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Tag: forklifts

STILL offers top performance for order picking

Posted on by David Priestman

Is order picking always the same? Not at all. Hardly any other field of activity in intralogistics is as diverse as goods picking. The range of applications is wide and requires appropriate technologies. STILL – one of the leading suppliers of intralogistics solutions and a successful market player for more than 100 years – says it can provide the right order picking vehicle for any customer requirement.

The requirements in order picking are diverse and so are the users’ needs for information. Is the picking to be done on the lowest shelf level or is it necessary to pick vertically – and if so, at what heights? In which industry will the picking be carried out? Which goods need to be picked – and are they rather large and bulky or small and heavy?

Also important: What kind of warehouse is it? Does the vehicle have to be designed to manoeuvre mainly in narrow spaces? Is it to be used in narrow aisles or is a combined use in narrow and wide aisles intended? And last but not least: what degree of automation is necessary and/or desired? There is a great variety of possible options, and STILL’s responses to customer requirements are comprehensive. The Hamburg-based company has the right vehicle for any application in its range.

“As different as the application profiles and thus the vehicles may be, certain requirements must be met in any case,” says Janos Poppe, product trainer for horizontal order pickers at STILL.

“Regardless of whether it is a classic order picker or a vehicle designed for narrow aisles: High reliability, energy-efficient use, easy battery handling and fatigue-free operation must be guaranteed. In addition, efficient work and high handling performance with our state-of-the-art vehicles are of course the focus of customer requirements,” adds Christian Ehlers, product trainer for vertical order pickers at STILL.

Just how varied intralogistics tasks are can be seen by looking at the different industries. In the automotive industry, mechanical engineering and the food industry in particular, but also in other trades and services, right through to retail, there is much more to it than ‘light’ order picking.

Aiming high in a confined space

If pallets need to be picked at very high levels or entire pallets stored and retrieved, this is where the MX-X from STILL comes into its own. With this truck, which is operated in narrow aisles, pallets can be picked at heights of more than 17.5m. Depending on the vehicle configuration, the MX-X can reach speeds of up to 14km/h with mechanical guidance and 10km/h with inductive guidance.

“With these travel speeds, the MX-X delivers maximum handling performance in any narrow aisle,” adds Ehlers. Lifting speeds of up to 0.6m/s and lowering speeds of 0.45m/s allow the MX-X to quickly store and retrieve pallets – or pick onto them – at any height. The tilt barriers enable a short distance between the driver and the pallet and thus fast and ergonomic order picking. “This means the vehicle delivers top performance in the tightest of spaces when picking at great heights,” says Ehlers.

Despite the great heights, the operator can work without worries. The design of the main and auxiliary lift provides impressive stability at any storage height. In addition, the MX-X is equipped with Active Floor Compensation (AFC). The AFC feature ensures that any unevenness in the ground between the left and right lanes is compensated for. With this assistance system AFC, STILL offers a real alternative to the costly reconditioning of the warehouse floor. In addition, the driver no longer feels the unevenness and thus always feels safe on the MX-X even at a height of 18m.

Master picking applications in wide and narrow aisles with ease

“Every order picking task should be easy to manage,” emphasises Ehlers. This is also what the EK-X series stands for. The EK-X up to 1,000kg, for example – just like its big brother, the EK-X up to 1,200kg – can be used flexibly and reliably in both wide and narrow aisles due to its compact and variable vehicle dimensions. It is used in a wide range of industries and applications. These include mechanical engineering companies, logistics service providers and central warehouses of large trading companies.

Thanks to its powerful, reliable and low-maintenance three-phase engines (with 24V as well as 48V battery), the vertical order picker reaches travel speeds of up to 11km/h and is able to transport loads weighing up to 1,000kg. The maximum reach height of the EK-X up to 1,000kg is 7.8m. “With the EK-X 10, the EK-X up to 1,000kg and the EK-X up to 1,200kg, our order-picking portfolio from STILL optimally covers customer requirements from the lowest level to the very highest heights,” says Ehlers.

The highlights of the EK-X series include innovative features such as Curve Speed Control or the OptiSpeed system. In addition, it is possible to use lithium-ion-based energy storage systems on the EK-X up to 1,000kg and 1,200kg. In connection with this technology, the opportunity charging option is also available. This connects the charger directly to the battery and thus enables fast, simple and uncomplicated intermediate charging. For customers who opt for a lead-acid battery in combination with “Li-ion ready”, it is also possible to prepare the vehicle for future opportunity charging.

Great focus on ergonomics and safety

When designing the EK-X up to 1,000kg, STILL’s developers placed great emphasis on ergonomics and safety. Thanks to the low cab floor height of just 200mm, the driver can reach the cab safely and without difficulty. The shock-absorbing cab floor takes the strain off the operator and a large-area presence switch allows a variable and comfortable standing position. On the vehicle, the operator not only has everything under control as well as a wide range of equipment options, but also optionally a driver’s cab that is 70mm deeper, which provides more freedom of movement.

Easy picking of heavy and bulky goods

For picking heavy and bulky goods on the EK-X up to 1,000kg, the truck has optionally been equipped with a walk-on pallet. “This makes it easy to pick heavy and bulky goods and contributes further to occupational health and safety,” explains Ehlers. A high level of safety is ensured by a contact switch and automatic locking of the pallet.

“Safety is the first priority, especially at great heights,” emphasises Ehlers. Thus, the EK-X up to 1,000kg has a sensor-controlled two-hand operation that guarantees accident-free operation, especially in narrow aisles. To ensure that the vehicle stays on track in narrow aisles, it is optionally equipped with mechanical or inductive guidance. “These and many more features stand for maximum user safety of our entire EK-X series,” says Christian Ehlers.

All-round talent especially for ground-level applications

For order picking tasks at ground level, STILL also has the right trucks in their product range. “The ideal trucks for order picking tasks at ground level are the horizontal order pickers in the OPX series by STILL,” explains Poppe. This is an all-rounder that can travel at speeds of up to 14km/h in the warehouse and has been specially designed for classic horizontal order picking.

“Nevertheless, the variety offered by this vehicle series is incredibly large,” says Poppe. It ranges from a simple vehicle with a load capacity of up to 1,200kg to load capacities of up to 2,500kg. Depending on the equipment, two pallets can also be transported and picked at the same time – also at an ergonomic working height of the forks to protect the backs of the employees during picking.

Picking in the second level

While the horizontal order pickers of the OPX series are mainly designed for picking in the ground level and the operator picks the pallet from the side of the vehicle, the vertical order pickers of the OXV series are also designed for picking work in the second level. The vehicle is equipped with a platform lift as standard, which enables the operator to pick directly onto the pallet when the platform is raised. “Unlike the OPX, which is designed for several pallets, the OXV transports exactly one pallet,” explains Poppe.

The vehicle, which travels up to 10km/h, can transport pallets weighing 700 or 1,000kg. Like the vehicles of the OPX series, it impresses with a high level of driving comfort and intuitive operator guidance. Simultaneous steering, lifting and driving is a breeze with the STILL Easy Drive steering wheel.

“In combination with the OPX and the EK-X order pickers designed for higher operations, the trucks of the OXV series perfectly round off the STILL portfolio in the order picker sector,” says Poppe.

Automation and autonomy in order picking

A few years ago, STILL also took a big step towards automation and autonomy – also with regard to order picking. Since 2016, the Hamburg-based company has been offering its customers not only the fully automated MX-X but also the autonomous version of the horizontal order picker, the OPX iGo neo. With the help of state-of-the-art sensor technology, the vehicle recognises its operator as well as its surroundings. By means of a multi-level safety concept including a pedestrian protection system, the OPX iGo neo protects people, warehouse equipment and goods. Based on the generated data and defined algorithms, the vehicle makes decisions: obstacles are avoided or the vehicle stops completely if the available space is too small to avoid the obstacles.

The OPX iGo neo significantly increases picking performance and reduces picking errors. On the one hand, because the autonomous helper takes over driving and steering during order picking and the operator can thus concentrate fully on the work. On the other hand, because up to 75% of the strenuous and time-consuming getting up and off the vehicle is eliminated and the walking distances with loads are greatly reduced.

Looking at STILL’s broad portfolio, Ehlers sums up: “It is STILL’s mission to offer every customer the right vehicle for any picking application.”

Mitsubishi launches powerful new electric forklift

Posted on by David Priestman

Changes to fuel subsidies, enhancements in battery technology and increasingly stringent emissions regulations mean electric trucks are becoming the new favourite – even in industries where diesel was once considered indispensable.

And now electric trucks offer more capabilities than ever before with the arrival of the new EDiA XL from Mitsubishi Forklift Trucks.

Built with a wealth of unique and innovative features, Mitsubishi says its EDiA XL is the perfect alternative to IC engine trucks, having been designed to outperform not only its electric rivals, but also any diesel forklift.

Stewart Gosling of RDD, the exclusive UK importer for Mitsubishi Forklift Trucks, explains: “The new EDiA XL will do everything a diesel can do… only better. It is the first electric to fully overcome every issue that may have stopped some owners of IC engine trucks from making the switch to electric.”

Available in 4-5 tonne models, EDiA XL will handle heavy-duty applications with ease.

“In the past many industries favoured diesel for its brute strength, but electric forklifts like EDiA XL offer power like never before,” adds Gosling.

Take for example, the AutoBoost feature. This kicks in automatically to provide torque and acceleration boosts where and when they’re needed, like on ramps and steep inclines, so power drops are a thing of the past.

Even harsh environments are no match for EDiA XL. Its Electric Differential Lock feature gives the truck better traction and control both indoors and out.

“EDiA XL is an exceptionally intuitive forklift,” says Gosling. “Handling is smooth and precise, high lifts are rock-steady, while Four Wheel Steering enables a 100° lock delivering the smallest turning circle on the market – perfect for working in tight spaces. There’s no challenge the EDiA XL can’t overcome.”

Operator comfort has been placed front and centre with EDiA XL. With its ergonomic, adjustable seat, and its range of advanced control options, EDiA XL helps operators stay productive. Not least because noise levels inside the cabin are extremely low at just 65dB, and microvibrations are minimal thanks to the rubber-mounted cabin.

Gosling concludes: “The placement and design of the mast means operators have unparalleled visibility while working in a comfortable, stress-free environment, giving them the confidence to work efficiently and safely. Every detail has been considered in the EDiA XL. It really does set a new standard for forklift trucks.”

GS Yuasa launches battery range in Europe

Posted on by David Priestman

GS Yuasa has launched a new range of traction batteries for the European material handling market. The launch sees the manufacturer – which describes itself as a world leader for vehicle and industrial batteries – expand upon its class-leading Japanese traction battery range with an all-new line up of European DIN and BS sizes.

The new range of individual 2V cells, full-tank solutions and accessories utilises the very latest technology and premium Japanese engineering for maximum quality and long life. Available in 24, 48 and 80V solutions, the extensive range provides coverage for all makes and models providing reliable power and hassle-free performance.

The new European-sized range is available as a fully plug-and-play solution, meaning it can be easily integrated into a wide range of applications. All batteries offer low maintenance, minimised water consumption and quick charging. They are supplied in a high durability, dip coated tray and are fully recyclable.

As an original equipment supplier, GS Yuasa says it is trusted by engineers worldwide. Its traction batteries are the preferred choice to the Asian materials handling market, and GS brand traction batteries are still widely referenced for their unrivalled quality many years after discontinuation in Europe.

James Hylton, Managing Director of GS Yuasa Battery Sales UK, said: “We’re delighted to have launched our traction range in Europe and offer our world-renowned quality and long service life to the materials handling industry.

“Our experienced engineers have developed this range using their extensive knowledge of traction technology to ensure the highest performance and reliability. We are already receiving a huge level of interest from materials handling suppliers and manufacturers who are delighted GS Yuasa have returned to the European market.”

GS Yuasa  says an optional Air-Mix system enhances electrolyte mixing, prolonging service life and reducing the risk of stratification and premature battery failure. The system brings a number of additional benefits including a 20% reduction in energy consumption during charging and reducing overall charge times by 30%. A fully integrated filling solution makes maintenance quick and easy while an optional LED indicator means electrolyte levels can be checked with just a glance.

New order picker for medium rack heights

Posted on by David Priestman

With the Linde V modular B vertical order picker, Linde Material Handling (MH) is launching a new high-performance, robust turret truck. The “man-up” vehicle expands the intralogistics specialist’s product range for wide and narrow aisle warehouses, thus offering distribution centre operators and manufacturing companies an even greater choice of customized solutions.

Many warehouse operators solve the need for additional storage space by adding more racking and expanding racks upwards by one or two levels. As a result, the demands on the vehicles used for picking are growing in parallel: Picking heights can exceed 7m, which means the vehicles must have a stable chassis as well as provide an ergonomic and safe working environment so that operators can fully concentrate on the picking process.

“Picking is the value-adding activity in a warehouse and therefore at the core of the business,” Matthias Holzwarth, Product Manager VNA Trucks, puts it in a nutshell. “With the new Linde V modular B turret truck, we offer our customers a powerful yet cost-effective solution for precisely these requirements.”

With a load capacity of 1,000kg and a reach height of up to 7.83m, the vehicles meet customer needs such as those found in online retail, small parts logistics in distribution centres and factory supermarkets. At their core, they are based on the larger V modular series, with the “B” in the model name standing for “Best Value” and indicating that the vehicle comes equipped solely with features necessary for this picking height.

Convincing set-up

The trucks’ maximum driving speed of 11km/h means movement is rapid. Comfort is provided by the spacious cab, which is decoupled from the chassis and thus cushioned from vibrations. A soft mat absorbs vibrations when the mast is raised during travel, and operators find secure footing on the firm surface at the edge of the cab floor while order picking.

The low railing of the driver’s cab allows for easy, reliable picking of goods from the rack, and the optional outward tilt function allows for the extra few centimetres of movement that are often needed for better access in the racking.

The mast design provides excellent visibility of the surroundings, and the electric steering makes it easy to manoeuvre with precision. Thanks to the modular vehicle concept, the vertical order pickers can be individually adapted to specific customer requirements. Depending on the power requirements, for example, a 24v and a 48v motor are available.

The Linde V modular B is also equipped with various safety features. For example, the vehicle can only be moved when the driver touches the sensors on the control unit with both hands while standing on the dead man’s switch in the foot well. The electrically monitored side barriers must be closed for operation at platform heights of 1.2m and above.

To prevent collisions with ceilings and walls, travel speeds and lifting heights can be individually adjusted by the service engineer to suit the respective conditions on site. For narrow aisle applications, scanners are available in the drive and load direction, which detect people and obstacles in the vicinity. The personnel protection system also actively intervenes in the vehicle’s drive mode in the event of an emergency, thus preventing collisions.

BYD attracts attention of fruit industry

Posted on by David Priestman

BYD Forklift Europe, the world’s leading manufacturer of New Energy Vehicles (NEVs), has brought a selection from its range of 100% zero-emission forklift trucks to Fruit Attraction 2021 in Madrid at its stand 6B01 in hall 6. BYD is using its presence at the show to demonstrate to the Spanish and European fruit and vegetable industry the many cost savings and operational benefits of running an emission-free materials handling fleet.

With the unique BYD Iron-Phosphate Battery at the heart of each of its products, BYD forklifts enhance a business’s green credentials whilst also offering significant cost savings and operation benefits. Furthermore, 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 companies in the fruit and vegetable sector a safe, reliable, and long-term materials handling equipment partner.

Fruit producers will also be reassured to learn that BYD has an established professional dealer network covering 100% of the Iberian Peninsula, ensuring fast and local service and support.

Visitors to BYD’s stand in the ‘Auxiliary Services’ area of Fruit Attraction will be greeted by a selection from its fast-charging BYD Iron-Phosphate Battery powered range of equipment, including:

  • The eye-catching BYD ECB20S, BYD’s latest forklift truck. Displayed at an exhibition for the first time in Europe, the BYD ECB20S completes its three-wheel counterbalance range. This fully-equipped workhorse offers a tremendous amount of options, and like all BYD Iron-Phosphate powered equipment it allows you to top-up the battery at short intervals during operator breaks, ensuring highest levels of availability around the clock.
  • Two versions of its popular stacker truck, the BYD EPS14, one with a fold-down platform and one which is walk-behind. With a nominal capacity of 1400kg and lifting heights of up to 5400mm, these stackers can comfortably handle most internal operations found in a busy fruit processing environment.
  • The versatile BYD PTW20S pallet truck, for heavier nominal loads up to 2000kg, can be used to load and unload trucks swiftly and efficiently, as well as in areas such as a warehouses where space is at a premium.

Any business in this sector operating a forklift truck or a fleet of materials handling equipment will already most likely be using electric-powered equipment. The main difference is that, most of these will be powered by traditional lead-acid batteries which are not only notorious for spilling acid and leaking gasses, but also run with a considerably reduced capacity the more they are used.

That’s why manufacturers of forklifts are rushing to embrace lithium-ion technology, as it eliminates these health and safety issues and offers longer-lasting batteries with a greater operational window. However, as a sector-leading innovative company, BYD is a step ahead of the game as its 100% maintenance-free Lithium Iron Phosphate (LiFePO4) batteries offer many more benefits than standard lithium-ion batteries.

For example, they can be charged from 20% battery life to 100% in just 60 minutes. The efficiency of the BYD Iron-Phosphate Battery means the total cost of ownership (TCO) of a BYD forklift can be as much as 60% lower than an equivalent lead-acid battery powered rival.

BYD is unique amongst forklift makers in that it designs, manufactures and develops its own batteries and battery management systems (BMS), the same tried-and-tested technology that sits at the heart of its market-leading range of electric buses that can be seen in major cities and airports across Europe and the rest of the world. Additionally, BYD produces critically-acclaimed passenger cars and trucks, ensuring its technology is operating successfully in the most challenging and demanding conditions.

“BYD understands the business of fruit and vegetable producers and processers, and have developed a range of products that are very well suited to handle the lifting and moving challenges they face,” says Ignacio García, BYD Forklifts Country Manager Iberia. “With a growing network of dealers in the region and a range of safe, reliable equipment, BYD can also help companies operating in this industry sector to enhance their green credentials.”

Visitors to Fruit Attraction 2021, which is taking place in Madrid on 5th-7th October, are invited to visit the BYD Forklift stand to find out how to reduce their logistics costs, optimise their operational efficiency, and demonstrate a quantifiable improvement in their environmental profile which they can use to help win new customers and retain existing business.

Intralogistics experts present hybrid talk series

Posted on by David Priestman

“Thesen am Tresen – The STILL Logistics Talk” is the title of a talk series for investment decision-makers and logistics enthusiasts developed by the Hamburg-based intralogistics company STILL. The first round of talks will be held during the German Logistics Congress in Berlin from October 20 to 22.

STILL will turn the gourmet restaurant “Hugos” at the Berlin Hotel “InterContinental” into a recording studio during the 38th edition of the congress of the German Logistics Association (BVL).  For 40 minutes each in a total of five talks, logistics experts from industry, trade, logistics services and science will discuss provoking theses that are of concern to them today and in the future. The discussions at the bar will revolve around the topics of globalisation, digitalisation, the environment, automation and security, and will be hosted by the logistics journalists Anita Würmser and Thilo Jörgl.

For those interested who are not attending the congress, the sessions will be broadcast live on the internet. Those who cannot watch the free live streams will have the opportunity to watch them afterwards on the STLL website. Through this hybrid format, STILL aims to make this valuable content accessible to a wider audience.

“We will discuss the megatrends in the field of logistics in an innovative format that people are familiar with from television. We are delighted that decision-makers from the most important industries and renowned scientists have accepted our invitation to share their knowledge publicly in an entertaining format,” states Frank Müller, Senior Vice President Brand Management / Sales & Service Steering STILL EMEA. Researchers from TU Dresden, Helmut Schmidt University in Hamburg, the Fraunhofer IFF in Magdeburg and the Fraunhofer IML in Dortmund are those who have accepted the invitation. Representatives from Warsteiner, Hermes Fulfilment, FIEGE, DB Schenker, SICK, BLG Logistics and logistics experts from KION and STILL are among those on the panel from the business world.

Thesen am Tresen – The STILL Logistics Talk at a glance

Wednesday, October 20, 2021, 11.00-11.40 CET – Globalisation

Can we manage without China? How Covid is changing value chains.

Andrea Eck, Member of the Board of Management, BLG Logistics

Christine Mezger-Behan, Vice President Logistics System, KION ITS EMEA

Ralf Düster, Member of the Executive Board, Setlog Holding

Anita Würmser (host)

 

Wednesday, October 20, 2021, 15.00-15.40 CET – Climate and Environment

Everything but exhaust fumes: Here’s what the forklift truck of the future will look like.

Rolf Beckmann, Director Engineering, FIEGE Group

Daniel Küster, Supply Chain Director, Warsteiner Group

Prof. Dr. Thorsten Schmidt, Chair of Technical Logistics, TU Dresden

Frank Müller, Senior Vice President Brand Management & Sales & Service Steering STILL EMEA

Thilo Jörgl (host)

 

Thursday, October 21, 2021, 11.00-11.40 CET – Digitalisation and Artificial Intelligence

The warehouse is dead. Long live the warehouse! How artificial intelligence is changing logistics.

Tobias Zierhut, Senior Vice President – Mobile Automation, KION Group

Prof. Dr. Dr. h. c. Michael ten Hompel, Executive Director, Fraunhofer Institute for Material Flow and Logistics IML, Dortmund

Anita Würmser (host)

 

Thursday, October 21, 2021, 3:00-3:40 CET – Automation

A digital dump is still a dump: How to avoid automating the wrong way.

Kevin Kufs, CEO, Hermes Fulfilment

Prof. Dr. Julia Arlinghaus, Director, Fraunhofer Institute for Factory Operation and Automation IFF, Magdeburg

Marina Hein, Vice President International Key Account Solutions, KION ITS EMEA

Thilo Jörgl (host)

 

Friday, October 22, 2021, 11.00-11.40 CET – Safety/Research

Mostly cloudy: How cloud applications prevent accidents in the warehouse.

Erik Wirsing, Vice President Global Innovation, DB Schenker

Andreas Höll, Technical Industry Manager, Sick

Prof. Dr. Alice Kirchheim, Chair of Logistics Systems Technology, Helmut Schmidt University Hamburg

Ansgar Bergmann, Technology & Innovation – CTR, Project Manager CTO, STILL

Thilo Jörgl (host)

 

 

Planning software now offers realistic forklifts

Posted on by Keith McKinley

Planning and engineering offices can now use realistic forklift trucks and warehouse equipment for their warehouse planning with CET Material Handling software from Configura.

“Using Configura’s software, CET Material Handling, planners are now able to give their 3D visualization of the warehouse and the intralogistics material flow an even more professional view. They can select from a great variety of different Linde truck models to create a realistic 3D warehouse layout design,” Intralogistics Consultant Andreas Mönk said for Linde Material Handling (MH).

With headquarters in Aschaffenburg, Germany and production plants around the globe, Linde MH develops high-performance solutions for intralogistics. The intralogistics specialist offers fully networked electric and combustion engine forklift trucks, warehouse equipment, fleet management software, automated solutions, driver assistance systems, financing offers as well as services around the forklift truck, and operator training.

“We are pleased to welcome Linde Material Handling to our growing global community of material handling companies that use CET Material Handling to plan warehouse solutions,” Configura’s Global Head of Material Handling Johan Gustafsson said. “CET Material Handling is a 3D system configurator that simplifies and accelerates the sales process of warehouse solutions and we’re confident it will enhance the customer experience.”

Configura’s software, CET Material Handling, brings salespeople, project managers and engineers together into one software to design, build, implement and sustain material handling solutions. The software automates common tasks, enhances collaboration across departments and reduces drawing time from months to days, and in some cases, hours.

Manufacturers make their products available in CET by creating an Extension. Extensions are an addition to CET that contains the specifications and data for a given product. Linde Material Handling’s Extension is available for any user for free with manufacturer’s approval through Configura’s Marketplace.

Configura’s software, including CET, is used by thousands of people worldwide including engineers, salespeople, designers, kitchen specialists, dealerships and manufacturers. Configura has revolutionised the way office furniture is sold in North America and is now gaining momentum in Europe’s commercial interiors industry as well as other industries including kitchen and bath and material handling. More than 100 manufacturers around the world – including NEDCON, Dematic, Marbodal, Nobia, Steelcase, Herman Miller, Haworth, Sunon and Kvik – use CET to sell their products.

 

Bespoke solution for refractory manufacturer

Posted on by David Priestman

A UK refractory manufacturer seeking to replace an ageing forklift has benefitted from a bespoke materials handling solution from Roburtrucks.

Derbyshire-based DSF Refractories & Minerals (DSF) is the largest shaped refractory manufacturer in the UK, producing heat-resistant materials for extreme-temperature applications, including the lining of glass furnaces and petrochemical reactors, exporting more than 80% of their refractory shapes. The company is a major importer of minerals and other raw materials, which it processes on-site for its own production requirements, as well as supplying other refractory manufacturers.

For over 10 years, DSF had used a counterbalanced machine to load and unload large refractory blocks from its kilns. As it reached the end of its service life, increasingly frequent issues were causing production downtime and costly repairs. Additionally, the machine’s stabilising attachment often damaged the refractory blocks and loads were sometimes unstable during movement. As this was an older machine that did not have power steering, this caused operator fatigue, which was highlighted by DSF as a possible risk of injury to the company’s staff.

Following an introduction to DSF by Endeavour Forklifts, Roburtrucks was appointed to design and build a bespoke handling solution, which would be fully fit for purpose in a hazardous manufacturing environment.

Objectives

Following a customer consultation with DSF, Roburtrucks began the design phase for a machine that would deliver the following materials handling and health and safety objectives:

  • Incorporate power steering
  • Grab refractory blocks safely and securely
  • Ensure load stability when moving across uneven floors
  • Be comfortable for operator use
  • High reliability for continuous operation

Solution

Roburtrucks designed and manufactured a highly compact counterbalanced Stacker, featuring a unique securing clamp. The machine provides a lifting capacity of 1000kg (or 800kg with the removable clamp) and delivers two operational uses. As well its bespoke functionality, the removal of the clamp enables the machine to be utilised as a conventional counterbalanced Stacker for other purposes in the factory.

In order to prevent damage to the refractory blocks, the lifting clamps designed and engineered by Roburtrucks were coated with Secutex multi-functional geotextile, which allows some leniency in the material to ensure secure grabbing characteristics.

Results

The new machine delivered by Roburtrucks was quickly proven to increase productivity for DSF through the secure handling of refractory blocks weighing up to 600kg. Able to operate safely and efficiently across uneven floors in a challenging environment, the bespoke solution addressed all previous health and safety concerns. Equally, the reliability of the new machine has proven significant with no downtime incurred to date.

Russell Ferns, Health and Safety Officer, DSF Refractories & Minerals, commented: “From the introduction to Roburtrucks by Endeavour Forklifts through the design and build process, delivery and driver familiarisation, the service we have received was second to none. Nothing was too much trouble for the Roburtrucks team and this was a challenging project.

“We had experienced a number of failed attempts to get the right piece of kit for the specific purpose we needed but Roburtrucks delivered on its promise that the truck would meet all the desired objectives. Our long-term relationship with Mark Bann from Endeavour Forklifts meant that we weacre able to trust his judgment when recommending Roburtrucks to our company, which proved to be an excellent partnership.”

CLICK HERE to find out more.

 

New functions for Linde Logistic Trains

Posted on by David Priestman

With new trailers and a cloud-based tugger train guidance system, Linde Material Handling (MH) is making horizontal packaged goods transportation even more attractive. Innovative functions for C-frame and Bridge-Frames ensure greater safety and flexibility.

The tugger train guidance system determines the optimal route for drivers, reduces error rates and employee training time, and responds to order-related changes with adjustments in real time. Thus, even complex tasks become manageable and can be reliably carried out.

Horizontal goods transportation by means of tugger trains is particularly advantageous where large quantities of different parts and components have to be delivered over long distances to the right place at the right time. This is the case in the automotive industry, as one example, where each vehicle consists of many thousands of components that are assembled piece by piece until the finished car finally rolls off the production line.

“Here, bundled material transport using tugger trains makes more economic and ecological sense than individual transports and furthermore, they are in line with the Lean philosophy,” explains Mal Rexhepi, Product Manager Automation & Load Train Solutions. Further advantages of production supply enabled by tugger trains include the reduction of in-house traffic volume and the associated lower accident potential combined with plannable processes.

New frame features

From September 2021, Linde MH will be launching new trailer models for the Linde Logistic Train – including the LT-C with C-frame, the LT-B with Bridge-Frame and the LT-BM with Bridge-Frame and movable middle support. The improved frame functions ensure even greater safety and flexibility.

One new feature is the innovative and patented lifting profile mechanism for the Bridge-Frames. It not only enables the transport of a wide variety of rolling racks and trolleys, but also, with the appropriate design, the lifting of pallets without load carriers if these have been placed in the trailer with a pallet truck, for example. For this purpose, the lifting profiles are initially concealed in the trailer frame at the beginning of the loading process so that the operator can push in the trolleys unhindered.

The optional middle support, which can be moved freely against the direction of travel, allows the use of several different container sizes in the same trailer without significantly increasing the train length.

The highlight of the C-frames is the fork stabilisation control. The patented solution prevents the forks from sagging even under the highest possible loads and thus ensures safe transport of the load. The ergonomic ejection mechanism is another helpful feature: When the driver releases the lock using the foot switch, the load is pushed away from the back of the forks, making it easier to pull the load carriers out of the trailer.

All Linde MH frame models are fitted with a mechanical load locking mechanism as standard: As soon as a container is placed in the frame, the lock closes automatically. When the driver gets into the train, the frames are automatically lifted, upon leaving the driver’s platform, the load is lowered. When the tugger train is moving, the lowering of the frames is technically impossible. Conversely, it is impossible for the operator to set the tugger train in motion with the frames lowered.

For outdoor use, the frames can – beside many other options – be equipped with a weather guard to protect the load. The mechanical all-wheel steering ensures the high directional stability of the tugger trains: No matter how many trailers are used, the entire train remains on track. Thanks to a standardised interface, the trailers are even prepared for semi- or fully automated operations. Trolleys have also recently been included in the scope of delivery. They are available in various designs and can be further equipped, for example with modular rack superstructures.

Guidance system

The changeover from individual to bundled material transportation brings with it many advantages – as well as greater complexity with regard to logistical planning for warehouse employees. “It is necessary to organise routes and load carrier changes as efficiently as possible in order to avoid time losses and errors. To accomplish this, the entire cycle from upstream production to final assembly must be carefully planned and coordinated,” explains Oldrik Wagner, Product Manager Software Solutions. “With our tugger train guidance system, we can now provide step-by-step support to operators in carrying out their tasks.”

The tugger train control system receives all relevant information on material transports from the ERP or WMS system without any media discontinuity. From this, it generates individual driving orders and displays them on a large touch screen in the cockpit. Order by order, the drivers are directed to the respective assembly workstations along the predetermined, optimal route.

This process is preceded by the configuration of the tugger trains, trailers, stops, routes and reports by means of multilingual software. Via the dashboard, warehouse managers have an overview of the entire application and can trigger key figures and reports to further optimise its use.

25% of electric Toyota FLTs are Lithium-ion

Posted on by David Priestman

Nearly a quarter of all Toyota electric-powered forklift trucks ordered for delivery in the UK now feature Lithium-ion battery technology.

“While lead acid remains by far the dominant battery type within the electric-powered forklift market, sales of Lithium-ion forklifts have been on a sustained upward curve for some time,” says Gary Ison, Sales Training & Product Development Manager at Toyota  Material Handling UK.

“Lead acid batteries have been a highly capable forklift power solution for years, and it is estimated that in the region of 90% of all electric forklifts in operation throughout the world are still running on these battery types. But Lithium-ion battery technology is now seen as the next evolution in forklift efficiency.”

Lithium-ion’s share of the electric forklift market is widely expected to proliferate significantly over the next five years with a report recently undertaken by India-based analyst, Research Dive, forecasting that the global Lithium-ion forklift battery market will be worth close to US$1,348.5m by 2026.

Gary Ison says: “Over the last decade or so, electric-powered forklifts have become an increasingly popular choice for businesses across all industry sectors who find themselves under growing social and legislative pressure to operate in as environmentally sensitive way as they can.

“Traditionally, electric lift trucks have relied on lead-acid battery technology but the Lithium-Ion solution has now become well established as a viable alternative. Today, in the right applications, Lithium-ion is revolutionising the way some companies operate their intralogistics processes.”

Growth in the Lithium-ion powered forklift market is being driven by a number of factors, not the least of which are the energy efficiency benefits and savings on fleet running costs that Lithium-ion offers.

But of equal significance are the advances in both battery and charger technology that have alleviated the health and safety issues that, for a while, were linked with Lithium-ion  batteries following a number of high profile fires at industrial buildings reportedly started by malfunctioning Lithium-ion batteries.

“There is no doubt that, some of the problems experienced by the early adopters of Lithium-ion battery technology made people cautious, but the science has moved on and it is easy to understand why more and more electric truck users are interested in Lithium-ion,” says Gary Ison.

He continues: “Lithium-ion batteries have the ability to be recharged in as little as one hour – which increases a truck’s overall availability. One hour’s charging will give in the region of 4 to 5 hours of operating time. Also, as these batteries allow for opportunity charging, trucks can be recharged anywhere by the operator during breaks in a shift or other periods of downtime. As a result, there is no need to swap batteries – so dedicated charging rooms and spare batteries aren’t necessary.”

Lithium-ion’s quick and easy opportunity charging functionality means that Lithium-ion battery fleets are most beneficial at sites where trucks are working at high intensity over multiple shifts or extended periods.

“Lithium-ion’s suitability as a power source for lift trucks is not driven by the number of forklifts in operation at a site but by the intensity of their schedule. A company that runs one reach truck 24 hours-a-day will benefit from switching to Lithium-ion batteries while a facility with a dozen machines that are used for light duties from 9-to-5 would commercially probably still be better served by trucks powered by lead acid batteries,” explains Gary Ison.

Infrastructural considerations

“But,” he cautions, “at any multi-shift operation with a high number of trucks working it is essential to manage and schedule operator break periods and consider the scenario where several trucks are ‘plugged in’ for recharging at the same time.

“This is because during the shorter ‘opportunity’ recharging process a Lithium-ion  battery can draw down up to four times the power from the National Grid than that which is needed to charge a traditional lead-acid battery over 8 – 12 hours.

Gary Ison continues: “If charging schedules are not properly managed and too many Lithium-ion  batteries are on charge at the same time there is risk that a building’s power supply could be overloaded.

“At Toyota we advise customers considering switching to Lithium-ion to speak to their utilities provider to flag up any potential power supply issues from the outset. But good charging discipline will deliver the consistent power levels required to allow the trucks to work around the clock – even within the most demanding environments.

“At Toyota we employ bespoke simulation software that enables us to consider all aspects of a client’s operation from the outset and model the optimum choice of battery and battery charging regime for any facility. From there we can advise on power requirements and help customers considering switching to Lithium-ion batteries to look at the bigger picture when assessing Lithium-ion batteries’ suitability for an application

“So, if you are considering switching to Lithium-ion, make sure your MHE supplier really understands your business and undertakes a thorough survey of your handling operation as well as – most importantly – the infrastructure of your site.

“With Lithium-ion offering so many benefits it is easy to forget that, for some users, the traditional lead acid battery will still represent the best option. Our pride in the Toyota brand means that we will always provide the right power solution for every electric truck application. It doesn’t matter if it’s Lithium-ion or lead acid – as long as it’s right for the customer.”

Reach trucks are Lithium-ion ready

The first three models in Toyota’s recently-launched BT Reflex family of reach trucks – the high-performance R-series, the E-series (which features Toyota’s iconic and unique tilting cab) and the flexible O-series for inside and outside use – are  all Lithium-ion ready.

The new trucks come with a choice of three intelligent energy packages to suit every customer’s application requirements: a 300 amp/hour battery for lighter duties; a 420 amp/hour battery for medium intensity work; and a 630 amp/hour solution for high intensity workhorses. All three packages are based on Toyota’s own modular Lithium-ion battery system and deliver a high degree of operational flexibility.

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