A specially adapted Kalmar forklift for GrowHow UK Ltd's forklift fleet.

Kalmar has received an order for 16 specially adapted Kalmar DCE100 heavy-duty forklifts from GrowHow UK Ltd, a UK fertiliser manufacturer and process chemicals supplier.

To keep pace with production and delivery, GrowHow's forklift operators handle six bags of fertiliser, each weighing around 600kgs (1,323lbs), at an extended load centre of 1.8 metres (5.9 feet), at a time. The bags also need to be stacked four-high, presenting a unique challenge for Kalmar.

Kalmar area sales manager Steve James explains: "The drivers need to accurately position the forks into the lifting points on the bags. But when stacking above the first level, the fork pockets on the bags are out of view when using a standard forklift. The solution was to develop an elevating cab so the drivers can continue to look down onto the fork tips even when the mast is fully raised."

The customised cab allows operators to elevate the cab by an additional 1.9 metres (6.2 feet), bringing its maximum height to just over 5 metres (16.4 feet). Kalmar's site survey determined that to be the optimum position for visibility.

For enhanced health and safety, each forklift is equipped with a camera and monitor inside that allows the operator to see that there are no obstructions on the underside of the cab, should he or she want to lower the cab's position. Longer forks were also developed with visible markings so operators can see the ideal position for lifting six bags of fertiliser at one go. The forklifts have 10-tonne capacities.

Kalmar claims the DCE range is highly fuel-efficient and presents lower running costs over the forklift's lifetime. This is due partly to the CAN-bus electronic control system that allows the forklift's operating parameters to be adjusted to suit the site.

A Kalmar option, the Optidrive system, automatically maintains engine revs at the optimum level and controls gear changes to ensure that the right amount of power is delivered to the transmission or hydraulic functions depending on travel and lifting speeds. This contributes to fuel savings, Kalmar says.

Ed Sharp, GrowHow's production manager, says good customer service played a key role in awarding Kalmar the contract.

"Whilst we had to be sure that the trucks were up to the task, it was vitally important to us that we had a sound working relationship. Kalmar's clear understanding of our needs coupled with their professional approach was a significant deciding factor," he says.

Neither party will disclose the value of the order.

GrowHow was established at the end of 2007, following the merger of the UK activities of Yara International ASA and Terra Industries Inc. GrowHow's Ince manufacturing site was established in 1965 and employs about 400 people. It occupies 55 hectares (136 acres) and produces around a million tonnes of fertiliser each year, supplying key market sectors of grass and arable farming.