Leading UK pallet network distributor Palletways lists two gas-powered Bendi forklifts as essential tools to cope with almost exponential growth at its Lichfield site.

Growth at Palletways' Stargate Distribution division, a warehouse fulfilment operation, exposed the need for more articulating trucks 18 months ago, according to divisional manager Bob Richards.

Stargate offers 112,000 square feet (10,405sqm) of covered storage in two warehouses at Lichfield, with a second site in Scotland and a third store scheduled to open this year in north London.

Richards opted for gas forklifts, arguing that they produce a saving of 90 minutes a day in not having to change batteries or "an annual saving of GBP6,500 (USD12,755), which does not include the cost of standby batteries".

"We also chose gas because I know from experience that when we get into three- or four-year-old electric trucks, we will start to have inherent problems. The reliability of the gas trucks has also been incredible."

Such reliability is essential for a frenetic operation like Palletways which must cope with tight operational windows daily to fulfill its deliveries. Dealing with 300 incoming double-deck trailers every day, the Bendis work from 6.0am until midnight. Between 6.0am and 2.0pm, the Bendis work flat-out on goods-in operations, unloading vehicles in the yard and placing them in the racking. Then they are working on replenishment tasks, ready for the pickers who start at 4.0pm, and after that they work until midnight doing full pallet picks.

For Palletways, the manoeuvrability of the Bendi forklifts was another key factor. Because of their ability to operate in narrower aisles, Richards estimates that the operation can access up to 3,000 more pallet spaces than with other forklifts.

Palletways uses RF technology for stock location but it is currently working on product recognition by customer barcode which will allow the Bendis to scan loads on incoming lorries and place them directly into the racking, thus cutting out any double handling.

Leased with a full maintenance contract, the two refurbished Bendis lift loads to 8.2 metres, with a capacity for 900 kg to 7.7 metres. Training was done on site by Palletways' own RITB-trained instructor.