual. To simplify mast replacement, the reach carriage now remains within the vehicle chassis during dismantling. In this way, the vehicles can be rapidly moved to another location and quickly put back into operation there. This reduces time requirements and costs by up to 50%.

 

Mixed fleet for German manufacturer

When POLI-TAPE required various loading equipment in confined spaces working at heights of up to 12 metres, Hyster supplied a rental fleet of forklifts equipped with driver assistance systems and tracker. The result was transparency and efficiency in POLI-TAPE’s warehouse and production facilities with minimal downtime and damage.

Whether shop windows, vehicles, or textiles, films from POLI-TAPE are used to cover and label a wide variety of surfaces. Products of the family-owned company from the western German state of Rhineland-Palatinate are present in more than 90 countries. At the headquarters in Remagen and in subsidiaries in the USA, France, and Italy, around 400 employees are committed to top quality. They produce films for transfer to textiles, self-adhesive digital printing, and special films for labelling and advertising technology.

Such a product portfolio entails a variety of sensitive materials and complex processes. In addition to the normal Euro pallet, the company moves oversized loading equipment, for double transports or two-metre rolls of film weighing several tonnes. For this variety of tasks, POLI-TAPE was looking for a partner who could cover all transport tasks along the entire supply chain from a single source.

From film to glue to paper, a wide variety of materials arrive in Remagen. Finished products leave the company every day. A shift operation supplies and removes production over 16 hours via seven ramps. 40 forklift trucks maintain the flow of goods; if it comes to a standstill, customers all over the world are waiting for their goods. One of the most critical breaking points in this process is the twelve-metre-high warehouse. If a high-bay or reach truck fails in the narrow aisles, in the worst case one of the lines comes to a standstill. The precisely coordinated orders for films in all possible shapes and colours have to be rescheduled.

Another challenge is the lack of space. 27,000 sq m for storage and production are used up to the last corner. There is no room for space-consuming turning manoeuvres and the number of internal movements is constantly increasing. At peak times, the vehicle fleet moves up to 1,000 fully packed loading units on a single day. Indoors, it is particularly important to drive quickly, yet carefully. Outdoors, forklifts have to negotiate uneven floors to prevent the goods from sliding. Hyster uses its broad portfolio to ensure little transport damage and maximum efficiency.

Equipment

The electrified fleet includes high rack and reach trucks, high speed trucks, pallet trucks and front stackers of the following product ranges:

  • S-series pallet trucks with payloads of 1.4 to 2.0 tonnes
  • P-series pallet trucks with and without platform for payloads from 1.6 to 3.0 tonnes
  • Stand-on/cross-seat pallet trucks up to two tonnes capacity of the RP series
  • Customised high rack and reach trucks model R2.5 and C1.5
  • Counterbalance trucks with 3 and 4 wheels from the J series
  • K Series medium and high lift order pickers

The Solution

Globally successful with a strong local dealer network, POLI-TAPE has found a reliable partner in Hyster. Kowalski Transportgeräte GmbH is one of the 17 local dealers in Germany, Austria, and Switzerland. Together, the two companies developed a comprehensive solution with individually configured forklifts of all classes including fleet management via Hyster Tracker and 24/7 service.

Today, the fleet supports all processes between warehouse and manufacturing with 40 rented Hyster forklifts. To find the right solution, Kowalski held many discussions on-site. Every specific customer requirement was analysed, understood, and implemented in individual configurations. Today, the fleet optimises efficiency in a confined space with maximum comfort for drivers.

Manoeuvrable pallet trucks supply the lines with basic components such as film, glue and paper in the area-efficiently designed production. At the end of the line, suitable forklifts take over the sensitive goods, cut and wrapped, for internal transport to the warehouse. Industrial trucks maintain the steady flow until everything is packed and ready for dispatch.

The process is labour-intensive. Only a few things can be automated. The variety of load carriers need people. Well-trained warehouse workers are hard to find in empty labour markets. Equipment that makes work easier is an important criteria in the job for many. Hyster meets these demands with manoeuvrable vehicles that are easy to control.

Hyster can cover all requirements with more than 140 different models at POLI-TAPE. Among others, small high-speed trucks supply the production. Manoeuvrable pallet trucks bring goods efficiently from A to B. Counterbalance trucks safely take over even heavy and bulky items with the best all-round visibility. Driver assistance systems additionally minimise damage to vehicles and goods. Especially in high-bay warehouses, sensors and cameras facilitate precise storage and retrieval at any height.

The logistics operation gets everything from a single source, including maintenance and service. At an operational level, the fleet manager at Kowalski has a contact person and a permanent mechanic who knows the fleet. In the background is Kowalski’s 18-strong service team, including an in-house workshop, a well-stocked spare parts warehouse, and fast deliveries from the Hyster central warehouse in Nijmegen, the Netherlands, 50km away. There are hardly any breakdowns.

Hyster Tracker brings additional operating efficiency. The telematics solution provides all the necessary data in real-time. For example, the fleet manager recognises critical points in the process and can train drivers in a more targeted manner. Key data helps control predictive maintenance. Before each start, the system has the capability to check whether the driver is sufficiently trained and capable of operating the truck. All necessary checks are carried out via user-friendly displays, which also provide alerts during operation, for example in the event of excessive speed.

“If there is high downtimes, even the best forklift truck is of no use. That’s why we rely on the solid brand-name trucks from Hyster. They are as robust as a Volkswagen with premium service from a single source.”

The Results

Compared to the past, the Hyster fleet has significantly reduced unplanned downtime. Wear and tear on the vehicles and time-consuming transport damage have also decreased. Efficiency has increased. The warehouse staff are more satisfied. The ergonomically designed vehicles not only help protect operators’ comfort and wellbeing, but also relieve the time pressure caused by unnecessary damage.

“With comfortable hand movements and perfect all-round visibility, I can also store and retrieve goods precisely from above,” says a warehouse worker. “The similar handling of all Hyster trucks also makes the changeover easy in the fast-paced daily business.”

POLI-TAPE has completely digitalised its fleet management via the Hyster Tracker. Transparency in fuel consumption and driving behaviour enables targeted improvement measures. Clear key figures in real-time allow for predictive maintenance. For POLI-TAPE, breakdowns have been reduced to a minimum.

Hyster is the right choice. We have a modular system that meets every need. The units can be optimally adapted to our requirements and individually configured. Service is available around the clock. Unnecessary downtime and dissatisfied employees due to poor equipment are a thing of the past,” said Peter Wieland, Supply Chain Manager of POLI-TAPE Klebefolien GmbH.

 

 

Time to look after your assets

At a time when companies are focused on keeping business costs to a minimum, a strict materials handling equipment maintenance and servicing regime is more important than ever, says Toyota Material Handling UK Ltd’s Service Sales Manager, Andy Pritchard.

Regardless of whether your business operates a single pallet truck or a large fleet of varied materials handling equipment, when sourcing forklift trucks it is important to deal with an organisation that has the infrastructure in place to guarantee the highest levels of lift truck service and maintenance support.

A regular servicing and maintenance regime is the best way of preventing significant truck downtime – and all the cost and disruption to a business that can entail. And, with repair costs for serious truck damage rising, a commitment to forklift maintenance and servicing is becoming more important than ever.

Toyota offers a range of after-sales care and support packages to suit the business needs of companies of all sizes operating in all industry sectors. For example, the ‘full service’ package involves a comprehensive parts and labour plan that covers preventative maintenance, breakdowns and parts used in service and breakdown repairs.

Most Toyota customers agree a planned service contract at the time that they buy or rent their truck or trucks. With the support of Toyota’s dedicated after-sales development team to guide them through the various options available, Toyota customers can choose their plan with complete confidence, safe in the knowledge that it will keep their trucks safe and in good working order to ensure that they get the most out of their materials handling equipment at all times.

Customer satisfaction is our number-one priority and we do everything we can to meet our customers’ needs and expectations. Since service is a key differentiator, it’s important to us and, of course, our customers, that we carry out preventative maintenance and any repairs that are required quickly and efficiently.

We apply the Toyota Service Concept, a structured approach to optimise our services that is based on 12 key values that include ‘Poka Yoke’ – a Japanese term that means ‘mistake-proofing’ or ‘inadvertent error prevention.’ For example, by constantly upgrading the quality of spare parts and checking them before shipping, we ensure that the right part will be delivered in time.

Across the UK we employ some 600 technicians. We guarantee to respond to a customer’s request for assistance within four working hours and have a 96% first time fix rate. We aim to get things right the first time so we make sure parts are available when they are needed. And, we service any make of truck – not just Toyota models – which is essential for those clients that operate mixed fleets.

95% of spare parts are always available and any Toyota parts that are not held in stock are delivered within 24 hours. The genuine Toyota parts used are designed and tested to be safe and to prevent equipment failure, which means downtime risk and repair costs are lower and a client’s operational efficiency and, therefore, profitability is increased.

 

 

Flexi brings new VNA truck ranges to IMHX

IMHX 2022 will see the launch of Narrow Aisle Ltd’s latest Flexi ACiON (pictured) and Flexi LiTHiON VNA truck ranges.

With all drive, hydraulic and power-steering functions digitally controlled, the trucks in the Flexi ACiON (lead acid battery-powered) and Flexi LiTHiON (lithium-ion battery-powered) collections are described as a ‘tour de force’ in articulated lift truck drivability, reliability and battery energy saving.

The introduction of digitally controlled motors for steering and all other key functions delivers a more integrated truck performance and results in greater reliability, more pallets moved per hour and significantly reduced maintenance costs.

Full digital control means that all models are ultra-energy efficient: regenerative energy produced every time the truck’s mast is raised or lowered, as well as during forward and reverse travel and by movement of the steering wheel, feeds back to the battery to maximise the time that the truck can perform between battery changes or charges.

In addition, noise levels are significantly reduced and steering and mast control operations – whether using the lift/lower or sideshift functions – are carried out with optimum precision at all times.

But it is not just ‘under the bonnet’ where enhancements have been made: when developing the new Flexi ACiON and Flexi LiTHiON range, Narrow Aisle’s design team sought to produce the ultimate driver-friendly articulated forklift trucks on the market.

All aspects of operator visibility have been improved. For example, the trucks’ HiVis overhead guard has been redesigned and reconfigured to ensure perfect upward visibility of the forks and the load when stacking. The guard also features a soft grey finish that is proven by optometrists to be ‘easy on the eye’ to further aid the operator’s through vision.

Clear forward visibility is ensured by the use of three-stage lift masts, which feature four-lift cylinder technology that not only delivers full fork vision to make pallet entry clear and straightforward, but also provides class-leading lateral stability.

The latest Flexis have been developed to make order picking duties easier and safer. For instance, the ‘Halo bar’ feature provides the most comfortable single-handed action to mount or dismount the truck during intensive applications. All models are fitted with a fully weight adjustable premium seat which, combined with the trucks’ adjustable steering column, reduce operator fatigue – even during the longest shifts.

Models in Narrow Aisle’s Flexi ACiON and Flexi LiTHiON Truck ranges can operate safely and efficiently in aisles down to just 1.6m wide and can lift loads weighing up to 2.5 tonnes to heights of 14m. The Flexi’s 220° articulation feature that makes turning easier and faster is incorporated into all models in the range to ensure more pallet movements per hour.

In addition, visitors to the Narrow Aisle stand will be able to see the unique FlexiPick layer order picking system. The FlexiPick allows users to take advantage of the increasingly popular layer quantity FMCG order assembly concept. It allows retail customers to order boxed products on a larger quantity with up to five different products (SKU’s) per pallet, without the need to invest in the kind of high fixed cost automated handling technology that previous layer picking systems have relied upon.

Thanks to its articulated chassis design, the FlexiPiCK system is the perfect platform for layer picking technology. When using the FlexiPick full pallet loads of the most popular layer quantity products in the DC are arranged in an aisle format at ground level and with assembly stations positioned at the end of each aisle. The FlexiPick’s integrated hydraulic arms carefully lift single or multiple layers of product and deliver each individual layer picked to the assembly station where a load is made up of full layers.

The FlexiPiCK system works comfortably in access aisle of less than two metres – which hugely reduces the floor space footprint required. Furthermore, steel guidance rails are not required for the system to function at faster picking rates, which allows a more flexible load assembly aisle layout with more product options included.

Layer picking has become increasingly popular in the USA, where it is seen as a solution to manual handling stress injuries on high volume case picking operations. By picking orders in layers, FMCG companies can reduce case quantity picking costs by a huge amount – which provides opportunities to offer reduced costs to clients that place larger orders in layer quantities.

With its headquarters, design and manufacturing facilities in the UK, Narrow Aisle Ltd has supplied over 10,000 Flexi articulated forklift trucks to users throughout the world and has a global network of over 65 authorised distributors.

 

Four new Konecranes Lifetime Advantage upgrades

Konecranes Lifetime Advantage upgrade packages have been regularly bringing customers the most recent advances in safety and productivity available for their lift trucks for over three years. Now, the latest chapter in this long-term commitment to improving lift truck performance presents four more innovations from Konecranes.

Two of the four new upgrades directly address safety issues. The first safety upgrade, a container checking safety system for Konecranes empty container handlers, allows drivers or service technicians to check or perform maintenance on containers while the container is gripped by the spreader, reducing the downtime needed for container repairs. The system uses mechanical locks to put the driving gears into neutral, block hydraulics and prevent the container from lowering. As an extra precaution, an indicator light on the fender flashes until the driver deactivates the system.

The second safety upgrade is a collision warning and object recognition camera system for Konecranes reach stackers, mounted on the counterweight at the back. When an obstacle is detected in the direction the truck is moving, an alarm alerts the driver, becoming more urgent as the object gets closer. The camera provides a clear image of what is in the truck’s path on the control panel so that the driver can adjust direction to avoid the obstacle.

“Safety and productivity are our highest priorities at Konecranes, so we work hard to include enhancements for both in every Lifetime Advantage release,” says Johan Kårhammer, Global Spare Parts Operations Manager at Konecranes Lift Trucks. “Our latest upgrades are type-specific – for empty container handlers, reach stackers or forklifts – offering an additional level of specialised improvements so that our customers have access to the best range of options to suit their particular needs.”

The other two upgrades in this release are designed to improve productivity on all Konecranes forklift trucks and empty container handlers equipped with an MD4 master display. The first one is an engine shutdown software solution. If the coolant temperature goes over 103°C (217.4°F) or the oil pressure goes below one bar, a pop-up message appears on the display. The driver can then decide to turn off the engine or keep it running. Managing temperature and pressure increases productivity, decreases downtime and extends the lifetime of the lift truck because the engine runs more efficiently and stays in good condition longer.

The second productivity upgrade is a height indicator. When a laser senses that the total height of the machine (in other words, with an extended mast, including the load) reaches a specified limit, an alarm goes off and a pop-up window appears on the display. Settings can allow the driver to proceed with the knowledge that the height is now at its predefined maximum, or they can prevent lifting the load any higher. Keeping the height manageable increases productivity and safety in lifting operations.

“The Konecranes Lifetime Advantage programme is intended to support customers in their day-to-day business operations,” says Patrik Lundbäck, Director and Head of Sales and Distribution at Konecranes Lift Trucks. “The success of our upgrades is due to the cooperation of our program team and our global distributor network working together with customers to continuously add value to their container handling operations.”

 

Inside the transformation of Yale

The launch of the Yale Series N is just one element of an exciting transformation within Yale Europe Materials Handling. Behind the scenes, the company is evolving the way it does business across the board in a bid to meet changing customer needs. 2022 will be the first time Yale reveals this transformation to the world, but the foundations have been laid in recent months and years. With wide-ranging changes and new ways of selling, engineering and building Yale products, Robert O’Donoghue, Vice President Marketing and Solutions, EMEA at Yale sat down to delve deeper into what has been going on behind-the-scenes as Yale embraces the future.

Q: A lot of the conversation around the new Series N range was about a wider business transformation of Yale: what sparked this?

Robert O’Donoghue (RO’D): The way our customers are buying materials handling equipment has changed dramatically over the past five years. Businesses want to work with a partner that understands their business and delivers the right solutions for their applications. We need to ensure Yale is their first port of call and that we can add more value earlier in the decision-making process.

The transformation is wide ranging – including how we have designed and built our new Series N range, but the changes don’t stop there. Some will be noticeable, whereas others have been a seamless transition. It’s an incredibly exciting period in our history.

Ultimately, we want our business to be focused on the success of our customers. This is why the Series N is designed to offer a new level of excellence in lift truck solutions. By moving away from defined categories of basic, standard and premium lift trucks, the Series N offers a new customer experience that enables them to define their own truck specification.

Q: How is Yale rising to meet the changes in customer buying habits?

RO’D: Our research has shown that customers are self-educating earlier in the buying process than ever before, so it’s important that Yale is there at the start of this journey to guide them to the solution they need.

We discovered that 68% of primary research by our customers is happening online. For this reason, we launched a brand-new website in 2021.

Having digested the wealth of information out there, as many as 57% of buyers have already completed the decision process of what they think they want in a materials handling solution before they engage with a salesperson – so our website is designed to be informative and inspiring, with a focus on industries and solutions.

Q: With so many customers self-educating online before they speak to a salesperson, has that changed your approach to sales?

RO’D: Yale needs to be involved in conversations as early as possible; after all, people want to buy from people. We have developed the HYImpact sales process that engages high up within a customer’s organisation early in that buying journey.

Today’s best practice is to fully understand the customer’s industries, their applications, needs and wants, and recognise how we might help the customer in ways that only Yale can. We’ve found what matters most to our customers is access to information: that’s knowledgeable salespeople and advice on suitability for their intended application. We’re transforming the availability and quality of what we provide so our sales team become trusted advisors.

We’re really rising to this challenge and embracing our new sales approach. Our dealers are also critical to our success and ensuring that we grow within the market, as is having the best partners with the best tools to deliver on that service.

Q: One area of significant change you mentioned is how you design and build Yale products; how does the Series N factor into this?

RO’D: The Series N marks a completely different way of providing products to our customers. The entire range is based on a single platform, enabling our customers to build a truck to meet their specific applications. They no longer have to settle for superfluous features and functionalities; they can define exactly what they need from a lift truck. With the Series N, customers can reject the status quo and set their own standard.

The most respect we can give our customers is to understand their needs in a deep way and have a platform that is both modular and scalable to configure the optimal solution.

Q: How else has the company pivoted to this new ethos?

RO’D: Changes to our Craigavon manufacturing facility have enabled us to create a more agile production line, providing better lead times for our customers.

Simplifying and streamlining our operations has improved on cost-efficiency, scalability and quality; we can now make any mix of product on the assembly lines, meaning we can react to customer needs rather than anticipating them. This helps us to supply products quicker to our customers and get our products integrated into their operations.

Quality still remains a top priority, and our new processes incorporate automation to ensure consistency across multiple products.

This is an incredibly exciting era for Yale, and we can’t wait to hear from our customers and dealers about their Series N experiences. There is a lot more to come, so keep an eye out for more news from us! Our success relies on the success of our customers; our investments in our facilities, digital solutions and new products are all driven to support them in reaching new levels of efficiency and productivity.

UniCarriers upgrades stackers for next-level productivity

UniCarriers has launched an upgraded series of compact pedestrian stackers with state-of-the-art features designed to enhance operator comfort and productivity. As the latest innovations in the world-class UniCarriers portfolio of market-leading stackers, the CSW125 compact pedestrian stacker and CDW125 compact pedestrian stacker for double pallet handling are ideally suited to cross-docking applications.

These compact pedestrian stackers excel at shop replenishment, order picking and short-distance internal transportation in environments such as warehouses, supermarkets and production areas, says the manufacturer. The narrow chassis of just 660mm allows easy working in tight spaces while achieving lift heights of up to 2090mm. Due to its low weight, the single stacker CSW125 is especially valuable if working on mezzanine floors.

The CSW125 and CDW125 stackers now feature a new advanced ergonomic tiller head that offers greater operator comfort thanks to large rocker buttons optimally placed for better access. The robust and impact-resistant tiller head is IP65 rated against water and dust damage and is completely weatherproof to withstand all conditions when working indoors and out. This minimises maintenance and downtime to ensure lower total cost of ownership. The tiller arm is designed to reduce stress on the operator’s arms and hands enabling them to stay comfortable and focused over long shifts.

The compact pedestrian stackers have also been upgraded with a new speed regulated electric proportional valve for controlled lifting/lowering and smooth handling. This supports maximum throughput and efficiency as operators can quickly, confidently and safely handle goods.

UniCarriers says it is dedicated to delivering high-performance trucks built to meet the ever-increasing market demand for efficiency and adaptability. That’s why the CSW125 and CDW125 compact pedestrian stackers come with a range of new options including an advanced multi-function display, battery creep, an audible battery level warning, service alarm, automatic log off, and the ability to revert to low speed at log off. Pedestrian stackers can play a vital role in every part of the pallet handling chain from intake to dispatch, and to increase uptime, UniCarriers utilises a modular build using fewer components for faster repairs and servicing. It’s all part of UniCarriers full-maintenance site support.

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