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61 The Irish Magazine for the Materials Handling, Warehousing & Logistics Sectors The Irish for Materials Warehousing & Sectors
www.handling-network.com 61 combilift.com 25 combilift.com
Contact Us Today 59 NEWS Applications open for IFOY Awards 2024 Hoppecke launches new battery chargers 64 INTERVIEW With Sam Moffett, Moffett AS 66 AWARDS Category details of the IFOY Awards 2024 68 CASE STUDY Luscombe Drinks raise a glass to Combilift 69 PRODUCTION The intricacies of making a refuse collector 70 SUPPLY CHAIN Irish Sea sailings
The trak charger HF giant effectively replaces eight individual chargers, saving both floor and shelf space. A single unit with one power connection, it is the ideal solution when space is at a premium, or businesses are planning to refurbish or build a new warehouse.
Stuart Browne, General Manager at Hoppecke Industrial Batteries, explained: “Businesses in electric intralogistics are running increasingly bigger MHE fleets these days and with the cost of warehouse space on the rise, efficient use of it, and this includes the battery charging area, is a top priority. The trak charger HF giant addresses the space issue, whilst also tackling the need to improve battery availability, which is especially important in 24-hour operations, with a quick charge capability.”
Suitable for single or multi-shift operations, the trak charger HF giant can be configured to charge batteries with differing voltages (24V to 80V) and capacities (64Ah to 1550Ah). Incorporating high efficiency HF power modules, the unit offers major cost
savings by comparison with older 50hz chargers.
Long operating hours and short charging periods impact forklift performance, so rapid battery charging is a cost-effective way of boosting availability. Since Hoppecke’s new charger achieves up to 95% state of charge in just 2.5 hours, intensive operations can easily incorporate opportunity charging during break times and shift changes.
After six charges at four-hourly intervals battery capacity returns to 100%, whereas without opportunity charging, capacity would be 62%. Heavy duty operations can take full advantage of this capability to maximise their working hours.
With the trak charger HF giant automatic battery recharging is independent of depth of discharge. The charger automatically transitions to recharge mode at the end of charge, compensating for self-discharge. Paperless evaluation provides greater transparency and the charger’s large data memory enables users to track its
entire service life. Another key feature is a special cooling system, which protects components from dust and dirt.
No cause for concern arises from battery faults, since the trak charger HF giant features the fastest pre-emptive safety shutdown on the market. Meanwhile, redundant switching of the power output stages ensures the highest possible operational safety. Safety is further improved by parallel power output stages, so even if a module fails, businesses can continue to charge their trucks.
Charger operation is via intuitive touchscreen control, with a series of colours enabling users to check charging status at a glance. Obtaining parameterisation and runtime analyses is straightforward, whilst a download function allows data storage on external media. With the trak charger HF giant flexibility is built in. A rolling side panel allows for quick and easy integration of optional extras, such as Hoppecke’s trak collect battery controller or trak monitor management system.
62 | NEWS 1
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Sam Moffett is one of 23 entrepreneurs who have been shortlisted for this year’s EY Entrepreneur Of The Year Ireland awards.
The EY Entrepreneur Of The Year programme is a global recognition programme run in 145 cities in more than 60 countries. Currently in its 26th year in Ireland, the programme works to recognise, promote, and build a supportive community around Ireland’s high-growth entrepreneurs and is considered one of the strongest examples of such programmes globally.
The EY Entrepreneur Of The Year Ireland alumni community comprises over 580 entrepreneurs representing some of the greatest business minds across the island of Ireland. Collectively these businesses employ more than 200,000 people and generate revenues in excess of €23billion.
The theme for this year’s programme is The Art of Entrepreneurship. This year EY will recognise and celebrate entrepreneurs who apply their unique vision and skill to create and build businesses that leave a valuable and lasting impact on the local communities and the economies in which they operate.
The EY Entrepreneur Of The Year Ireland programme is supported by Premium Corporate Sponsor Julius Baer International, and Government sponsors Enterprise Ireland and Invest Northern Ireland.
Based in Clontibret, County Monaghan, Moffett Automated Storage Limited was started by Sam in 2017. Moffett Automated Storage provides a fully automated storage solution to warehouses that use pallets. The company covers all aspects from warehouse design and planning, engineering and production of machinery, installation of equipment, and software development together with aftersales support and maintenance. With customers worldwide, Moffett products can be applied to any company that stores pallets on a medium to large scale.
Moffett machines work 24/7 all year round in any environmental conditions of between -30c to +40c. The company offers a unique service in Ireland and has very few competitors worldwide. Its backup support team offers a 24 hour service to resolve any issues. Moffett invests 50% of software development into research and development leading to further growth in this recession-proof business. Moffett Automated Storage Limited was named as Overall National SFA Small Business Winner 2023. Handling Network caught up with Sam to get an update on the progress of his company.
How has your business progressed since the launch and official opening in Monaghan?
The launch was a blur as the day passed so fast! The company awareness grew massively, and we strive to continue to grow the name. It has also helped with employment which is a bonus.
The location of the factory base is significant from a family history in engineering and innovation, with the Moffett Mounty truck mounted forklift originating here.
I have grown up beside this building from when I was born, and it has a history beyond work and business. The main manufacturing area was built in the 1970s, while the office and extension happened over the years. I invested over €680,000 in refurbishing the office block which has given a significant up-lift to the building and the lifestyle of the staff.
Has the general design evolved much or is it more bespoke related to customer requirements?
Coming from a product-based family, I felt I knew how to sell a product. A major change has been how to sell a system solution which is very different.
As for the products within the solution, we have had minor date changes. Recently, we received Enterprise Ireland support to upgrade some of our machinery and we look forward to a 2.0 version of what we do that will leave us innovating and leading in our industry.
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The official opening of the new Moffett AS HQ in Clontibret, County Monaghan, performed by An Taoiseach Leo Varadkar and attended by other public representatives
Explain in brief the Moffett AS/R concept from its origins and to where it is today
Traditional AS/R has been stacker cranes and it remains the industry norm. With our Taxi solution, we wanted to achieve better redundancy while offering something that was scalable as the business grows. We managed just that and our proprietary software which are manufactured in-house gives us the opportunity to exceed these expectations.
business helping people design the warehouse. This is a very extensive process, and I call our board room the ‘’war room’’. This is where we work with the client, understand their business, their challenges and what they want to achieve. We work with them to nail down all their requirements and agree the best way forward. We start with an RFI (request for information) this gives a good guide to how we start the design.
Is operational training provided and ongoing monitoring, after sales and support?
We offer 24/7 - 365 support globally and we initially design the software around the ability to support the system from our Monaghan HQ. To date this is a key part of our sale. We have the capability to operate any system word wide; from drive our taxi to monitoring resistance or battery temperatures.
A great benefit to the taxi solution is that if one unit breaks down it will not affect the operations or product selectivity. Our clients love this!
From a sustainability aspect, how efficient are the systems and has payback been calculated?
From the three different industries we look at, it ranges from 2.5 years to 5 years depending on the demands of the systems and how it is used.
For a sustainability perspective, the MAS solution stores up to 70% more pallets that a traditional warehouse. The fact that we can either increase the current warehouse by 70% or reduce your warehouse requirement by 70% is excellent. The racking design allows MAS to use existing buildings where some AS/R require new builds, again, this help with sustainability.
Outside of all things warehousing, your main hobby is rallying, with your company name carried on your rally car. How has the season been so far?
I started the year with some rallying, but with the arrival of our second child (Jake), it put the brake on that quickly. My family and work are my main priorities right now. Hopefully I will have more time to return to it again in 2024.
What and who are your main customers i.e. target audience –home and abroad?
We target three primary industries, but the simple fact is moving pallets is something a lot of people in the industry are doing!
Manufacturing is one key customer for MAS as we can offer to take the pain of warehousing away from their business and allow them to focus on the core business. They also have the option to take the product back in-house if they have subcontracted the warehousing out.
3PL - for this we can offer significant space savings or additional pallet locations. This means in a warehouse the 3PL can achieve a lower overhead rate per pallet, allowing a return of investment in as low as 2.5 years.
Cold storage - this is pallet count. Energy saving is the big element here. We find that with the major pallet increase per sq.ft., we reduce the energy, and the warehouse only requires doors the envelope of the pallet with zero lights required in our AS/R system.
Another string to your bow is warehouse planning and consultancy. What’s involved here?
Yes, my history has been material handling over many years while finding solutions for clients. This is the fun side of the
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Monaghan based business Moffett Automated Storage is named Overall Winner of the Small Firms Association National Small Business Awards 2023. Sam Moffett, Managing Director from Automated Storage receiving the Overall Winner of the Small Firms Association National Small Business Awards 2023. Picture Conor McCabe Photography.
The green light is now shining to indicate that the application portal for the International Intralogistics & Forklift Truck of the Year (IFOY AWARD) is now open, with an entry deadline set for October 30. Intralogistics companies involved in manufacturing and developing worldwide can apply to participate in what is an ideal opportunity to showcase new innovations and projects. Eleven categories covering all areas of intralogistics are up for voting in the twelfth edition of the award for 2024.
Those involved in Forklift trucks and warehouse technology equipment as well as custom-built special vehicles are welcome to enter the competition. Automated and autonomous industrial trucks, stationary and mobile robots, software and outstanding technical details or components, such as ergonomic innovations, safety solutions or warehouse aids, now represent the majority of IFOY awards applicants.
Awards are also given for successfully implemented integrated warehouse and automation projects at customer sites. A separate IFOY AWARD will be presented to start-up companies.
Applications are also open to start-up companies with their
products and solutions. Applications can only be submitted via the Internet at www.ifoy.org.
At the announcement of this year’s awards, Anita Würmser, Chair, IFOY explained further: “The conditions of participation can be requested from the IFOY office. Due to its technical expertise and outstanding marketing value, the IFOY AWARD has established itself as an indicator of cost-effectiveness and innovation and is regarded as a coveted innovation award in intralogistics. The jury, which includes the editors-in-chief of leading international logistics media, makes its decisions independently, according to transparent criteria and on the basis of professional expertise.”
IFOY TEST DAYS & TEST CAMP INTRALOGISTICS in April 2024
At the IFOY TEST DAYS, the nominees undergo the three-stage IFOY audit, consisting of the IFOY Test, the scientific IFOY Innovation Check and the jury test. Essentially, the nominees are not compared with each other, but with their competitor products on the market. Next year, the IFOY TEST DAYS will again be held as part of the TEST CAMP INTRALOGISTICS at Messe Dortmund, which opens its doors on April 10 and 11.
The IFOY TEST DAYS will begin two days earlier - on the afternoon of April 8 with the first functional tests. On April 9, the IFOY finalists will undergo the scientific IFOY Innovation Check and present their innovations to the jury of trade journalists, who will be traveling from 18 countries. This panel includes Fleet Transport/Handling Network, which has represented Ireland on the jury for a number of years.
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“The TEST CAMP INTRALOGISTICS is a testing event with an additional congress,” continued Anita. “This event format is all about hands-on testing of selected innovations and new developments in warehousing and material handling technology. Decision-makers from industry, trade and the service sector with a concrete interest in innovation and investment have the opportunity to extensively test the exhibits themselves on around 10,000 square meters of hall space and to discuss current trends and developments with experts. The sponsors of the IFOY AWARD, which is under the patronage of the German Federal Ministry of Economics and Climate Protection, are the
WAREHOUSE TRUCK “LOWLIFTER ”
Mainly manual warehouse equipment up to approximately first rack level such as pedestrian-controlled low-lift trucks, tractors, tugger trains, horizontal order pickers etc.
M OBILE ROBOT
Mobile autonomous or automated robots, such as AGVs, AMRs, cobots, robots for automatic unloading and loading of trucks, automated industrial trucks, etc.
S TATIONARY ROBOT
Automated storage systems, stationary robot-based solutions for intralogistics applications such as palletising and depalletising, cobots, picking robots, etc.
I NTRALOGISTICS SOFTWARE
This category is open to apps and intralogistics system or software solutions in the context of application possibilities, such as warehouse management systems, forklift control systems, driver assistance systems, fleet management systems, etc.
I NTEGRATED CUSTOMER SOLUTION
Open to integrated warehouse projects successfully implemented for a customer.
S PECIAL OF THE YEAR
Components or technical equipment that significantly improve profitability, sustainability or the physical or psychological conditions for the user, such as ergonomic innovations, safety assistance solutions, automation solutions, drive technologies, supporting devices in the warehouse, forklift attachments, etc.
C RANE AND LIFTING TECHNOLOGY
German Association for Materials Handling and Intralogistics and the Robotics + Automation Association within the VDMA. IFOY partners are Messe Dortmund and Cascade, the world’s leading forklift attachment manufacturer. The IFOY AWARD’s pallet partner is CHEP, the world market leader in the pooling of pallets and containers. Logistics partner is LTG,” she added.
AT A GLANCE:
T HE 2024 IFOY AWARD S CATEGORIES
COUNTER B ALANCED T RUCK
All types of counterbalanced trucks up to 8 tonnes.
H EAVY LOAD FORKLIFT AND SPECIAL VEHICLE
Forklifts/vehicles for special tasks, special vehicle construction, drones, cargo bikes, container forklifts, heavy load forklifts over 8 tonnes.
WAREHOUSE TRUCK “HIGHLIFTER
Warehouse trucks from circa; second rack level such as high rack, narrow aisle and reach trucks, pedestrian operated high lift trucks, order pickers, etc.
Cranes for various applications, such as gantry and bridge cranes, bracket and wall-mounted travelling cranes, slewing cranes, suspension cranes, light cranes, etc. Lifting equipment for various applications, such as chain and rope hoists, winches, magnetic and vacuum lifters, lifting table and working platforms, etc.
IFOY S TART - UP OF THE YEAR
Innovative prototypes or functional developments, intralogistics products, software, vehicles or components from start-up companies.
Text: Jarlath Sweeney – editor@fleet.ie
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The global pandemic highlighted the importance and need for efficient warehouse space management for the food and beverage industry. It ensures convenient access to bulk product storage, streamlining operations and ensuring timely customer fulfilment. Recognising the ongoing challenges in this area, Monaghan based Combilift, a prominent manufacturer of space-saving handling equipment, provides a solution in the very narrow aisle (VNA) forklift, through its Aisle Master range. Luscombe Drinks, an organic drinks manufacturer located in Devon, England, is one company that is seeing benefits from the adoption of the VNA forklifts.
“When I first started investigating possible forklifts, I initially thought
of VNA man-up or reach trucks, but our materials handling consultant recommended the Combilift Aisle Master. I trusted his advice, and after visiting two local Aisle Master users, I was immediately won over by the performance and versatility of the vehicle,” said Operations Manager Tim Wigley of Luscombe Drinks.
“Our previous on-site storage system was based around a counterbalance truck, with inside and outside areas with three metre aisles. On top of this we were paying for external storage of 600 pallets plus incurring the extra costs for transportation, so it made sense to look at building our own facility on site.”
By adopting the Aisle Master, Luscombe Drinks achieved narrow aisle widths of 1,900 mm rack to rack, accommodating 1,390 pallets in a compact space of 1,225m². The Aisle Master efficiently utilised vertical space, lifting two-tonne pallets and raising one-tonne pallets of bottled drinks to an impressive height of 7.65 metres on the top beams.
COMBILIFT A ISLE M ASTER –KEY FEATURES AND BENEFITS:
V ERSATILITY
The Aisle Masters operate seamlessly on any surface, eliminating the need for separate machines. They can transport loads from trailers to the racking position in one operation.
E NHANCED EFFICIENCY
Made with top-grade materials, Aisle Master forklifts have robust chassis for rigorous indoor and outdoor usage.
O PTIMISED STORAGE CAPACITY
By optimising racking layouts and reducing aisle widths to as little as 1.6 metres, storage capacity can be dramatically increased. This results in a 50% expansion in warehouse
Lu SCOMBE D RIN k S –C u STOMER TESTIMONIAL
“Having the Aisle Master in place has also opened our eyes to other possibilities. Outsourcing cold storage is even more expensive than ambient so the next stage will be to build our own and get a second Aisle Master with a cold store spec. This will give us more control over our stock, there will be two machines available when the workload is heavy, and we can cut costs even further.”
Combilift provides valuable services tailored to customers’ needs. Combilift’s offerings include visual aids, expert recommendations, and personalised support, all designed to help optimise storage space.
Text: Rob Van Dieten – rob@fleet.ie
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The production process in any manufacturing business, particularly automotive and industrial, is at the heart of its sustainability. In the case of refuse collection vehicle specialist Dennis Eagle, its direct interest is to reduce energy consumption, improve processes, replace old equipment with more efficient equipment, improve the fabric of the buildings and the safety and wellbeing of staff.
While the Leamington Spa based company has always had an ongoing programme to meet this end, the effort and investment to achieve these goals has never been greater than it is now.
Recent and ongoing improvements in sustainability at the Warwick production facilities can be summarised as follows:
E LECTRICITY SAVINGS
A new transformer and low voltage board was fitted in 2022. It is far more efficient than its predecessor and it is estimated it will save 41,601kWh of electricity annually. Alongside the subsequent cost savings, this alone reduces the company’s emissions by 9.6 tonnes of CO2 per year.
A new air conditioning control system has been installed to manage use in all office areas. It follows uk Government guidance on how to restrict its use and recommendations for maximum energy efficiency.
Across the entire company, LED lighting has been installed both internally and externally. This alone has reduced the energy need for lighting by 70 percent. A temperature issue in the paint booths meant that Dennis Eagle couldn’t initially install LED lighting in them, but this challenge has been overcome and a trial is now underway. Emergency lighting has also been upgraded to a more energy efficient system.
B UILDING IMPROVEMENTS
A new roof has been fitted to unit 1 at Warwick. This is better insulated for better temperature control and to reduce wasted energy. Speed doors have also been installed in the factory. These allow much quicker entry and exit and so, once again, reduce heat loss from the buildings.
Meanwhile, in the Fabrication Shop, the extractor fans in the roof have been replaced with fans featuring more efficient motors to further reduce energy consumption in this workspace.
Eq UIPMENT UPGRADES FOR EFFICIENCY
Where feasible, air tooling has been replaced by direct electric power which is more efficient than an electric compressor. Other compressors have had their timers and overrides changed to save more energy and a transducer has been fitted to the main compressors to balance loading. The remaining air tool oilers have also been upgraded to reduce oil waste.
Dennis Eagle management has also carried out a full Argon Line replacement to reduce the risk of leakage and remove waste. And with similar goals, the ongoing Air Leak Repair project aims to eliminate leaks and the waste it entails.
New bulk tanks have been installed for diesel, hydraulic fluid, transmission fluid and AdBlue. These include a filtration system to ensure vehicles going to customers will always be delivered with totally clean fluids, plus it minimises the risk of environmental pollution and waste.
There has also been a full upgrade of welding equipment for maximum safety and efficiency.
New distribution boards throughout the site add to these savings thanks to lower energy usage and improved efficiency.
The factory units have also had Ecotile flooring fitted over the concrete floors. This not only provides better temperature control but is also more comfortable for people to walk on.
On the factory floor, fork lift trucks have been fitted with telematics to monitor their efficiency. This has enabled a re-organisation of the fleet and a reduction in usage, leading to cost and emission savings.
Text: Jarlath Sweeney – editor@fleet.ie
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In the aftermath of Brexit freight traffic on all routes linking Ireland and Great Britain dropped significantly. Contributors to this decline included traffic moving between continental Europe and Ireland being re-routed onto direct ferry and container routes. In addition, there was a reduction in Ireland-GB trade due to significant precautionary stocking in advance of Brexit, and a diversion of traffic moving between GB and Northern Ireland from the previously high-frequency WalesIreland sailings to routes through Belfast or Larne.
to P&O ferry routes mainly focused on Northern Ireland, and, perhaps more importantly, the fact that after two years of working with post-Brexit trading arrangements, a level of familiarity with the new control processes has been built up by traders and all of those involved in the transport chain. It is unclear, at time of writing, how the full implementation of the Windsor framework will impact freight volumes. It remains possible that this will lead to the introduction of Green and Red Lane systems at RoI ports for traffic moving through there to and from Northern Ireland.
EU SEEKS TO ENHANCE TRADE LINKS WITH M OLDOVA
UK DROPS BID TO REPLACE E UROPE’S “CE” q UALITY MARK
uk Premier Rishi Sunak’s Government has now said that uk companies can continue to use the European union’s product safety mark indefinitely. Companies can now continue to apply the Eu “CE” label to sell goods in Britain instead of having to apply for the “ukCA” mark. That new mark was due to kick-in from 2025. The change of plan arises from the growing perception that that a uk-based quality system may not ensure a sufficiently high standard for the goods to which it is applied.
However figures published by the Irish Maritime Development Office (IMDO) in its 2022 Irish Maritime Transport Economist show a recovery in freight traffic volumes on the routes linking Dublin and Holyhead and Liverpool in 2022. Total trailer volumes on these routes for 2022 were 761,117 units, a 5% increase on 2021 but still 18% below 2019 levels. On GB routes operating through Rosslare though, volumes have continued to fall, and in 2022 were 62,000, a 40% drop on the 2019 figure. Ferry traffic volumes through Northern Ireland ports appear to have peaked in 2021 with a 929,032 figure and dropped back by 5% for 2022.
Seeking to explain the increase in Dublin figures, the IMDO points to a more competitive shipping rates being put in place on Republic of Ireland (RoI) routes, significant disruption in 2022
On 20 July 2023, the Eu Council issued a new set of regulations governing the bloc’s trade with Moldova. An Association Agreement “expresses the desire of the Eu and Moldova to strengthen and widen relations in an ambitious and innovative way to facilitate and achieve gradual economic integration and to do so in compliance with the rights and obligations arising out of the World Trade Organisation membership of the parties”. Moldova shares a significant border with ukraine and considerable volumes of traffic moving to and from that country transits Moldovan facilities. The new agreement could be seen as being a part of a process to extend Eu membership within the region and, in doing so, significantly increase trade volumes.
The British Government has also dropped a mechanism to remove all Eu law from the uk Statute Book by the end of 2023. Immigration restrictions have also been eased to meet the requirements of industries under pressure to recruit necessary workers locally.
There have, at the time of writing, been no indications from the uk Government or the Devolved Administrations in Wales, Scotland, or Northern Ireland that the planned implementation of import controls on food and other products which have already been significantly deferred, will go back even further. Irish exporters continue to be advised by the Irish Exporters Association and others to assume that the current schedules will be implemented.
Doubts do persist as to how the physical Port Control infrastructure at Holyhead and elsewhere on the British West Coast, will be built and staffed ahead of the end-2024 deadline for full implementation of controls.
Text: Howard Knott - howard@fleet.ie
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