🚚 Fleet of 12 reach stackers for a 3PL operator running 24/7
Third-Party Logistics
📍 Poland
The situation — A 3PL warehouse handling mixed FMCG and retail pallets across 18,000 m² of racking, operating three shifts a day with 60 truck movements per shift.
The challenge: Their existing counterbalance forklifts could not reach the top beam at 7.2 m, and aisle width of 2.6 m made manoeuvring slow. Battery changes mid-shift were costing 40 minutes of lost time per truck per day.
What we supplied:
- 12 × CQD seat-based electric reach stackers with 7.0 m three-stage mast
- Side-pull battery packs with a spare set on charge per truck
- Fork positioner and side-shift fitted for mixed pallet sizes
Result:
- Put-away time per pallet cut by 32%
- Zero mid-shift battery downtime
- Aisle width reduced to 2.4 m, freeing 180 m² of storage
❄️ Cold-store conversion: 8 stackers rebuilt for −28 °C operation
Cold Chain
📍 Russia
The situation — A frozen food distributor in a region with winter temperatures down to −35 °C needed to move pallets inside a −28 °C cold store and across an unheated loading dock.
The challenge: Standard lead-acid batteries lost 60% of capacity within two hours. Hydraulic oil thickened, lifting became jerky, and condensation inside controllers caused weekly electrical faults.
What we supplied:
- 8 × cold-chain riding stackers with heated LiFePO4 battery compartments
- IP67 sealed controllers, motors and connectors
- Cold-grade hydraulic oil and heated tanks
- Rust-proof frame treatment for the condensation cycle
Result:
- Full 8-hour shift on one charge at −28 °C
- Electrical faults effectively eliminated
- Two trucks replaced three standard units
⚗️ Explosion-proof fleet for a solvent and paint warehouse
Chemical & Petrochemical
📍 Saudi Arabia
The situation — A coatings manufacturer storing solvents in a Zone 1 area needed to move 200-litre drums and palletised raw materials without introducing an ignition source.
The challenge: Zone 1 classification ruled out every standard electric truck. Drum handling also required a rotating clamp rather than forks, and static build-up on the forks was an identified risk in the HAZOP study.
What we supplied:
- 4 × explosion-proof counterbalance forklifts, Ex db ib mb sb IIC T4 Gb
- Explosion-proof drum clamps and rotators
- Conductive towing straps and spark-proof fork treatment
- Full certification pack supplied for the site safety file
Result:
- Compliant operation inside Zone 1 and Zone 2
- HAZOP actions closed with documentation
- Manual drum handling eliminated
📦 Narrow-aisle picking: 3-way forklifts in a 1.6 m aisle
E-Commerce Fulfilment
📍 United Kingdom
The situation — An e-commerce fulfilment centre added 4,000 new SKUs and needed more pallet locations without moving walls. Available aisle width was 1.6 m with racking at 9 m.
The challenge: No conventional forklift or reach truck could operate in 1.6 m. Renting additional space was quoted at a cost that exceeded the equipment budget by a factor of five.
What we supplied:
- 6 × electric three-way forklifts with 180° rotating fork carriages
- Man-up order pickers for the highest two beam levels
- Camera systems and height pre-select to speed up put-away
Result:
- Storage density increased 41% in the same footprint
- No additional rent
- Picking rate up from 68 to 94 lines per hour
🏭 Line-side feeding automated with AGV pallet trucks
Automotive Components
📍 Mexico
The situation — A tier-1 automotive supplier ran three shifts and wanted to remove forklift traffic from the main assembly aisle where 200 operators work.
The challenge: Manual line-side feeding required a driver on every route, and pedestrian/vehicle segregation was the single largest safety action on the risk register.
What we supplied:
- 9 × laser-navigation AGV pallet trucks on fixed line-side routes
- Fleet management software linked to the MES for call-off
- Automatic charging stations at the end of each route
Result:
- Forklift traffic removed from the assembly aisle
- Line-side stock-out incidents down to zero in the first six months
- Night shift feeding runs unmanned
🥫 Stainless steel pallet trucks for a daily wash-down meat plant
Food Processing
📍 Australia
The situation — A meat processing plant washes its entire production floor — including handling equipment — with chlorinated water at the end of every shift.
The challenge: Painted pallet trucks were rusting through within eight months. Grease lubrication was not permitted in the hygiene zone, and the plant needed documented cleanability.
What we supplied:
- 24 × full stainless steel hand pallet trucks, 304 grade
- Food-grade hydraulic oil and wash-down-safe seals
- One-piece forks with no crevices for bacterial traps
Result:
- Truck service life extended from 8 months to beyond 5 years
- Passed customer hygiene audit with no non-conformances
- Total cost of ownership reduced by more than half
🏗️ Rough-terrain forklifts for an unpaved block yard
Building Materials
📍 Nigeria
The situation — A concrete block manufacturer stores and loads product on compacted laterite with potholes and a 12% ramp up to the loading area.
The challenge: Three warehouse forklifts were destroyed in under two years — transmissions failed on the ramp and solid tyres punctured repeatedly.
What we supplied:
- 4 × 4WD all-terrain forklifts with 5 t capacity
- Rough-terrain pneumatic tyres and increased ground clearance
- Sealed wet disc brakes for the dusty environment
- Two spare wheel sets supplied with the order
Result:
- Continuous operation through two rainy seasons
- Downtime reduced from 3 days/month to nil
- Loading time per truck cut from 90 to 45 minutes
🛒 Double-pallet stackers halve the trips in a retail DC
Retail Distribution
📍 Germany
The situation — A retail distribution centre picks 90,000 cases a day onto standard Euro pallets and moves them 180 m from the pick face to the dispatch lanes.
The challenge: The travel distance was fixed and could not be changed. Every extra trip directly reduced throughput, and the operation was running out of dispatch capacity.
What we supplied:
- 10 × double-pallet riding stackers, two pallets per trip
- Turtle-speed fine positioning for accurate lane entry
- Side-pull batteries for round-the-clock operation
Result:
- Journeys per shift reduced by 47%
- Dispatch capacity increased without new building
- Operator fatigue complaints eliminated
