EUROPEAN ISSUE
ISSN-No. 1868-2251 1/2. European Issue | June 2012 | 10. Volume
The Pan European Forklift Magazine
| The Green Way – Clark about to expand throughout Europe Page 10–11 | Are articulated Forklifts ready for Europe?
Page 18–19
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PREFACE
A deeper look in what’s going on Is Europe facing the next crisis? What am I talking about the next crisis, there has always been one and the markets are in pretty different shape – so to say. This does influence every part of economy and the material handling business is in the midst of all – STAPLERWORLD – FORKLIFT-WORLD – the Pan EUROPEAN Magazine for the forklift and warehouse industry is again featuring a large variety on different topics – a lot of things are going on. Mitsubishi is closing Almere factory and is about to concentrate the electric lift truck production in far away Finland – not a bad idea because the Rocla-guys know exactly how to build quality warehouse equipment and also AGV-systems. Peter Wolf, manager of the brand activities for the “three diamonds” has a hell of a job and I do wish him all the best – the sad thing on shifting the production is that a lot of talented workers will loose their jobs – not good for an underperforming Dutch economy.
– d a o L r u Yo Measure Our
Every manufacturer beside the large four (Kion, Jungheinrich, Nacco, Crown) has faced that warehouse equipment is the vital part of the programme – no wonder that Rolf Eiten, Sales and Marketing director of Clark Europe stresses in our interview that the partially made in Korea new warehouse equipment is one of the key components for future growth – this may of course affect the co operation with OMG – a fine source of warehouse equipment based in northern Italy that also produces for TCM. But this another fascinating story – UniCarrier, the new home of Atlet, Nissan and TCM is about to work on a tight schedule for the releasing of more details about what’s to come – what will remain, headquarters in Amsterdam, production facilities in Pamplona and Mölnlycke and distributors/ importers in some European countries a pretty challenging situation – flavoured with the fact that the Pamplona made lift trucks will not carry the name Nissan for too long. Let’s wait and see – insiders do argue that in September there will be more to come. In the meantime poor Emilia Romagna – considered as one of the richest and most developed regions in Europe and has the third highest GDP per capita in Italy has been hit by a series of earthquakes that also affect a number of promising companies even in the material handling business – Italy still is home of a thriving part of our business just to mention Levante, Armanni, Cesab, OMG, FAC, CV-Italia, Icem, Braviisol, Bolzoni, Montini, Atib, Nuova Detas and many more – all of those can be seriously been hit by the devastating devolpemnts – but Italians are proud and ingenuous people as we all know and so my strong believe is that not only the material handling business will be soon back on the block. So, there is a crisis, not only regarding the struggling Euro and instable financial economics – how will industries behave in times were Volkswagen claims that the most important market now is China – will all the manufacturing business move away and leave deserts were once stood factories? The answer is no – but business is changing and as Ralf Mock, CEO sales and marketing Nacco tells us: Counterbalanced forklifts is selling iron – warehouse equipment is selling solutions and this is what the industry has to face – and we will accompany this very important development pretty close. I am glad to present the first issue in 2012 of STAPLERWORLD – FORKLIFT-WORLD – the Pan EUROPEAN Magazine. I value your comments and our team will be happy to talk to all of our readers – users, dealers and manufacturers. Sincerely yours Oliver Bachmann
oba@staplerworld.com
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Forks up to 90 t Payload Standard- and Special Forks with all Shapes and Dimensions Attachments Special Attachments and Alterations for Special Lifting Applications and Loads Special Forklifts Lifttrucks and Warehouse Equipment for Instance made of Stainless Steel Repairs Straightening of forks, shortening of masts, renewal of profiles, Repair of Attachments and Fork Carriages
CONTENT · IMPRINT
COUNTERBALANCED LIFTTRUCKS Clear view with CamFork-Forks with integrated camera
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Cargotec delivered zero-emission forklifts for Ford
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“When things get tight, small is beautiful!”
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Offshore-Forklift masters Extreme Conditions
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Hard Work in German Foundry – tough Job for Special Forklift
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The Green Way – Clark is heavily working on a solid base in Europe
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Heavy forklifts doing their bit for wind power
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New Paper Roll clamps
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WAREHOUSE EQUIPMENT What does the forklift truck of the future look like?
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Important Developments for Electric Lifttrucks and Warehouse-Equipment
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“Bend”.ing all over, are articulated trucks ready to hit Europe?
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More Power and Strength from Batteries, how new Technologies will affect Material Handling
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The smoother the ground the better the forklift truck performance
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Warehouse Equipment-Range rounded up suffienctly
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PEDESTRIAN CONTROLLED TRUCKS Stainless Steel Pedestrial Stackers
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TPE HL working at Milan Malpensa airport
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Rocla AGVs increase efficiency and safety in a cheese factory
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CEO Dipl.-Wirtsch.-Ing. Oliver Bachmann Register Court: Mainz · HRB-No.: 8678 Editor-in-Chief Oliver Bachmann Tel.: +49 (0) 61 39-29 34 43 Fax: +49 (0) 61 39-96 04 55 Mobile: +49 (0) 152-9 21 95 80 oba@staplerworld.com Editorial Staff Susanne Obigt, Ilonka Schwing (STAPLERFACTS) Advertising IMP InterMediaPartners GmbH In der Fleute 46 | 42389 Wuppertal-Langerfeld Sven Anacker, Uwe Riemeyer Tel.: +49 (0) 202-27169-0 | Fax: -20 mail@intermediapartners.de Circulation (European Issue) 4 times per year Printingcopies 10,000 copies Layout JOY DESIGNS | Jennifer Dietmann | 68766 Hockenheim Fon: +49 (0) 62 05-255 35 42 | www.joy-designs.de Printing Silber Druck oHG | 34266 Niestetal Fon: + 49 (0) 5 61-52 007-0 | www.silberdruck.de Single Copies STAPLERWORLD Europe English Within Germany: 20.00 EUR (plus shipping, incl. tax) Within rest of Europe: 28.00 EUR (plus shipping) Subscription (1 year) 4 issues STAPLERWORLD EUROPE English + special issues English Within Germany: 85.00 EUR (incl. shipping and tax) Within rest of Europe: 110.00 EUR (plus shipping) Notice of Cancellation 8 weeks before end of subscription year Terms of Payment Payment within ten days afer invoice receipt: 2 % discount. Payment within twenty days after invoice receipt without discount.
SPECIAL FORKLIFTS
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Publishing Company TechTex-Verlag GmbH & Co. KG Schaeferstrasse 2 D-55257 Budenheim Tel.: +49 (0) 61 39-29 34 43 Fax: +49 (0) 61 39-96 04 55 info@techtex-verlag.com www.techtex-verlag.com www.staplerworld.com
Spare Parts for Container Handlers and Terminal Tractors
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World leading special Profile Producer
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Baumann Sideloaders work in Fichtelgebirge Lumberyard
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Offroad-Reachstacker for German Army and very special applications
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Transfer-Carrier for Terminals and Industry
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Global Logistics Provider Sees Payback from LEDs in just Over a Year
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Banking Arrangements Budenheimer Volksbank Account: 5 34 65 Bank Code: 550 613 03 BIC: GENODE51BUD IBAN: DE8055 0613 0300 0005 34 65 VAT No.: DE 239 327 294 All rights reserved by the publishing company, as well as for reprints, extract reprints, photostatic copies and translation. The publishing company assumes no responsibility for unsolicite posted manuscripts. For articles by name the author takes the responsibility.
STAPLERWORLD ENGLISH 01/2012
COUNTERBALANCED LIFTTRUCKS
Clear view with CamFork-Forks with integrated camera Bad visibility is a recurring situation in dayto-day operation. Very often this leads to inefficient working but also damages of the transported goods and accident risks may appear. This is not only annoying, but possibly also dangerous. Until now, a camera was mounted at the side of the fork or at the fork carrier. However, in case of loaded cargo visibility was still burried or blurred. For this application, the German manufacturer of Vetter developed in cooperation with the camera manufacturer Motec the new CamFork QualityFork with integrated camera. The camera is placed where it belongs: fork tip-integrated for best and clear view. There are significant advantages concerning safety at work, time and cost saving – not only in case of loaded cargo but also for high-rack storage or truck loading.
Fork and camera are perfectly coordinated for an ideal visual field and safe mounting of the camera inside the fork tip. Wiring is carried out safe in the fork arm, there are no protuding edges. The form of the fork is maintained and damages are efficiently avoided. The camera itself complies with industry standard, safely protected against shock, moisture, coldness and dirt. Reference lines in the monitor for the pallet pocket and bottom line of fork assist in fast and
effective loading. CamFork applications are for example wholesalers and retailers, beverage logistics, forwarding agents, distribution centers, manufacturer of consumer goods, ports etc. Image: Vetter
Further Information: www.vetter-forks.com
Cargotec delivered zero-emission forklifts for Ford Cargotec has delivered 17 all-electric forklifts from its Kalmar ECF50-90 - Pro Future(TM) range to Ford Motor Company. One Kalmar ECF90-6 and two ECF70-6 models have been delivered to Ford‘s Craiova Assembly plant in Romania in April and a further 14 forklifts will be delivered to Ford Germany‘s Cologne facility next month. Emissions are an important consideration for organisations such as Ford Motor Company with the health and safety of its workforce and stringent environmental policies at the forefront of decision making. The Kalmar all-electric forklift series, which is capable of handling loads from 5 to 9 tonnes, is part of Cargotec‘s already long list of Pro Future(TM) solutions, which have passed certain industry-leading criteria regarding power source, energy efficiency, carbon efficiency, local emissions and recyclability.
STAPLERWORLD EUROPE 01-02/2012
With the majority of Ford Motor Company‘s applications in Romania and Germany indoors, the company has long recognised the benefits of the zero-emission Kalmar electric forklifts. The all electric forklifts run quietly and smoothly. Another crucial factor to Ford was manoeuvrability, wherefore Cargotec‘s ability to provide a compact variant was another major positive for working in confined spaces. Ford Motor Company specified 12 of the Kalmar ECF70-6C models supplied to Cologne specifically adapted with a shortened wheelbase to optimise productivity in the narrow indoor operations. The machines will be used to feed steel dies which shape metal to form vehicle chassis during the manufacturing process. Cargotec‘s Thomas Malmborg, Vice president, Fork Lift Trucks said: „We are delighted that a world renowned manufacturing giant such as Ford Motor Company has recognised the benefits of working
in partnership with Cargotec. Today‘s economic climate increasingly sees a tough balancing act for companies striving to meet ever higher productivity targets while minimising their ecological impact. With the Kalmar ECF50-90 electric range, it‘s easy to meet demands for a better environment as there simply are no emissions. And by taking harmful emissions out of the equation, customers – especially those operating indoors – can operate in a cleaner and safer environment.“
Further Information: www.cargotec.com
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COUNTERBALANCED LIFTTRUCKS
“When things get tight, small is beautiful!” FLY detail: even in a super compact truck, there is enough space for operator’s feet and legs
FLY special version, with the electronic steering support
Company history
niche of the super-compact sized truck has allowed a good number of spot sales all the same. High levels of client satisfaction feedback reported from dealers in countries like Spain, Portugal, Germany and Denmark is now encouraging Levante’s extra efforts to significantly increase its presence in the European market, establishing direct partnership with dealers in all countries. Today’s factory production capacity is quite limited, with 50 to 70 units of 24V forklifts per year as its maximum volume, however, Company Management declares a clear intention to invest in new facilities and personnel, in order to meet new market requirements. Intentions of growth were clearly shown by the company articipating both at the last Cemat fair in Hannover, and also at Chicago Promat Show in 2009 and 2011, chasing another long-term target: the USA market.
Levante is a small company based in Ostiglia, a town in the center of the Italian North, not far from the cities of Mantua, Verona, Modena and Bologna. Starting in the year 2000 as a trading company, Levante’s initial purpose was to import a complete range of products for material handling: hand pallet trucks, scissors, stackers, platforms etc. The history of Levante as producer began in 2002, with the super-compact forklift FLY project, created, thanks to the project manager teams’ several years of experience in the warehouse truck sector. Almost simutaneously, Levante created Bingo and Clever: two small multifunctional mini-lifters. In 2009 the company Levante became part of the PBM Group, one of the largest battery charger producers in Europe. After twelve years from its opening, today Levante has an excellent positioning in the domestic Italian FLY 06-08 market, partially due to its doorL2 mm 1.290 to-door sales network, but also Ast mm 2.745 to partnerships created with important brands, such as for example BTCesab. Since 2006 the company offers a custom made orange-colored version of the super-compact forklift FLY06/08 to its dealer network. As to the rest of the Europe the brand name Levante has yet to be widely recognized by its market operators, however the market
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FLY 10-12 L2 mm 1.410 Ast mm 2.865
The super-compact forklift FLY FLY is a three-wheel super-compact 24V forklift truck, with a turning capacity possible in the same space as a reach truck. Since 2003 the FLY range has had four main models, with espective capacities of 0.6, 0.8, 1.0 and 1.2 tons: FLY06, FLY08, FLY10 and FLY12. Both FLY06 and FLY08 models have the same super-compact chassis, of only 1290 mm length and 845 mm width. With an AST of only 2745 mm (forking a euro pallet from the shortest side, including 200 mm of safety margins), this model can be used in narrow aisles, in some cases replacing a reach truck for specific uses, with maximum lifting heights of 5400 mm. FLY10 and FLY12 can still be considered as narrow aisle trucks thanks to the reduced length of 1.410 mm, granting an AST of only 2865 mm, which is from 150 to 200 mm less than the majority of 1.0/1.2 models produced by main brands. Recently, Levante added two new 24V models to its typical super-compact FLY range: the standard chassis FLY M (L2 1570 mm, AST 3025 mm) with capacity of 1,2 tons, suitable for standard uses, plus the FLY06L and FLY08L models, created for lighter uses (with a reduced power traction and lifting motors) but still operational in narrow spaces (L2 1290 mm, AST 2745mm). All trucks in the FLY range have AC power on their traction and all are produced in Levante premises, using only Italian and European components supplies. The traction controller is Zapi, but on demand all models can be equipped with a Curtis one. Masts are produced by Lift-Tek Elecar, the electric power steering is supplied by Elektrosistem, while distributors come from Salami. FLY is extremely straight forward to service, this is also thanks to a specific “plate” where all electronic components are assembled. Simply by loosening specific screws the movement of the plate onto the top of the battery is possible and from this position, is easily serviceable.
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COUNTERBALANCED LIFTTRUCKS
Levante FLY detail
Even with its super-compact size, FLY is comfortable for operators of all sizes, taking into consideration even the largest of foot measurements. Electric power steering grants extra space for operators’ legs, while the roof always allows a clear view of the loading area when the mast is lifted. The reverse current braking system enables easy mobility on ramps, with a maximum climbing ability of 15/20% (FLY06, with/without max. load).
Not only forklift trucks… Standard masts reach 5400mm as a maximum lifting height. Extra heights are available as “special” for some models .
On customer demand, the driving direction can be chosen using the double pedal or the manual inverter. Standard mast heights reach 5400mm (3 stages with full free lift) but, again, on emand, six meters are instead possible for many of the models. All models of FLY have the variable base-tilting mast; masts are interchangeable with all models, keeping the 800mm integrated side-shifter as a standard. There are several typical fields of usage for FLY: in general it is wherever there is a need to operate in narrow spaces or in situations where the customer would use the same machine to get both into the warehouse (with shelves placed at a distance of 3 meters or less) and also downloada lorry. According to Levante’s statistics, here are a few examples of its fields of usage: medical and chemical productions and warehouses, greenhouses, mechanical parts production, food and beverage warehouses, forwarding agents, hardware Production areas, hardware stores, confectionery production, carpenters’ stores, clothing stores, bank warehouses, electronic arts production and stores etc.
STAPLERWORLD EUROPE 01-02/2012
FLY is easy to service: the compartment plate with all electronic components is easily moved onto the battery.
Bingo was born in 1996. In 2002 the minilifter got today’s new shaped chassis and name New Bingo. With a capacity of 100 or 200 kg and many different devices applicable on the light aluminum mast, New Bingo can be a solution for several different uses. The standard models with lifting heights of up to 1.500 or 2.000 mm, can also be supplied in a stainless steel version. The mini-lifter Clever was born to speed up work for the air conditioning and/or electric lines installers. It features 120 kg lifting capacity and a lifting height of 2.900 mm. Clever can be easily moved horizontally and loaded on a vehicle, thanks to its lifting system made by a built in actuator with endless screw. Both mini-lifters New Bingo and Clever includes maintenance free acid lead batteries and on board chargers.
Further Information: Levante srl Via dell‘economia, 10 46035 Ostiglia Mantova Tel. +39 0386.801814 www.levantelift.com
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COUNTERBALANCED LIFTTRUCKS
Offshore-Forklift masters Extreme Conditions A natural gas drilling platform north of the Russian Pacific island of Sachalin would not be top of most people’s list for an extended stay. This not overly inviting location has average yearly temperatures of around 0 °C, which can plummet to -50 °C in winter. In spite of this the region is booming, as there are around 700 million tonnes of crude oil and 2,500 billion m³ of natural gas deposits buried beneath this coastal region which covers an area of 20,000 km². Extraction of natural gas in particular is expanding, which is then liquefied on site to make transportation in this compressed form more manageable.
The “Offshore package” ensures that forklifts working in these extremely corrosive surroundings can withstand long term exposure to the elements without risk of down-time. All coated components, for example, benefit from salt water resistant double pack paint applied to a specified depth. The pistons in all the hydraulic cylinders undergo chemical nickel and chromium plating and components such as hydraulic valves, hand brake and other operating controls are protected from spray water by special seals. The coatings applied to all connecting elements also prevent any occurrence of corrosion.
The harsh conditions on drilling platforms pose challenges not only for the workforce but also for the equipment needed such as forklift trucks. As well as the extreme cold, exposure to sea water causes rapid corrosion and the concentration of energy in the extracted gas is potentially explosive. All the components of any forklift used in this environment must therefore be fully compliant with ex-protection directives.
Powered by a high performance ex-protected encased 80V-ASM AC drive, the explosion proof features of the offshore forklifts are equally rigorous: the construction of all electrical and mechanical components rules out any risk of ignition in the potentially explosive atmosphere and the machine as a whole is fully compliant with the ATEX directives (Zone 1/Gas-Ex) which apply in the offshore industry.
Sichelschmidt GmbH has extensive experience in the design and manufacture of forklift trucks for these demanding applications: the company delivered its first machine to the offshore sector in 1981 and has enjoyed a reputation with major operators and suppliers of drilling rigs for its sturdy long life products.
Battery charging is a particularly challenging procedure on drilling platforms, as unlike in other industries there are no non-ex-zones where this can safely be carried out. Sichelschmidt has de-
The first truck for the Sachalin extraction area was put into operation two years ago, and a second has now been delivered. The design of this four wheel truck with a capacity of 1,600 kg is based on the very popular M700-4 EEX model which is widely used in the chemical sector, but has been tailored to meet the very specific requirements of offshore operation.
Images: Sichelschmidt AG
Further Information: www.sichelschmidt.de
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The offshore forklift was thoroughly tested and approved by the rig equipment supplier at Sichelschmidt’s facility in Wetter/ Ruhr and has now completed the 12,500 km journey to its new home in the north west of Russia.
Well protected against the cold, corrosion and risk of explosion: Sichelschmidt offshore forklifts
l p a t s . ww www.staplerworld.com
veloped a charging box which protects the connector between the battery and the charging unit from the surrounding environment. If the box is opened during charging the process is immediately interrupted, allowing safe battery charging in areas where the risk of explosion is present. The truck is also designed to withstand the extreme climate as the cab and choice of lubricants are based on the specifications of the cold store model.
www.staplerworld.com
STAPLERWORLD EUROPE 01-02/2012
COUNTERBALANCED LIFTTRUCKS
Hard Work in German Foundry – tough Job for Special Forklift
The Swiss Georg Fischer Group owns since 1995 a company of the former combine Gisag based in Leipzig. This facility employs some 270 employees and manufactures commercial vehicle axle housing, frames for tractors and parts for robots and wind turbines – foundry output estimates some 4,000 t / month. The melting process is in need of heavy forklifts. So an extremely reliable, versatile high-performance cb-truck for handling of molten metal was needed. The German sales force specified a DCE 160-1200. The device was designed for 14.500 kg Loading capacity at 750 mm LC. Equipped with a rotary device the forklifts moves 7.5-ton converters, which holds an additional 6.5 t melt. The melting process follows a fixed sequence:
„Lifttrucks in foundries,“ explains sales specialist Frank Ende „are subject to the toughest loads, temperature, vibration, air quality and the enormous threat posed by the up to 1,500° C hot cargo.” Kalmar designed a matched lift truck. Most important is an optional Dafo fire extinguishing system, which clears the engine compartment and cabin with an emulsion. A manually releasable brake permits the quick removal if necessary, though the truck can be towed out of the danger zone. In addition, counterweight mounted hyd-
raulic controls offer the option to operate basic hydraulic functions when the driver is not present in the cabin. Makrolon and Lexan additional front windows for the protection against metal splashes are a novelty. Hydraulic hoses on the mast had to be changed into fireproof ones. Additional headlights enhance the drivers sight and an audible reverse signal keeps pedestrians out of the way if truck backs up. The reinforced fork carriage picks up a Stabau rotary device, which enables to rotate the converter endlessly. Approximately 4,000 hours is the annual working time of the lifttruck/attachmentcombination. Therefore the service intervals were compressed to 400 h. About four years of real hard working life are to be expected for the Kalmar DCE 160-1200, according to Thomas Sickert, Director of smelter, then it will be pushed aside and work as a standby machine. Pictures: STW
Further Information: www.kalmarind.com www.cargotec.com
Special levers mounted on the counterweight help to get the machine out of dangerous situations manually.
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COUNTERBALANCED LIFTTRUCKS
The Green Way – Clark is heavily working on a solid base in Europe Three Korean manufacturers try to catch the attention of European customers – Clark is by far the most historic name – Rolf Eiten is in charge of sales and marketing and STAPLERWORLD spoke with him about several new developments – the new warehouse range and how to cover one of the most complicated markets in the world – Europe
Lateral battery exchange once common for the “big four” now Clark is ready to tackle the challenge. What is the annual production figure of Clark (CB-trucks), how many trucks are being exported to Europe? R. E.: Clark Europe has increased number of orders in 2011 by 34% vs. last year. What are the key markets for CLARKCB-Trucks’ in Europe? R. E.: Clark Europe is represented in Europe, Africa and Middle East. We serve these markets through our growing dealer network. Of course, there are some stronger key markets like Germany, France or the UK but every market in Europe is important to us. Especially Eastern Europe is a fast growing market and we focus on new partners in these regions. We found some very good dealers and expand our sales and marketing activities in Eastern Europe. Additionally, the Scandinavian countries become more important to us. We have found new partners in Finland and Denmark and our expectations were met in the first months. One of our main goals for 2012 is to achieve higher market coverage in our main markets. Furthermore we have been aiming to develop a dealer network for the Russian Federation as well and it started to pay off already.
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How weak is the market outside Germany, Benelux and France? R. E.: Germany, Benelux and France account for approx. 46% of the whole European market. So we can see that these markets are extremely important for the truck and warehouse business. Especially through the crisis in southern Europe (e.g. Greece, Portugal or Italy), these markets are even more important than ever. Nevertheless, we observe some emerging markets (in particular) in Eastern Europe that offer great potential. How important is UK for Clark? R. E.: UK is a good market for Clark. We continue to improve our network but still about 15% of the market potential in the UK is not covered by us yet. We will give priority to it in 2012. Clark wanted to attempt the Scandinavian market two years ago, how are these things progressing? R. E.: The development is quite good. We found new dealers in Denmark and in Finland. For 2012 we have Norway and Sweden on a priority list.
Eastern countries are facing a rapid growing market; the major international players are on eyelevel with smaller companies, how does Clark cope with that? R. E.: Eastern Europe is an important market for us. Especially of course also because the proportion of RCB trucks is much higher than in Western Europe. A real growth factor for Clark will be te further development of our network in the Russian Federation. How important is the Italian warehouse technology for the European dealer network? R. E.: In order to offer a whole range of trucks and warehouse equipment (full liner) it is important to us, but as you may now, Clark is entering the warehouse equipment market with its new generation of product which are engineered and produced by Clark. Launch of new products will be done in summer 2012.
Hand pallet truck made in Korea – warehouse equipment is one of the future sources for revenue.
COUNTERBALANCED LIFTTRUCKS
When can we expect the first warehouse trucks made in Korea or China by Clark and will it substitute all Italian products at once? R. E.: As I said, launch of new products will be released in summer 2012. Of course, we will focus to sell the new products with priority but as it is not the full range of warehousing products yet we will need complementary products from a 3rd party supplier for quite some time. Are all European dealers connected to the central warehouse in Mülheim? R. E.: Most of the European dealers are getting their new forklifts from the central warehouse in Mülheim. Just some larger sized dealers are getting their products as a full container load consignment directly from the factories as all of the African and Middle East dealers are doing. All of the administrative workload is handled by our European HQ in Mülheim. Furthermore all of our dealers are getting their spare parts from our central warehouse in Mülheim. Our feeling is that Clark at the very moment is a counterbalanced-truckcompany with little emphasis on warehouse equipment, is that true, how important will the warehouse part become in the near future R. E.: Of course, we sell more RCB trucks than warehouse equipment. But the warehousing market it is a very important market for us and will play an important role in the future. The warehousing market is by far bigger than the RCB market and also appeared to be even more stable during crisis periods. For that reason Clark is investing into the development of its own range of warehousing products. What new products are reaching the market in 2012? R. E.: As mentioned before Clark will present a new pedestrian stacker and a new pallet truck next year. The PX20 pallet truck and the SX 12/16 electric stacker with load capacities of 1.2 and 1.6 tonnes and a maximum lifting height of 5.2 meters was developed by Clark’s global development team. “Stringent safety requirements, practical performance and unrestricted user-friendliness – the factors which the market has so far primarily as-
STAPLERWORLD EUROPE 01-02/2012
Towing tractors CTX40/ CTX70 are becoming increasingly popular not only in the automtiove industry – its more efficient for transporting goods over long distances. superlastic rubber tyres. This 80V fourwheel forklift with its 4, 4.5 and 5 tonne load capacities represents a significant complement to the successful GEX range (1.6 - 3 tonnes). The conceptual design of the GEX, which features two drive motors, 100 percent AC technology and maintenance-free oil-immersed disk brakes, is identical to Clark’s industry-proven three- and four-wheel models in the 48 and 80 Volt segment. This already guarantees excellent performance, optimal manoeuvrability and safe load handling. Images: Clark
sociated with counterbalanced forklifts from Clark. With the PX20 pallet truck and the SX 12/16 electric pedestrian stacker, we are now setting new standards in the field of warehouse technology”. This confidence is based, among other things, on the use of proven concepts and components, which have already proven their worth when tested in other Clark vehicles. Furthermore we will launch the new 80 V GEX40-50 with up to 5000 kg nominal load capacity at 500 mm load centre. It will be available from summer 2012. Already now we have quite a number of customers in the loop who are desperately waiting for it. This truck will add a lot of additional business opportunities for us. Especially those customers who are taking focus to the so called “one stop shopping attitude” are affected.
Further Information: www.clarkmheu.com
Pedestrian stacker X16 developed with German engineering capacities – these products are going to affect the cooperation with OMG in the future.
Not to forget the Clark towing tractors CTX40/ CTX70 which were launched in 2011 already and are taking up speed in sales now. Bigger size fleet customers show a lot of interest already and with the new factory installed full cabin option which will become available early 2012 these products will get another push. Additionally, Clark is entering a new load class for its electric-powered equipment with the GEX 40-50 with pneumatic or
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COUNTERBALANCED LIFTTRUCKS
Heavy forklifts doing their bit for wind power
Hyundai‘s heaviest forklift, the 250D-7E with 25 t load capacity, on its first job at CSC in Germany.
Cuxhaven Steel Construction GmbH backs Hyundai fleet – Heaviest Hyundai forklift on its first job
Germany’s first commercial offshore wind farm is currently being built in the North Sea 90 km northwest of Borkum. Here, 80 wind turbines are being erected where the North Sea is 40 m deep. They are to supply electricity for some 400,000 homes. For this project, CSC Cuxhaven Steel Construction GmbH in Cuxhaven, part of Bremen-based Bard Holding GmbH, is manufacturing the support structures, so-called tripiles, weighing 450 t. A tripile is the transition piece between the three piles sunk into the seabed and the base of the 150-m wind turbine. For transport work on the company’s premises, the firm is deploying forklift trucks from Hyundai, including the heaviest machine with 25 t load capacity.
these high-load transporters would be overdimensioned. Instead, they can be moved better and faster using forklifts, reports Dirk Rowold, head of logistics. It was at the CeMAT tradefair in May 2011 that the contact came about with Hyundai and its dealer Isfort Staplertechnik in Heek. Since then, Isfort has delivered four forklifts to the steel builder: one diesel forklift 250D-7E with 25 t load capacity, a diesel forklift 160D-7E, a further diesel forklift 30D-7E with 3 t load capacity and a battery forklift 50E-7E with 5 t load capacity. The 250D is the heaviest forklift in Hyundai’s range. It was only introduced at the 2011 CeMAT. At CSC, it is on its first mission in Germany.
“The diesel forklifts work on the plant grounds measuring 250,000 sqm and often have to travel long distances,” reports Rowold. So it is an advantage, he says, that the two forklifts in particular have speed on their side. Unloaded, they easily top 30 km/h. Loaded, the 250D can tackle gradients of 34% without any problems. The vibration damper in the lifting gear ensures quiet handling behaviour also under load. Modern Cummins engines, ZF drives and Kessler axles add up to a source of optimal power delivery and high performance under any deployment conditions. The driver has a switch to select two operating modes: in the STP mode, the forklifts save
CSC can build the steel giants, regardless of weather conditions, in a self-supporting, nearly 50-m-high hall with a surface of some 17,000 sqm. The company has direct access to the heavy-duty loading quay with adjacent harbour. The foundation units are loaded using the firm’s own gantry crane, which is able to lift 500 t. CSC has a headcount of 300 in Cuxhaven and processes some 40,000 t of steel a year. When such steel structures are so huge, many of the components are not exactly small either. For the very biggest parts, three Goldhofer heavy-duty vehicles are available. However, many smaller parts, too, have to be transported, and for them
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Cooperation all partners are considered to be happy: (l-r) Richard Isfort, owner of Isfort Staplertechnik, Dirk Rowold, head of logistics at CSC, Jens Brücker, sales rep at Isfort Staplertechnik.
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fuel in lighter work, while full power is available in the power mode for heavy loads. The fully automatic drive switches smoothly between gears. Thanks to the tempomat, the selected speed, at the push of a button, is automatically maintained, which again has a fuel-saving effect. A test has shown that the Hyundai forklift consumes up to 20% less fuel than other comparable forklifts.
In the judgement of drivers Nico Keil and Daniel Costa Rivers, too, the two heavy forklifts are given good grades throughout. Keil points to their simple operability and comfort. “They are also pleasantly quiet and, thanks to the particle filter, you don’t smell exhaust fumes anymore.” Costa Rivers adds: “The forklifts are state of the art, with loads shown on the display, for instance – and in the comfort for the driver with driver’s seat heating and ergonomic back rest with lumbar support.” The thrifty engine and the large tank also permit long refilling and work intervals without interruptions.
At CSC, they are unconditionally happy with the new machines. “The value for money and the quick delivery of the forklifts as well as the overall fruitful collaboration with the dealer Isfort have proved our decision was the right one,” is how head of logistics Rowold sums up his experience so far. Manfred Klein Images: Hyundai
Further Information: www.hyundai.eu
www. staplerworld .com
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The head of logistics underscores in particular the merits of the quick-mounting device for the fork using the Terminal West system. In this system, changing, narrowing or widening the forks involves loosening only one bolt on each side. Rowold: “This enables the fastest individual adjustment to the specific parts to be transported.”
Since the heavy forklifts – shown here is the 160D-7E with 16 t load capacity – often have to travel long distances on plant grounds measuring 250,000 sqm, it’s an advantage if they go about at a nippy 30 km/h.
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The new 250D-7 has, as standard, integrated scales at the lifting forks. With high precision – max deviation: below one percent! – they show the weight of the current load and sound an alarm when the maximum permissible load is exceeded. A rear-view camera, too, is standard in the heavy forklift, as is air conditioning.
www.staplerworld.com
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COUNTERBALANCED LIFTTRUCKS
New Paper Roll clamps The Paper Handling Pioneer Bolzoni Auramo is well known for its expertise in paper handling equipment, and the company holds the market leader´s position in sales of paper handling tools in Europe. There is a special program for the paper industry to develop roll and bale handling into an efficient yet damage free operation. To come up with the best solutions, the manufacturer (parent company of Meyer Salzgitter) is closely co-operating with the paper industry worldwide in order to find innovative solutions for the forest products handling. Roll Care System for paper roll handling “Damage free handling has always been our goal when developing new paper roll clamps” – says Lars Petersson, Forest Products Handling Division Manager. “We have implemented an internal education program to give our sales force all around the world very high competence in paper handling. This action allows us to help and advice our customers in a professional way. How to select the right clamp for dedicated handling? What’s the correct clamping force? What kind of contact pad is most suitable? These are the questions daily given to our sales force. We have the answers!”
To reduce risks for paper damage in the logistic chain, the Italian manufacturer offers a variety of optional damage-reduction and quality control tools. We also support our customers in using the tools and analysing the performance of the handling chain. With this information we can advise our customers in choice of clamp attachments and settings of clamping force. To further support our customers, we provide the widest program of clamp attachments for paper handling – this secures that the right clamp is always available. On the offer is a “Driver Training Program”. Aim of this program is to educate and inform how to reduce damage when handling paper rolls. Excessive clamping force is one of the most common causes of paper roll out-of-roundness damage. The varying paper grades roll weight and diameter plus the high value of the rolls themselves are all factors requiring an extensive control of clamping force on behalf of the operator.
Options: CTX, well proven, fully automatic computerized pressure control system for paper roll clamps.
Cascade presents the new paper roll clamps H series with a slim profile and a capacity of 2.2 and 2.4 tonnes. The new paper roll clamps 22H and 24H were designed with swivel arm for factories with high production volumes, storage, printing, newspaper publishing companies, processing companies and kraft paper, newsprint and coated paper. With its optimized arm design the model 22H is lighter yet stronger than the Model 45F, which it replaces. „This paper roll clamp has the industry‘s best strength to weight ratio, resulting in a first-class life,“ Brad Vandehey, product manager at Cascade. The Model 24H with a higher capacity enables the transport of heavier loads by maximizing the capacity forklift thanks to superior specifications. Excellent visibility speeds up transport.
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Forcematic, fully mechanical pressure control system to be applied to paper roll clamps in order to prevent overclamping causing roll out-of-roundness. During the PPI exhibition in Amsterdam we will show our knowledge as above, together with some of our most famous products inside Paper & Pulp handling. Image: Auramo
Further Information: www.bolzoni-auramo.com
The streamlined, thin arm profile, smooth contoured panels allow easy access between the rollers and cause a reduction of part damage during retraction. With a unified design on the arms and the frame in addition to structural integrity and outstanding durability is achieved, you may know of a clip from the house and expect Cascade. Image: STW
Further Information: www.cascorp.com
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Attachments accompany the Paper Logistics Top issue is damage limitation to paper rolls whatever the specification may be. Therefore Hans H. Meyer offers training for safe and efficient paper handling. The manufacturer offers special seminars for paper roll handling and provides safety and regulation guidelines. The new generation G 360° paper roll and tissue clamps combined with the optional intelligent pressure system‘Force Matic’ – feature damage reduction and further roll care features. There is also a wide choice of contact pad facings to choose from. The new features improve the handling of paper rolls and avoid damage with even more reliability. 360° continuous rotation drive are also features of the new generation. Paper and tissue roll clamps from Meyer have established themselves on the market with their reliability and robustness. The clamp achieves these characteristics through the own developed modules and high engineering standards.
This includes the powerful 360° rotator which has a two-component-direct-drive with hardened worm and halved worm gear made of bronze which gives a very robust mechanism and, a positive five teeth connection at all times. This increases the life cycle and the maintenance requirements decrease. In addition, the direct drive permits accurate and safe positioning of the roll – a decisive advantage for damage free paper handling plus the rotator incorporates both a hydraulic and mechanical locking mechanisms to positively secure the clamp at any degree of rotation. The slim arm construction of the “Generation G” is designed with a long and short arm configuration to handle paper rolls in the horizontal or vertical condition, has rounded edges to reduce damage and ensures the best grip, even with tight stacking. Truck drivers benefit from the slim
Rotating Roll Clamp combined with 24-t-lift truck Rotation 360° continuous, Torque 25.000 Nm at 125 bar differential pressure. Opening range suitable for rolls with diameters from 1.000 - 3.000 mm Each arm with 4 articulating contact pads Height of each contact pad: 300 mm Width of each contact pad: 900 mm Edges of all contact pads rounded. Contact pad surface: screw-on polyurethane coating, 10 mm thick Contact pads kept in position by non protruding torsion wire springs Contact pad protected by eye shaped pad protectors Clamp standard equipped with pressure relief valve and manometer gauge Clamp body protected by U-profile which are also supporting feet Short arm with wear and tear protection bars. Capacity: 6.000 kg at 1.500 mm l.c. Lost load 480 mm, Centre of gravity at 630 mm Weight: 5.280 kg No. of hydraulic functions required: 2 (clamping/rotation) Mounting: pin type in order to fit TCM FLT with nominal capacity of 24.000 kg at 600 mm
Further Information: www.kaup.de
line build, giving good visibility above the clamp chassis. In addition, the truck can achieve a higher residual capacity. The product range offers multi-arm-clamps for picking up several rolls. Apart from the classic 360° rotating paper roll clamps this manufacturer offers a complete product portfolio for the transport of rolls from manufacture to end user. Meyer engineers have in particular extended the accessory programme. For instance, the danger of transport damage is eliminated with the Force Matic. The unit automatically recognises the optimum clamping pressure by a mechanically controlled valve which does not need elaborate electronics. Without this control, the risk increases for the rolls to telescope at too low a pressure or, be squashed or damaged on the surface with too high a pressure. The wide choice of pad facings – e.g. chequered cast pads, polyurethane, diamond shaped rubber or smooth rubber allows optimum matching of each attachment to paper quality and application conditions. The wide choice of accessories comprises of mast-tilting sensors, roll protectors or other pressure pre-selection devices with pressure gauge. Images: Hans H. Meyer Further Information: www.meyer-world.com
Image: Kaup
Paper Roll clamps with variable short arm PRK 45 TB is a paper Roll Clamp 360 °with split arm. It´s suitable for forklifts in the 4.5-t-class (ISO III fork carriage). Load capacity is 3.500 kg at 650 mm load centre. Roll diameter is 250 to 1.300 mm. Weight is 950 kg. Most powerful product in this range is PRK 80-TS for roll diameters 700 to 2.050 mm and load capacity of 3.300 kg. Images: Durwen Further Information: www.durwen.de
WAREHOUSE EQUIPMENT
What does the forklift truck of the future look like? Despite continuing global warming, to which the industrial trucks sector hopes to contribute less and less in the future through new technologies, the full and half-cabins remain in strong demand worldwide, even for small equipment such as the three-wheel E forklift. The equipment of these cabins is what Fritzmeier, probably the largest and most important cabin manufacturer in Europe, has, once again, been looking at. A so called “Future Cabin”, more or less a prototype, displays a forklift cabin with several features that can be integrated into almost every newly designed forklift cabin – or with variations according to the customer’s wishes. The following features were contained in the displayed design study:
Fritzmeier Group Most important customer in the industrial truck segment is the American Nacco Group, according to STAPLERWORLD information. The Bavarian family company maintains eight production sites in Germany, France and Belgium to Austria, Romania and India. With the Cab Alliance network, in which four cabin manufacturers are united, Fritzmeier is a member of a worldwide research and production network. The network is currently represented in 11 countries.
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• Aluminium cabin doors with integrated window guide. Less covering offers the driver a better field of vision. There is also the reduced weight and even better and safer handling. The integration of functions ensures cost benefits in production. The slide windows are also electrically operated. • Mechanically operated shutter rear windows needs less installation space. Ventilation and rain protection maximise driver comfort. • Hydraulic four-point cabin suspension in collaboration with ZF-Sachs. The central component that determines the comfort of a driver’s cab are the installed vibration dampers. The steel spring module by ZF Sachs is already used in construction, distribution and special vehicles. It has now been used for the first time in Fritzmeier forklift truck cabins. The developers were able to integrate the dampers so that the critical cabin height was not exceeded. The extension of the suspension travel from 3 mm conventional rubber inserts to 50 mm ensures that the driver can focus on his task without worrying about his safety. • Sliding front window for the forklift truck cabin of the future – the front window disappears within the cabin under the roof liner in hot weather and is mechanically operated. The result: significantly less shocks as well as pitching and rolling motions and thereby less stress on the motion system and the driver’s spinal column. • Sliding front windscreen. Made famous by excavators. The front windscreen is spring operated upwards to close and it disappears inside the cabin under the roof on hot days without impairing the view skywards. • Easygrip door crossbar – this runs across the whole width of the door and is equipped with the slide switch for operating the window. • Plate glass door with integrated slide window. Imagers: STW Further Information: www.fritzmeier.com
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Important Developments for Electric Lifttrucks and Warehouse-Equipment The Hawker XFC range radically changes discharge/recharge operating procedures compared with conventional lead-acid batteries. The batteries can be used when in a partial state of charge and deliver superior and stable performance even at high discharge rates. The charging profile of the XFC technology allows a rapid recharge in less than four hours from 60 per cent depth of discharge and opportunity charging as often as needed without damaging the batteries. By comparison, conventional batteries only provide optimum performance when discharged to a specific level before being fully recharged for 8-12 hours which means extra batteries are required to support continuous operations or else equipment is unavailable. The new cells are designed to match the industry standards shape and size for materials handling equipment applications which means that original equipment manufacturers and operators have more choice and greater freedom to specify batteries that meet their performance requirements.They will fit DIN and BS-batteries. The 2V cells incorporate similar Thin Plate Pure Lead technology to the original XFC units but have even higher energy density coupled with the fast charge capability. The plates are much thinner than the leadantimony grids used in traditional motive power batteries which means they can hold up to 30 per cent more charge deliver up to 20 per cent more power. The positive and negative plates are low impedance which means high current flow is available in discharge and recharge modes to support demanding applications with rapid recharging. The electrolyte is absorbed in a superior quality microporous glass mat separator with high absorption and stability to provide consistent performance for up to 1200 cycles at 60 per cent depth of discharge. The battery is totally maintenance free and no water topping-up is necessary. Minimum gassing ensures the batteries are ideal for de-centralised charging applications in retail, public spaces and even in sensitive manufacturing environments. Batteries built with the XFC 2V cell boxes
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are highly resistant to shock and vibration. They are designed for a high energy throughput of up to 160 per cent of C5 every 24 hours.
Modular HF-Battery Charger features programmable Energy Effiency The new LifeSpeedIQ intelligent high-frequency modular battery charger from is designed to support flexibility and efficiency in the deployment and utilisation of a wide range of battery types. Modular design, fully-programmable performance and lower charging factor are key issues. Advanced communication and remote diagnostic facilities enable battery facilities to be configured for standalone or centralised management. The charger can be used with all batteries with corresponding charging profiles to support lift truck, materials handling equipment, automatic guided vehicle and other motive power applications. The charger allows fleet operators to take advantage of all of the energy-efficiency and battery-life benefits of high-frequency charging. Each charger is built using a number of identical power modules so that performance can be matched to the specific application requirement. The builtin controller manages the modules to operate at peak efficiency at all times. The The charger allows fleet operators to take advantage of all of the energy-efficiency and battery-life benefits of high-frequency charging.
The 2V cells incorporate similar Thin Plate Pure Lead technology to the original XFC units but have even higher energy density coupled with the fast charge capability.
modular design also supports continuous operations with simplified service and maintenance. Faulty modules are automatically bypassed and the charger operates at reduced power to ensure batteries are still charged. Replacement modules can be exchanged easily, and even hot-swapped, without disruption to ongoing charging tasks. The charger has a USB port as standard to allow download of charging history and upload of profiles and service updates. An LCD display provides a user-interface and delivers real time information on the charging process and events. Messages are provided in clear text and are visible from a wide viewing angle. Five different coloured backlights indicate separate states of charge or function. The charger will even interrupt the charge if excessive temperatures occur and charging will not commence if a defined percentage discharge is not reached. Simplicity and ease-of-use is further promoted through facilities such as an anti-arcing system that allows safe disconnection during the charge. Images: Enersys Further Information: www.enersys-hawker.com
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“Bend”.ing all over, are articulated trucks ready to hit Europe? As you all know, Great Britain is not only one of the most fascinating countries in Europe its also home of truly independent engineers who like to go their own ways and not really caring for the rest of the world. This also applies to forklifts - Bendi and Flexi are two brands that want to enter the reach truck market (roughly 24.000 units a year in Europe) Articulated trucks seem to feature a variety of technical advantages their usage is mostly spread to UK. This may change in the near future because Gary Griffin, former CEO of warehouse equipment manufacturer Loc (owned by Manitou) has founded IMH Europe to distribute the Bendi-Trucks all over Europe except their home country. Remember, the last time we exported our idea, it stuck in Europe, and around the world to this day:- the Man UP!
STAPLERWORLD MAGAZINE has taken the opportunity to speak to this innovative man to listen to his business plan? Gary, can you explain the so called twisted history of the two brands, Flexi now with Combilift from Ireland and Bendi, as far as we assume is still independent, how did all that happen? G.G.: Freddy Brown came up with the first Man-Up truck, a combined pallet placer and picker using a turret head, during the 1960’s and formed a company called Hi-
Space. The truck was called the “Spacemaster” and was then built by Toyota in Japan. Hi-Space, together with a racking company and a conveyor company came together to form the parent company Integrated Handling which, following a rapid success, was floated on the stock market. Feeling restricted by the constraints of the Public Limited Company, Freddy Brown left to form Narrow Aisle UK with a new man down product called the Rotareach. This company also prospered quickly, building Man up Machines firstly for Jungheinrich GB and then BT Rolatruc. After 10 years of rapid growth and the involvement of a venture capitalist, Brown decided to join Translift Engineering and went on to become a 50% shareholder in the Redditch based company the following year. Two to three years later in 1982, Freddy Brown became frustrated with the restrictive nature of the Turret Head VNA solution and developed the Articulated truck which ultimately became the Bendi. By 1990 he’d perfected and patented the solution. In 1992, Narrow Aisle built their front wheel drive version the Flexi. By 1999, Robert Moffet had started to build an IC engine version only of the articulated truck and for a while Aisle-Master as it was known was sold by Bendi in the UK until 2004 when Aisle-Master had ambitions to build electric trucks as well sell directly into the UK market. Please verify some figures regarding the actual program, are you focusing on LPG, IC- or electro-Bendis? G.G.: They tend to be kept inside the warehouse and 99 % of sales are electric, however Gas is available too. What do you think is their main advantage? G.G.: Many – compared to reach trucks they can save space and time whilst over VNA they can work in 1.800 mm aisles without guide rails or the need for VNA specification floors whilst being able to typically move 50% more pallets and more space saving in the transfer aisles. They can also go outside and load vehicles.
This is what the production looks like.
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Gary Griffinworked for several forklift manufacturers and now owns IMH in France to sell Bendi-trucks.
Why have so little users chosen those trucks to roam in their warehouse? G.G.: Its not been available - in the UK, articulated trucks are rapidly approaching a volume 40% of the reach trucks sold. Freddy Brown was correct in restricting the companies activities to the UK but over the last 5 years preparations have been made to increase production capacity and they now have a growing number of committed distributors, promoting the Bendi product globally. Bending a truck always minimizes the stability, how do you cope with that? G.G.: That was correct with one of the first ever articulated truck designs. Towmotor in the 1950’s built a machine that articulated at the front to 90 degrees either way with a steer axle at the back. To stop it tipping over, a wheel, on an arm was used on both stacking sides. Bendi changed the steering axle at the rear for fixed stub axles, increased the weight and moved the centre of gravity to the rear axle. Who is the typical customer, are you sure you can integrate those trucks
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into existing fleets of order pickers, CB-trucks and of course reach trucks? G.G.: Third party Logistics, manufacturing and anywhere with a warehouse. Yes they integrate perfectly with CB and order pickers, but why would you bother with reach trucks? How about the pricing compared to reach trucks? G.G.: Higher than a reach truck but much lower than a VNA How about the battery capacity, can they work more then one shift, how quick may Bendis change their battery? G.G.: Bendi trucks use the same technology as any counterbalanced truck or reach truck, they can carry from 630 to over 900-Ah-batteries and are extremely easy to change from the side Can you proof they reach the same performance-level than reach trucks? G.G.: No, they don’t go that slow! 35 to 40 pallet movements per hour is typical, similar to CB Selling is one thing, supporting a customers with management tools evaluation programs and of course service and spare parts is the most important part of the business, what are you aiming for?
The articultated construction differs widely from competing concepts, IMH claims 35 to 40 pallet movements/hour.
G.G.: That’s what I’m here for and why IMH was founded; replicate what has been done with regional partners like Goscor, Bendi Australia, Power Lift and so on. My experience and contacts on the European market will enable me to set up a dedicated network of professional dealers Which countries show particular interest? G.G.: Germany, France, Spain, Italy and the Benelux countries
Finally – quality is important aspect – British cars do not enjoy the best reputation, how comfortable do you feel with the products, its serviceability and the surrounding “soft factors” at the moment? G.G.: That was Britain of the 60,70 and 80’s. The UK is actually one of Europe’s biggest manufactures with the Mini, Range Rover, Nissan, Honda plants all boasting UK manufacture. Also Consider where most the F1 teams are based. As we know, you want a 0, 5 to 1,5 % share in the European reach truckmarket, how close do you have to knit your sales web? G.G.: This of course depends on regional potential & Dealer capacity to provide the right level of service, but knowing quite well the markets mentioned above around 50 dealers should do it. Oliver Bachmann, spoke to Gary Griffin. Further Information: IMH Tel. +33-613-148080 www.imh-europe.eu
The far majority of the Bendis is electrical powered.
STAPLERWORLD EUROPE 01-02/2012
A walk-behind-Bendi in typical warehouse application
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More Power and Strength from Batteries, how new Technologies will affect Material Handling STAPLERWORLD – Europe´s forklift magazine took the opportunity to talk to Dr. Kai Ruth, Product Management Motive Power Batteries from Exide. You offer a complete range of batteries to both OEMs and dealers – how would you describe your systems competency as far as conceptual phase, set-up and operations of state-of-the-art charging stations at end customers are concerned? Dr. K. R.: As a division of Exide Technologies, GNB Industrial Power can draw from more than 100 years of experience in energy storage. It is this heritage that differentiates us from others, giving us distinct insights into the
Dr. Kai Ruth, Product Management Motive Power Batteries from Exide poses with his “baby” – the Tensor-High Power Battery
specific logistical requirements of our customers worldwide. Our core competency in energy storage, the battery, provides a solid foundation to offer all necessary or desired features or services for efficient logistical operations. It is the customer’s choice whether he wants batteries only, batteries in conjunction with chargers or even a complete energy management solution including consultancy and service. GNB Industrial Power is a one-stop-shop; customers will be served from one strong energy expert. On paper, GNB is defined as a full liner. Why is it that the market primarily perceives GNB as a battery manufacturer? Dr. K. R.: Traditionally, our vertical manufacturing depth has been vast. It has been and still is key to maintain our core competency in house. Particularly when markets are in downward motion, such as the ever so present recession we have just passed, customers become very cautious and focus solely on items principally needed – batteries. Now that the market has recovered customers adjust their wish list. In order to run their operations more efficiently, they are willing to outsource parts of or even the complete power supply to energy experts. We are here to take on this challenge.
So far, the PzS battery has been fundamental as part of the Motive Power environment. Which new technologies, such as lithium-ion batteries, can we expect from you at what time? Dr. K. R.: Users run their logistics often in different ways and consequently require specific vehicle types as offered by the truck manufacturers. Electrically operated vehicles have different needs as far as energy storage is concerned. Counter balance trucks, for instance, demand heavy weight as defined through their functional performance – which is provided by lead-acid batteries. New technologies such as fuel cells or lithium-ion accumulators have been developed and tested for years. Which technology, however, is best suited for which application at what time is still under debate. It is a given that companies are keen to reduce their environmental burden while ensuring efficient and cost-effective processes are applied across the product lifecycle. GNB houses a global research & development center in Milton, Georgia, which translates market needs into advanced and innovative solutions for its customers worldwide. What is your reaction when customers’ interest shifts from owning batteries, chargers and charging rooms toward paying ampere hours instead? Dr. K. R.: Many customers have already chosen rental energy solutions over purchased goods. This includes the payment of ampere hours. GNB is constantly in touch with these customers to offer tailor-made solutions that satisfy their needs. How do you position GNB versus Enersys, Hoppecke, Benning, Fronius and many of the charger manufacturers? Dr. K. R.: Being part of Exide Technologies, GNB Industrial Power benefits from latest developments in the automotive industry. Our in-depth knowledge of globally required energy storage solutions for nearly any kind of application, coupled with a wide-spread service network defines GNB as a system provider that respects and meets customers’ needs.
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TENSOR - The innovative high power cell for Material Handling Even a well established battery system like lead-acid has to answer the challenges of modern times: The number of shipment services in intralogistics is constantly increasing and material handling trucks are equipped with powerful three-phase motors as well as energy-recovery systems. As a consequence, the demands on traction batteries with regard to performance and efficiency are rising constantly. Therefore GNB has developed the new high power cell TENSOR, which combines the usually opposed attributes power, efficiency and lifetime. This was possible due the combination of well proven technology with new materials and concepts. The characteristics of TENSOR cells from GNB are low internal resistance and significantly improved utilization of the active mass. In summary: Every single part of the cell/battery was optimized to decrease the internal losses and to increase the available energy. The advantages for the user of a material handling truck are obvious: More available energy extends the running time of the truck and less heat evolution ensures a higher lifetime of the battery. Moreover, compared to standard lead-acid systems, it is unproblematic to fast charge a TENSOR cell, which again increases the availability of the battery. In total a running time plus, higher lifetime and energy savings are the core benefits for the user. The innovative TENSOR cell from GNB is commercially available since A
Commonly, operators are concerned that batteries can be charged successfully only with chargers from the battery manufacturer. How do you see it? Dr. K. R.: The battery itself fundamentally assures flawless logistical operations of any company. The operator is keen to avoid any down times and will rely on the warranty documentation of the respective supplier, containing and defining the battery’s professional usage, including battery change and charging. Warranty claims may be void in case of misuse or using chargers or components other than described. It is in the operator’s interest to avoid these incidents. By the way, the battery manufacturer may very well recommend chargers other than those manufactured in house.
Add-ons and so called miracle additives are known to rejuvenate older batteries. Holding a doctoral degree in chemistry, how do you feel about these? Dr. K. R.: Given the respective operational environment, batteries can provide maximum energy as long as operators closely follow the operator manual and pay attention to the proper treatment, service and charging. Battery aging, of course, limits the maximum energy output that may be retrieved. It is known that these add-ons or additives may be applied only during sulphation which can be neglected when properly operated.
Further Information: www.exide.com
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The smoother the ground the better the forklift truck performance It is a fact: without an ultraflat floor it is difficult to operate in a warehouse. Like some of our roads Bumps and hollows are not unusual but the so-called created bumps occurred by processing industrial flooring, the process is always the result of liquid or pulpy masses and this results in an industrial floor, from an initially liquid mass concrete with different additions of hard material. All forklift trucks, high level, order pickers and reach trucks, are as efficient as the floor on which they operate on - the larger the bumps in the longitudinal direction and the deeper the driving tracks in the aisles are, the slower the truck drives, the worse the steering direction of the mast and the cabin will be and the less loading handlings will be executed per unit time – the total cost of ownership will rise. The concepts of floor grinding originated in Great Britain, which are traceable from the year 1991. At that time simple hydraulic grinding machines with diesel motors were sufficient, comparatively basic and was a correspondingly accurate hydraulic leveling operation. Hans Voet, General Manager of Alphaplan from Belgium, when meeting STAPLERWORLD: “At that time there were no problems, the forklift trucks were only reaching speeds of around 6 km/h , most had an extensive DC-driving engine and had a lift hight of about 8.000 mm. Meanwhile they drive at approx 14k m/h, now with the lift height of 17.000 mm and they have much quicker AC-driving engines. Hans Voet first started as a representative of the English inventors of the floor repair machines Kevin Dare. But soon he was disturbed by the low accuracy, the slow speed and the difficult reproduced results. When the patnership came to an end in 2003 Hans developed the Qplane, his first full-automatic leveling grinding machine for floor repairs. It deviates from other constructions. It achieves accuracies of about 0,5 mm, unlike the competitor who brings it a maximum of about 2 mm.
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The Flemish (the northern part of Belgium) machine is clearly faster, it grinds up to 300 aisle meter/day and is thus eight times faster as the competitor, this being important data for the performance, because the majority of the renovation and grinding work is carried out in existing and operating plants.
Because speed is an advantage Voet has confidence, in contrast to other market participants, in that according to him very accurate and comprehensive VDMA-guideline for industrial floors in very narrow aisles warehouses. To this he was not able to participate, but he welcomes the specified tolerances and measurement methods. Further important guidelines for the floor repairs are the DIN 15 185
Further Information: www.alphaplan.com
STAPLERWORLD EUROPE 01-02/2012
WAREHOUSE EQUIPMENT
strips. Usual, however, is a decoupling of the base plate of the bearing building components through joint space, as the road construction is a concrete plate on a continuous supporting layer. In this case the measurement, reinforcement and monitoring are carried out to other principles, f.e. by regulations or fact sheets of the road building. Alphaplan is instructed by different sides. First there are the industrial floor manufacturers, who let the bumps remove by Alphaplan before handing over to the company. Also forklift suppliers, building companies, corporations do let grinding. Meanwhile 60% of the Flemish transactions are new warehouses. After analysis of a in-house made measuring robot, the FloorProfiler, who can measure fully-automatic approx 700 aisle meters/day, the data are transferred to the in-house made FloorShaver and Qplane. The FloorShaver is patented several times and levels itself without sensors, lasers, GPS or other systems and works full-automatic without a driver – in comparison this is a huge difference to the English machines, who are each operated by a driver.
Teil 1 and the new DIN EN 15620 (control of racks). The commercial recommendation TR 34 is quite usable but not quite useful. European companies generally rely on the rules that have been as influential for some time on the national legislation in other European countries in Europe and beyond. All important forklift suppliers recommend the VDMA Guideline. This mix’s the height difference between left and right track in the aisle as the waves in longitudinal direction.
Floor repairs: why, how and who does this ? An industrial floor is very complex. We quote from the leaflet T 1 1.2006 of the concrete leaflet civil engineering. This states: non-reinforced concrete slab with scheduled joint classification, joint less large-scale concrete slabs with continuous reinforcement and planned maximum crack width
STAPLERWORLD EUROPE 01-02/2012
From both construction variances it becomes clear that a simultaneously joint less construction and without cracks is technically not possible. For this reason it is recommended to coordinate it with the building constructor and the terms of use regarding the joints and crack problems. If sawn joints should be avoided by a joint less construction, a maximum arithmetical crack width should be determined that not only meets the requirements for the durability, but also of the use. In special cases large-scale concrete slabs can be applied at an early stage by a preload (centered crosswise without composite) simultaneously with relatively low reinforcement content, when the territorial conditions allow a lateral press of the span. Industrial floors of concrete should be measured, reinforced and monitored according to DIN 1045-1, if they in the sense of the norm have a supporting or reinforcing function, f.e. concrete floors of horizontal reinforcement in the hall or concrete
A big advance of grinding floors: die accuracy by grinding is guaranteed for 30 years, the guarantee for repairing industrial floors is 10 years, therefore it is clear who will let the new floor be ground before putting the new warehouse into service. When we take the costs into account. In Europe one has to pay around 30 euro/m² for a normal industrial concrete floor. The grinding costs range between 220 till 250 Euro per aisle meter or about 120 till 150 Euro when grinding into two wheel tracks (left and right) – what is about 22 euro/m². These are some costs: around 66 % on top of the ground-cost price. But the amortization is about 3 till 12 months, because the forklift truck continues driving now with the performance, which is stated by the manufacturer in its datasheet. This results in a higher performance and leads to lower personnel-, energy- and maintenance costs. Also in the existing warehouses the FloorShaver offers the possibility for grinding, as it works full-automatic and electronic: no noise, no harmful fumes, no oil spills, dust- and slurry free. Image: Alphaplan
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WAREHOUSE EQUIPMENT
Warehouse Equipment-Range rounded up suffienctly The Masate-factory of Nacco recently introduced a couple of new products that show the ongoing dedication to the internal logistic markets. Yale Europe Materials Handling’s launches new completely re-designed ergonomic low level order picker to increase productivity and lower cost of operation. The new MO20 low level order picker has been developed to optimise the speed and ease of picking when retrieving goods from both sides of a warehouse aisle. Designed to assist the operator in achieving increased pick rates the MO series, offers a large reduced height comfortable work platform. This allows easier pass through with easy ‘on and off’ access which helps to minimise operator movement and saves valuable time whilst picking. The easy to operate scooter control feature provides finger tip control when on the platform. In addition, a creep speed function allows the operator to move the pallet truck to the next pick location without having to access the truck. A key design element is the proximity of the operator to the goods.
What’s inside: • A 2,6kW motor delivers high performance acceleration and travel speed which provides maximum productivity over the full shift period and for horizontal transport activities such as cross-docking and load shuttling. Performance can be set by the service technician to suit the application needs. • Regenerative braking and anti-roll back on slopes are standard on the series and can be set by the service technician to suit the application needs.
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In addition to that a new towing tractor MO50T for long distance travel has been added to the program.
In addition to that a new towing tractor for long distance travel has been added to the program. The new MO50T tractor has been developed to optimise operations in industries where in line feed or milk run operations are prevalent.
The MO series includes a range of models with various fork lengths to cater for various pick requirements including ground level picking to pallet or roll cages and frequent second level picking. Planned for introduction in 2012 are the launches of models with a scissor lift function, raising operator platform up to 1.500mm, and independent fork lift function. The Mo 20 order picker is powered by a 2,6kW motor which delivers high performance acceleration and travel speed which provides maximum productivity over the full shift period.
It features a large reduced height and comfortable work platform, this allows easier pass through with easy ‘on and off’ access helping minimise operator movement and saving valuable time. The easy scooter control feature provides optimum speed control when the operator is on the platform. In addition, an ISO 3691 compliant coasting function (also known as creep speed) allows the operator to move the tow tractor to the next location without having to access the truck. The MO50T includes an universal flange suitable for many types of hooks and tow pins. Further Information: www.yale-forklifts.eu
Images: Yale
STAPLERWORLD EUROPE 01-02/2012
PEDESTRIAN CONTROLLED TRUCKS
Stainless Steel Pedestrial Stackers Stöcklin has been working for many years in stainless steel. According to division manager Bruno Haller, this is due to the following circumstances: „Until recently Stöcklin had been the biggest manufacturer of cylindrical stainless steel containers for fruit preparations and sauces throughout Europe. The acquired know-how in designing and processing alloyed steels is applied today in the production of ‚INOX industrial trucks‘, so that virtually all Stöcklin stacker types
may be made also of stainless steel (V2A) maintaining the identical shape.“ It all began with the drawbar low lift truck EDP, of which currently even small series for stock were produced. Contrary to some competitors the Swiss provider builds the lifting mechanism and roller forks, usually exposed to moisture, in stainless steel and not only in galvanized steel. The employed drive and control components are identical to the standard trucks. Soon, the market demanded additional stainless models, partly including the initial lift feature. No problem for the Stöcklin modular system, except the lifting frame. All estimates showed that the production of a still reduced number of masts will not pay off, and it would be the best to consult a provider specialized in lifting frames.
The German provider Winkel offers a very broad range of lifting frames, which are manufactured together with the load carrier according to the desired type of fastening. Only one drop of bitterness: Even for small lifting heights a third-party mast makes up more than 50% of the production costs and for a triple mast version this amount may raise up to 75%. Some of truck models like EDP, EDD, all of the EH types and EFP has already been manufactured or are ready for production. Most special truck types are also feasible in stainless steel, provided that the lower strength of the steel grades is taken into account. Consult us! We build your trucks according to your needs.
Further Information: www.stoecklin.com
TPE HL working at Milan Malpensa airport Italian manufacturer Armanni Carrelli Elevatori is in the business since 35 years. Now it has proved again as a competent supplier of special designed manually operated trucks. The TPE HL has been designed to handle loads up to 30 tons. Its part of the new “Heavy Line”. TPE HL is a forklift characterized by an extra-strong structure, equipped with 48 V motors, special lifting system and electronic and mechanical specific solutions, such as the sophisticated electro-hydraulic system for the servo-assisted driving and the calibrated cushioning system of the supporting wheels that can enable fast operations with minimal physical effort for the operator.
The project for development of TPE HL was founded by the request received from MLE, the logistics company operating in the cargo Milan Malpensa airport, for the supply of a small fleet of lifting trucks capable of handling containers from the flights operating at the airport and moving them from the square to the warehouse of the airport. They weigh about 10 tons and are positioned on special pallets of specific dimensions of 3.700 mm in length and 2.600 mm wide. In particular, the incoming containers from the cargo planes come to the pickup area on vehicles equipped with a top sliding roller trailer. By the TPE HL, the operator picks up an empty pallet from the ware-
house (equipped with a sliding roller platform) and reaches the area of collection. Here through the forklift truck, it lifts the pallet to a specific height by aligning it on the floor of the trailer. Now, with a simple manual push, the container is transferred through the roller planes from the trailer to the storing pallet and then is handled to the indoor warehouse. The same operation is performed in the opposite direction by transferring the containers, coming out and to be moved to the departing aircraft, from the storing pallets to the vehicles with trailers. Prior to the provision of the fleet of TPE HL, said containers handling was performed by hand trucks and required the simultaneous use of 4 operators. The solution developed by Armanni allows the use of a single human resource to perform the same operation resulting in a significant increase in operational efficiency and safety. Images: Armanni Further Information: www.armanni.com
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PEDESTRIAN CONTROLLED TRUCKS
Rocla AGVs increase efficiency and safety in a cheese factory “We were wondering, why should a good employee be doing this kind of boring work phase. We wanted to find a new solution to this,” explains Valio’s factory manager Heikki Makela. Makela contacted Rocla, who took upon this challenge. Rocla’s professionals examined the situation and the needs of a customer and came up with an optimal automation solution to replace the old way of working.
Valio, the biggest milk processor and market leader in dairy products in Finland, has chosen Rocla’s automated guided vehicles (AGV) for its cheese factories in Finland. In these locations more than 250 million litres of milk is being processed annually. AGVs handle the routine pallet transfers from production to shipping preparation. Rocla AGVs feature Valio’s product brands as design covers.
Rocla AGVs have fulfilled the expectations. Personnel have been very positive towards the automation. It has increased the work safety in the factory: thanks to the safety equipment and sensors there are no collisions or damaged products anymore. Using the AGV is also easy. ”The whole production personnel participated the basic training and a few persons were trained as main users. At the beginning Rocla’s 24/7 helpdesk was also in use, but for quite some time the automation system has been running on its own very nicely,” compliments Ms. Kujala.
The factory manager is proud about the added imago value of Rocla AGVs. ”For example, our American colleagues and other visitors have noticed the new AGVs right away – many of them are still using old technology with these transfers”, tells Mr. Makela.
Further Information: www.rocla.com
AGVs have been in full action since last spring. Valio’s logistics manager Tiina Kujala is very pleased with the new way of work. “Before same pallet transfers were handled by man-operated trucks. The premises are often very confined and distances are not that long. The work itself caused stress to employees and a challenge in work safety,” remembers Ms. Kujala. Pallets are being loaded with products in only a few minutes intervals. In order to keep the production line running smoothly the full pallets need to be transported right away to the shipment. In the old days the drivers needed to be ready all the time to move the full pallets to the shipment preparation.
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SPECIAL FORKLIFTS
Spare Parts for Container Handlers and Terminal Tractors The Waregem-based Belgian company TVH has been founded 1969 by Paul Thermote and Paul Vanhalst and is now the world‘s largest brandindependent supplier of forklift parts. They started with the import of used equipment from a Japanese production. Other activities include trading of industrial trucks (Doosan, Lafis, ICEM, Dambach) in Belgium and Luxembourg, the sale of used trucks (1,500 units always in stock) and the rental of aerial work platforms. Some 500 million EUR is the annual turnover – which is quite a sum. 80% of the turnover is achieved with spare parts. STAPLERWORLD-CONTAINER met Kristof Bolle, Allied Parts & Accessories Business Development Manager. Three years ago TVH started to cope with spare parts for large forklifts and reachstackers. A good reason to go into more details. When did TVH decide to enter expensive spare parts for Containerhandling equipment? K. B.: TVH is already active in heavy machines for more than 10 years. About 3 years ago, the decision was taken to create a dedicated team for what we call “Port Equipment (PE)”, in order to focus on container handling equipment, after seeing increase in number of inquiries for this kind of equipment & also due to special requests of customers. This decision was more an extension into all brands and increasing R&D for these brand and product types.
From our understanding most customers rely on their brands and their service-people, what makes you believe terminal operators will buy spare parts at another source? K. B.: This is correct and that is also why TVH follows the “quality” request from customers. Remember that TVH is surveying quality on all its parts, on the complete range of machines, regardless the expectations of our “PE” customers. Up-Time and total cost of ownership are very important in this particular industry, so we do have to meet the same standards as the existing suppliers to our customers. Right now about 10 % of total SKU in stock are for PE machines, which is giving customers good availability. On which brands and on which parts do you specialize? K. B.: As per normal TVH standard, it is TVH’s mission to cover the complete range of brands and parts for “PE” equipment, of which our customers’ fleet consist of. This without loosing the focus on quality as expected by the customers.
Only certain parts are refurbished and then only on special request by the customer. What is the future of this cost intensive business at TVH, will it become as prominent in the container business as TVH is in the every-day-forklift business? TVH: With regard to service levels @ TVH, it is certainly our goal to achieve the same levels. The biggest benefit for our customers is that they can use existing structures, system, knowledge and experience of more then 40 years of TVH, in order to achieve the maximum of synergies for our customers. Since the start of “PE” as separate department, growth in business is still on target, both in increase of turnover and number of customers. Images: TVH Further Information: www.tvh.be
Gearboxes, engines and axles for container handling equipment are pretty large and heavy how do you organize logistics which is, as we believe, much different from your daily business? K. B.: In reality, the basics on logistics are the same, so that is no problem for TVH. Although “PE” focus is quite new, some heavy equipment brands / parts already are included in TVH business since many years, and TVH is also used dealing with heavy or voluminous items like attachments, chargers, masts, forks, tyres, etc... So the experience is present @ TVH and the only possible restriction could be the usage of “express deliveries” on certain parts, but then again this is applicable on particular parts supplied by TVH for many years. Where do you source the parts, are they refurbished from used machinery or where to get them instead? K. B.: Since TVH policy is to supply “quality parts”, all parts are new, as per customers’ request. So this means TVH is staying with the best resources available in the market.
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SPECIAL FORKLIFTS
Sales Director Guido Glees (left) and Managing Director Dieter Wilden place great em- Lifting masts are drilled, milled and cut phasis on quality, service and logistics – parts are ready for delivery in five working days. to size, ready for installation.
World leading special Profile Producer The company Mannstaedt, located in Troisdorf, is part of the Georgsmarienhütte Group which has a total of 10.000 employees worldwide and generates turnover of 3,7 (2011) bn euros. Mannstaedt has the technical capacity to produce 250,000 tons of special profiles per annum making it the world’s leading producer of hot rolled special profiles made of steel. Strategic investments, reliable logistics and an optimised material flow enabled the company to overcome the economic crisis so successfully that it was working profitably again from the second half of 2009 onwards. Indeed Mannstaedt even managed to use the economic crisis to significantly expand its market shares. “We have already achieved a great deal but we still have more plans for the future. We have already built a new logistics centre and no longer store the rolled profiles along the mill train. Build up stocks, roll, process, dispatch – this is the only way in which we can improve our efficiency further. Moreover, the re-inclusion of popular “classics” in the portfolio of products has also contributed to a revival in business“, according to Wilden in a discussion with STAPLERWORLD. Wilden is a pragmatic as well as a dynamic personality – he has made it possible for the Troisdorfer company to become part of the Steel Production Unit of the Georgsmarienhütte Group of Companies, of which it constitutes part of the “core business“. Significant investments have been made. In 2008 the second fully automatic sawing system went into operation, which
produces profiles up to 80 kg/m fully automatically with precision of ± 1, or even 0.5 mm. Sales Director Guido Glees points out that further investments of 25 Mio € for 2012 and 2013 include a new state of the art robotic stacking unit, new breaking down stands for the medium section mill and a further completely automatic sawing system has already been ordered and is expected to be finished by the end of 2012. In future selected lifting mast profiles will also be tested by laser equipment prior to delivery to customers. The lifting mast profiles with weights of 10 to 80 kg/m are rolled on two mill trains. The complete product portfolio encompasses special profiles of 2 to 185 kg/m. Dieter Wilden and Guido Glees place great emphasis on organisation, processes and logistics as supporting pillars of the company. “We are able to deliver within five working days“, says Glees during a factory tour. “Customers have firmly established quantity frameworks and call these up in close collaboration with us. With a lot of customers, however, we have to conduct detailed negotiations concerning just-in-time and just-in-sequence“. Nevertheless they also manage to handle the situation when large quantities are called up spontaneously, although they prefer such situations to remain the exception. “We adhere to the specifications, process the best steels, over 50% comes from the Georgsmarienhütte steelworks, the price has to be reasonable and, above all, a considerable added value must be included because this is what makes the
Further processing (blasting, sawing, machining, cold-drawing and blanking) can be carried out on request – thus producing finished profiles
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Troisdorf products significantly different and better for the industrial truck customers. As the entire process chain, from steel production via rolling right through to recycling, takes place within the group of companies, the customer always benefits from an extremely high degree of reliability. Lifting mast profiles, profiles for sideshifters and fork carriage bars are produced in a wide variety of different forms, lengths and qualities. Our regular customers include such companies as Jungheinrich, Kion, Mitsubishi, Toyota and Nissan. Our company is particularly proud to be the only overseas supplier to deliver to all Japanese manufacturers of lift trucks (in some cases even as exclusive supplier). Since the 1980s Atlet has had all its lifting masts made by this partner. Since the early 1990s Mannstaedt of Troisdorf has been supplying cut-to-length and mechanically processed profiles to Atlet. Now Mannstaedt supplies the required profiles justin-time directly to the production line. Following a concept phase, the collaboration led to an individual overall solution, which differs in a number of ways from otherwise common processes and guarantees consistently top quality. For example, the profile surfaces are descaled directly at the mill trains. The processing of relevant functional surfaces takes place in a completely automatic high-precision drilling / milling centre. Processing is always carried out without cooling lubricants, this excludes any impurities. All quality-relevant work stages are executed in compliance with ISO TS 16949. Ultimately, the profiles are supplied with just one week lead time so that all parts belonging to one product arrive at Atlet at the same time for the next work stage.
SPECIAL FORKLIFTS Range of cold-drawn profiles: • • • • •
Profile width (mm): of 30 to 200 Profile height (mm): of 10 to 120 Profile rod length (m): of 0.5 to 13 Weight (kg/m): of 2.5 to 50 Cold-drawn lifting masts are most frequently used in warehouse equipment stackers with extreme lifting heights. Principal advantages here are the angle precision, the quality of the surface and considerably improved dimension tolerances. • Mechanical processing (drilling, milling)
Range of hot-rolled profiles Heavy sector Product range 15 - 185 kg/m Width max. 400 mm Thickness min. 6 mm Rod length up to max. 26,000 mm Light sector Product range 2 - 35 kg/m Width max. 180 mm Thickness min. 2 mm Rod length up to max. 18,000 mm
Mannstaedt The company, founded in 1825 supplies, for example the automobile, commercial vehicle and fork-lift truck industry. The portfolio includes 1,200 different products. In addition to the core process of hot-rolling, further processing steps such as shot blasting, precision sawing, mechanical processing, cold-drawing and welding are also offered. • 1825 Foundation of “Windgassen Friedrich-Wilhelms-Hütte” • 1911 Façoneisen-Walzwerk, Louis-Mannstaedt & Cie. AG • 1923 Klöckner-Werke AG • 1986 Klöckner Stahl GmbH • 1990 British Steel plc (100 %) • 1999 Corus Group plc • 2006 Georgsmarienhütte Holding GmbH The company located in Troisdorf is certified according to DIN ISO/TS 16 949, DIN EN ISO 9001 and DIN EN ISO 14001 and currently has approximately 725 employees. In 2006 a subsidiary company was set up in Atlanta. Important customers in the USA include Mitsubishi-Caterpillar, Nissan, Toyota, Raymond and Brudi Bolzoni. In addition to the hot-rolled lifting masts, specialities include cold-drawn special profiles for fork lift trucks. Cold-drawing of profiles following hot rolling produces extremely precise lifting masts with an excellent overall surface finish.
Further Information: Mannstaedt GmbH D-53840 Troisdorf | Tel.: (00 49 22 41)-84-0 | www.mannstaedt.de
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SPECIAL FORKLIFTS Loading a lorry with a 13 m long timber packages.
Baumann Sideloaders work in Fichtelgebirge Lumberyard 1898 is the year in which the Gelo-wood processing facility has been founded. Since 2003 Wolf-Christian Küspert is managing director. The daily output of the 90-employee operation is 1.000 fm. To move the huge quantities of wood with lengths up to 13 m Küspert rmploys 16 Baumann side loaders with 6-ton each capacity. Since 2009 he relies on the side loaders from Northern Italy – several brand changes in the past did not show the desired results. The side loaders work 16 hours a day – up to 3.500 h – an effort that has it all, so also the in-house workshop looks after the warranty has expired by the yellow-gray “Baumen” and their brothers from other manufacturers, but which are currently sold and replaced soon with more Baumänner already, three more machines are currently in the feed. „Wanted ... the opportunity to get a demonstration of triplex, this wish could meet any other provider,“ „What convinced me,“ said Küspert at a meeting with STAPLERWORLD. „It was worth it, because of the demonstration.“ Main features of the hydrostatically powered 6-ton sideloader with the designation DFQ 60/14/54TR is its triplex mast featuring 5,400 mm lift height. It offers a consi-
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The loading of the kilns require great sensitivity, hydrostatic drive makes it easy to maneuver the machines - inching pedal is a standard feature.
Features: Lifting Capacit: Mast: Lifting Height: Height over Cabine: Length: Width: Platformwidth: Platformheight: Forks: Tyres: Options for Gelo:
6.000 kg/700 mm LC up to 4.000 mm 5.000 kg/70 mm LC up to 5.400 mm Triplexmast 5.400 mm 2.850 mm 4.930 mm 2.200 mm 1.400 mm 1.050 mm 1.400 mm x 250 mm x 45 mm Luftbereifung 300-15 Michelin Gratings, leveladjustment ± 100 mm Two flood lights form ast, one on top of cabine Aircooler with coarse meshed wire mesh Michelin Tyres Grammer ACTIMO-Seat with airsuspension Central lube system
derable residual load capacity of 5000 kg at 700 mm LC up to full lifting height.
to Martin Stang, the responsible regional sales of dealer SCC, about 2 liters/h.
A Tier III engine (64 kW) powers the 11-ton side loaders with 1,400 mm wide platform (platform height of 1.500 mm). Hydromotors power the wheel motors with very sensitively regulated flow of oil. Latest common rail technology saves, according
Images: STW Further Information: www.baumann-online.it
Three Baumann DFQ 60/14/54TR are currently in use at GELO. Feature is the triplex mast with lifting height 5.400 mm
SPECIAL FORKLIFTS
OffroadReachstacker for German Army and very special applications
Kaup spreader may be detached for transport.
Technical data: • Lifting Capacity: 24.000 kg, 16 t second row • Lifting height: 10.000 mm Containerhandling on a Bundeswehr test ground.
• Temperature-range: -32 to +44° C • Length without spreader: 8.406 mm
Nearly every major special lift truck manufacturer (Hyster, Cargotec etc.) has dealt with a rechstacker being able to work under severe conditions although being lightweight, tuff and also pretty small so that it can be transported by rail under harsh European railroad profile obligations.
Pictures: STAPLERWORLD • Width: 3.117 mm • Height: 2.946 mm Further Information: www.herbst-smag.de
• Engine: Deutz TCD 2013 (190 kW), watercooled. • Fourwheel-drive, fourwheel-steering
HERBST SMAG Mining Technologies GmbH, based in Braunschweig, has developed the ORION HF 001-reachstacker that is now in service in Germany and at several places in the Near East were German Bundeswehr is being asked to propel ne strategic developments. Orion is 3.150 mm wide, 8.500 mm long (transportation length), it is equipped with a 20´-Spreader made by Kaup- to speed transport and loading the spreader is detachable. Weight of Orion is 56 t including spreader. The lifting device may be hydraulically adjusted to lift the container from any kind of trucks, railcars or other means of transportation. Driver cabin of Orion can be raised and lowered hydraulically. The new Reachstacker is also an alternative for rough terrain handling of nonmilitary loads. It meets Nato-specifications.
STAPLERWORLD EUROPE 01-02/2012
Drivers compartment with IFM-electronics for control, programming and safety-options.
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SPECIAL FORKLIFTS
Transfer-Carrier for Terminals and Industry When handling containers in ports, the unloading operation on the dock must be linked with the stacking operation in the storage location. The new Boxrunner straddle carrier is the economical connection between the ship shore cranes and automatic stacking cranes. Its thought to be a so called “high-power solution” for container handling in ports. The containerhandler (1 Box) transports containers from the ship-to-shore cranes (STS) to the stacking zone. Container terminal operators in particular have significant advantages from the new concept when it comes to the automatization of their container handling. Similarly, companies that must ship goods in containers also benefit from the straddle carrier, as until now they used less economical solutions such as trucks, trailers or stationary gantry cranes. The new concept is first choice in narrow ports: As it is able to take over various tasks, no other container transport equipment is needed.
Key customers were surveyed in advance The development of the flexible high-power crane was based on the many years of experience that Konecranes has in the strad-
Konecranes BOXRUNNER – flexibility, speed and safety to meet the highest customer requirements for container handling
dle carrier business and the broad knowledge in the field of container handling. “Prior to starting the construction process, we asked some of our key customers in container handling which characteristics are a must-have for the perfect straddle carrier,” says Jens Andreas, General Manager for straddle carriers at Konecranesfactory in Tauberbischofsheim, Germany. Many of the proposals are reflected in the main characteristics, particularly those concerning power and operation, such as speed, excellent handling, long service life, good driveability, as well as high availability with long service distances and low total operating costs. “The small Straddlecarrier (competitors are Kalmar, Noell-Terex, Liebherr) is a special machine for professionals who value sustainable management that takes into account subsequent costs, including performance characteristics, fuel efficiency and maintenance costs,” underlines Jens Andreas. “In its field, it has the highest life-cycle value in the industry. In this way, we have a very simple formula for creating added value to the customer: With the carrier we maximize productivity based on the highest possible availability and lower the costs of loss of use to a minimum. Hence, we increase the productivity of our customers’ work processes.”
Konecranes designs and manufactures the key components of the BOXRUNNER itself, in order to make sure that they work together smoothly. The new straddle carrier has a very solid frame, which ensures easy handling and precise steering. The BOXRUNNER, equipped with a diesel engine and rope hoist system, is offered in two versions: for twin-twenty operation with a carrying capacity of 50 tons and for individual operation with a carrying capacity of 40 tons. The maximum driving speed in 30 km/h and the hoisting speed is 25m/min.
Unique Konecranes technology For lifting, the machine uses a rope hoist winch. A technology which has already proven itself in the company’s rubber-tyred gantry cranes (RTG) and the rail-mounted gantry cranes (RMG). The straddle carrier has an electro-hydraulic system with a 4-axle steering system for less tyre wear, requires fewer spare parts, has a lubrication-free carriage and requires low maintenance. The cabin has an ergonomical design and offers an optimal view. The clear controls and indicators support safety, precision and speed control. “Thanks to its 4-axle steering system, the Boxrunner offers excellent steering. Every driver that has tested it was impressed with the excellent driving and steering,” says Jens Andreas.
Further information: Jens Andreas, General Manager Straddle Carriers Tel. +49 9341 89541-10 www.konecranes.de
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SPECIAL FORKLIFTS
Global Logistics Provider Sees Payback from LEDs in just Over a Year The amount of light has serious impact of forklift operation, orderpicking quality and of course energy costs. LED is one of the future topics in warehousing. Global logistics provider Kuehne + Nagel based in Germany, operates over 100 warehouses across the UK, the company recognised an opportunity to radically reduce its energy consumption by replacing the current lighting at its Minworth facility near Birmingham with a more energy efficient technology. In selecting LED technology, this facility was able to cut its energy needs and achieve additional savings on maintenance as well as vastly improving the quality of light for its workers.
Installation Snapshot • Two warehouses jointly covering 20,000 sqms/220,000 sqft • Number of LED fittings – 126 • Replaced – 250W and 400W HPS with 150W LED High Bay • Illuminance level – 150 lux • Mounting height – 13 ms/43’ • Energy saving –555,735 kWh, saving over £42,000 annually • Carbon reduction – 271 tonnes annually • Average w/sqm reduced from 3.85 to 1.05 • Payback period of 1.1 years The Minworth facility consists of two warehouses with a linking area jointly covering 20,000 square metres. The older of the two buildings was fitted with 136 x 250W high pressure sodium lamps (HPS), the newer facility with 100 x 400W HPS and the linking bay with a few metal halides. Engineering Manager Kevin Greene explains the lighting challenge to STWE-readers: “Overall we wanted to save energy, but we also wanted to improve light quality. We found that the 250W HPS did not provide sufficient light quality in the older warehouse, which is why we moved
to 400W HPS in the newer warehouse. However, they were actually averaging about 280W and 430W of power respectively. Also, sodium lights are not very effective at night and make it hard for the workers to read labels.” He adds: “In our warehouses, the sodium lights are running 24/7 and need changing every 20,000 hours. A scissor lift is required to reach them at 13 metres, which involves considerable cost, inevitable work interruption, and there is the additional problem of dealing with hazardous waste when you dispose of them. There were plenty of reasons to look for a more efficient lighting solution.”
Image: Dialight/KN Greene selected Dialight’s DuroSite Series LED High Bay fittings for the two Minworth warehouses, installing 63 x 150W LED High Bays in each with three to a row compared to five HPS lights. “The reason we chose Dialight is the length of time that the company has been in the market,
w
STAPLERWORLD EUROPE 01-02/2012
Further information:
. d l r o erw
l p a t s . ww www.staplerworld.com
whereas many of their competitors are relatively new. With the LED High Bay we have a very robust unit containing no hazardous materials that offers a 60,000 hour lifespan and is warranted by a well established company. Not only does it remove the maintenance and the disposal problem, it’s also a very workable light, perfect for reading labels. We allowed a few extra fittings to avoid shadows and the light clarity experience is brilliant.” The LED lighting in fact delivers a CRI of 72 compared to around 20 for HPS lighting out of a total scale of 100, so although the lux level of 150 remains very similar the lighting quality has vastly increased Energy savings.
www.
www.staplerworld.com
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Preview STW Europe 03-2012 E I Manitou´s new Industrial Lift Trucks E I How Manitou enters new fields of application. E I VNA-trucks 2012 – a host of new improvements E I Telescoping forks – market survey
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Weitere Fragen: Editor-in-Chief Oliver Bachmann Tel.: +49 (0) 61 39-29 34 43 Fax: +49 (0) 61 39-96 04 55 Cell: +49 (0) 15 22-9 22 55 39 oba@staplerworld.com Advertising IMP InterMediaPartners GmbH In der Fleute 46 42389 Wuppertal-Langerfeld Sven Anacker, Britta Steinberg Tel.: +49 (0) 202-27169-11 sa@intermediapartners.de steinberg@intermediapartners.de www.intermediapartners.de
E I RoRo-lift trucks speed up port handling E I Towing tractors become increasingly popular – whats on the market and on the drawing boards? E I 90 years of Genkinger E I Access systems for lift trucks
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STW Europe Edition 03-2012 Editorial Deadline: 30.08.2012 Advertisement Deadline: 15.09.2012 Issuing Date: 30.11.2012
STAPLERWORLD EUROPE 01-02/2012
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