Fully-electric Forklift Fleet for Greener Logistics

More and more warehouses are turning to electric material handling equipment to boost productivity, safety and sustainability. Advances in technology have brought cost-effective and practical alternatives that provide the power, stability and operating effectiveness of their diesel counterparts.

Electric forklifts are a prime example of how eco-friendly equipment can improve operational efficiency and bolster sustainability credentials, prompting greater customer retention.

Among those making the change is shipping & logistics service provider GAC UK, part of the global GAC Group of companies, Since receiving the final electric forklift at their Aberdeen warehouse in May, all GAC UK warehouses and logistics centres across the country now run exclusively on electric-only equipment.

“We set ourselves an ambitious target to fully embrace electrification across our warehouses,” says Laura Grizzell, the company’s GAC UK’s QHSSE Manager. “We had to be prepared for high upfront costs, operational adjustments, retraining, possible process changes and ensuring we could access renewable energy sources reliably. The benefits, however, outweigh such concerns. Replacing our diesel and gas-powered equipment with electrical equivalents is the cornerstone of modern sustainable warehousing. Beyond reduced emissions and improved air quality at our facilities, these modern forklifts require less maintenance and have lower operational costs. Increased reliability and reduced downtime further bring down costs that we can then pass on to customers.”

Growing demand

New focus on greener warehousing practices has prompted a major uplift in demand for electrical warehousing equipment. According to a Yahoo Finance report on the global market trends for electrical forklifts, by 2030 the market is set to reach £48.66 billion, up from £31.64 billion in 2023. This trend is being led by the drive to electrify and the rewards it offers companies like GAC UK as they drive to create long-term value with sustainability in their operations.

“Electrification offers many benefits – both for the environment and the bottom line. Lower operating costs, more predictable budgets, increased fleet management efficiencies, and adherence to emissions standards make a strong business case for industrial electrification,” says Grizzell. “We are seeing that, both in our UK warehouses and at GAC’s facilities globally. From our colleagues in Denmark transforming their vehicle fleet to electric power to our team in Qatar using solar panels to power their facility, green warehousing practices are now the norm and should be fully embraced.”

GAC UK’s rollout of a 100% electric forklift scheme at GAC UK follows similar schemes seen in the Asia Pacific and Middle East. GAC Dubai now operates more than 120 pieces of electrical equipment, from forklifts to order pickers and side loaders, while GAC Thailand and GAC Singapore are also in the midst of similar electric forklift programmes.

Such initiatives reflect the GAC Group’s commitment to “adapt, innovate and reduce” in its activities as part of its Roadmap to Sustainability to create non-destructive, long-term value. Embracing electrification where possible and adopting electric-powered equipment, particularly when powered by locally-sourced renewable energy, will have a long-term impact on creating a sustainable logistics sector.

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E-fulfilment Automation Attracts Repeat Customers

What brings you back to your favourite online retailer? Other than product quality and range, it’s probably how quickly and competently they deliver your order. Consequently, the efficiency of e-fulfilment warehouses is critical for sales, as service level is a defining factor for customer retention. Automation solutions from experts such as Prime Vision provide warehouses with the tools and data that increase the accuracy and speed of order fulfilment, leading to enhanced customer satisfaction and repeat orders in the future.

Order, receive, repeat

An intuitive, attractive e-commerce platform with a good range of products is highly effective at catching potential customers’ attention. However, beyond initial exposure, holding onto them relies not only on the product meeting expectation but also on the service that follows the payment. A long delivery time, or a late arrival, will often push a consumer to another retailer that can do it faster. Shipping the wrong item means an unhappy shopper too, along with a costly return. All result in lost revenue and potentially, damaged reputation.

Customer retention is essential for the long-term viability of any business and is dependent on fostering loyalty and trust. It’s no secret that attracting a new customer is usually more expensive than retaining an existing one. Performing poorly at the dispatch and delivery stage will most likely result in a one-off order. Customer lifetime value (CLV) to the retailer would be equal to that single purchase and, considering customer acquisition costs linked to marketing and sales, the return on investment (ROI) could be disappointing – especially if that one order is returned.
Repeat customers are more lucrative, so retaining them is a top priority, and e-fulfilment operations must function effectively to keep consumers coming back.

Meeting service expectations with automation

Today, an efficient fulfilment operation is an automated one, and there is a wide range of smart automation solutions available that can raise service level and ensure customer orders are more than a one-time deal.

For example, automatic storage and retrieval systems paired with Prime Vision mobile autonomous robots (AMRs) and computer vision systems allow items to move faster through the warehouse. As a result, parcels containing orders are sorted quicker, reducing overall delivery times and the risk of a customer choosing another retailer with a shorter lead time.

This is achieved while improving accuracy. Inventory management systems, analytics software and computer vision provide full traceability across the warehouse. Operators can therefore usually identify errors before an item is dispatched, minimising returns and boosting customer satisfaction. Additionally, bottlenecks in warehouse sorting processes can be identified and resolved, further promoting efficiency.

Automation in peak demand

Automated operations are exceptionally proficient at catering for periods of high demand too – like Black Friday or Cyber Monday. An overwhelmed logistics operation results in delayed deliveries that can scare shoppers away. On the other hand, offering a consistent service level during these peak times is highly profitable. The latter is no easy task with current labour shortages in the sector. Thankfully software, robots and computer vision systems are very scalable. This means businesses can achieve higher warehouse throughput with limited resources, ensuring that existing staff aren’t overworked during peak periods.

Solutions such as Prime Vision’s Flow Projectors remove mind-numbing, time intensive tasks such as label reading, instead projecting a number that corresponds to a destination or chute on each parcel. Therefore, workers find sorting faster and easier. With these twin benefits, automation enables high demand to be met sustainably, protecting the existing workforce and safeguarding customer loyalty.

Data and discerning buyer behaviour

Gathering sales, warehouse stock inventory and other customer relationship management (CRM) data also empowers businesses to enact a feed-forward approach that can predict and influence customer behaviour. Working out buying habits means e-commerce platforms can use cross-selling or ‘frequently bought together’ features, encouraging shoppers to order more. For consumable products that are purchased repeatedly, the platform can suggest setting up a subscription.

On the fulfilment side, access to historical warehouse CRM data also allows buyer behaviours to be identified, so businesses can tailor their inventory management to capitalise. Bespoke analytics software backed by expert consultation focusing on particular areas of the fulfilment process are solutions Prime Vision has offered to its customers for leaner warehouse management.

Such an approach allows warehouses to optimise inventory volumes and individual product locations by actioning findings on what sells when and where, like surfboards in summer or by the coast. Businesses can then ensure availability for seasonally popular products and reduce delivery times by holding them locally. Often-paired items can even be stored in close proximity within the fulfilment facility itself. Once the data is gathered and analysed, the results can be a true eye-opener and, by addressing even a minor issue, a smoother, more efficient operation and time-saving practices can be established.

Get e-fulfilment right first time

In the experience of Prime Vision, automating e-commerce logistics can positively impact sales. The ability of automation to improve the efficiency of every aspect of a warehouse operation means faster delivery and reduced errors, enhancing customer service and fostering loyalty. Scalability ensures that this service level stays consistent even during peak times, protecting staff from burnout and maximising profitability at key moments. Using data to analyse and predict buyer behaviour can be used to enhance fulfilment operations, translating into high value, repeat purchases thanks to order accuracy and the speedy service received by customers.

Automation: Key to Sustainable Warehousing

The way to sustainable warehousing is through automation, says Craig Whitehouse, Managing Director of Invar Group.

Creating more sustainable logistics operations is a priority for businesses, governments and increasingly, consumers. The warehouse is the beating heart of the supply chain, but it may not be immediately obvious that investment in warehouse automation can significantly contribute to sustainability goals.

On the face of it, automation may appear resource heavy, requiring metals, plastics and electrical power. How can this be more sustainable than resource- and energy-light manual processes?
However, sustainability isn’t just about the headline issues of rare earth metals and carbon emissions, important though these are. We need sustainability in land use and water management, in transport capacity, in the reduction of waste in all its forms, in enabling the goods and packages we handle themselves to be more sustainable. Further, labour and money are also finite resources, which need to be managed sustainably. Automation, of physical processes and of control systems, can contribute to achieving sustainability goals in all these areas.

Consider, for example, Automated Storage and Retrieval Systems (ASRS) in all their variety. By using high-density storage right up to the eaves and in very narrow aisles, the required building footprint, with its associated impact on hydrology, can be reduced – along with the amount of steel and concrete that goes into construction. ASRS can save energy too, as lights-out operations are often possible, and less empty space is being heated, air-conditioned, or refrigerated.

Automated processes, perhaps combining ASRS, conveyor runs and Autonomous Mobile Robots (AMRs), can greatly reduce or even eliminate the requirement for carbon-emitting forklift trucks – with all the health and safety benefits of a reduced exposure to the possibility of collisions, back injuries and repetitive strain grievances. And as labour is a scarce resource in itself, freeing people up for more thoughtful, dexterous tasks.

However, automation can offer even more. The automated loading/unloading of vehicles reduces waiting time and thus the yard space required, enables more efficient vehicle utilisation, and again has safety benefits. Automated handling can also reduce waste through lowering stock damage, and with the latest packaging innovations can facilitate the use of ‘greener’ packaging solutions, with less waste of cardboard as a result of more compact packages.

These benefits can be amplified through the appropriate use of automated planning, management and control systems. Warehouse simulation, together with tailored Warehouse Management Systems (WMS), can optimise layout and activities to minimise movements and thus energy consumption – for example, by minimising the number of movements in and out of cold stores. A well-attuned WMS can also contribute to more efficient and sustainable use of transport, making it is easier to plan and assemble full loads for a destination within the necessary timescale. Automated goods-to-person order picking using, increasingly more affordable mobile robots combined with pick-to-light technology, or voice with human operators, can reduce mis-picks, and thus waste and returns.

Meanwhile, environment management systems can save on heat, refrigeration, and turn the lights off when an area of the warehouse is free of workers. Management systems for AGVs and AMRs can, within limits, plan for vehicle recharging off-peak, which is both cheaper and may reduce the demand for fossil-based energy generation.

Finally, machine monitoring systems informing preventative maintenance procedures can ensure that equipment is operating at peak energy efficiency as well as contributing to safe and healthy operation, while the general use of digital systems can greatly reduce the operation’s consumption of paper. These are just some of the automation options which, sensibly combined, can make a real contribution across the whole range of sustainability goals of the business, from climate change to human welfare and, yes, sustainable profitability.

Invar Group, headquartered in Cranfield UK, is focused on delivering complete turnkey warehouse automation solutions using advanced technologies such as industrial robotics, AMR goods-to-person solutions, pick-to-light technology, sortation systems, as well as conventional warehouse automation. The Group comprises: Invar Systems, a developer of warehouse control and management systems; Invar Integration (Greenstone Systems), a front runner in solutions design, hardware integration and project management; and Invar Controls, specialists in the design, implementation and maintenance of PLC software and hardware.

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