At Cascade, custom isn’t the exception – it’s the standard. Nearly 70% of Cascade’s attachments worldwide are built to customer-specific requirements, meaning they’re designed to solve unique handling challenges that off-the-shelf products simply can’t address. From forklifts and telehandlers to AGVs and automated systems, Cascade works closely with customers to engineer attachments that fit their operation, their load, and their workflow.

“When customers come to us with a challenge, it rarely involves our off-the-shelf products,” says Rick Whiting, Head of Global Product Management at Cascade. “It’s about understanding how they move product, where time is lost, and what needs to change to make their operation the most efficient.”

That collaborative, application-first mindset is what drives Cascade’s custom attachment business. It’s also why customers across industries turn to Cascade when the job gets complicated.

Heavy Loads + Extreme Conditions = High-Capacity Rotator

In underground mining operations, standard material handling processes can be slow, labor-intensive, and risky. One U.S.-based mining site needed a more efficient way to clear out old mine shafts filled with rock, mud, and debris, with loads weighing up to 11,340 kg (25,000 lbs).

Previously, operators used long forks and chains to lower a bucket into the shaft, retrieve the debris, and then reconfigure the setup to dump the load – a process that could take more than half an hour per cycle.

Cascade engineered a high-capacity custom rotator with integrated jaws designed to securely grip the bucket and rotate it. By eliminating chains and simplifying the handling process, handling times dropped to just a few minutes.

“This wasn’t simply about making a strong rotator. It was about rethinking how the load was being handled,” explains Whiting. “By designing jaws that matched the bucket and combining them with high rotation torque, we dramatically reduced handling time.”

The result: faster cycles, less manual intervention, and a solution purpose-built for an extreme application.

Automation-Ready Handling: Custom Carton Clamp for AGVs

As automation expands, material handling attachments continue to evolve in tandem. One customer specializing in air conditioning units needed an attachment capable of handling multiple palletless products – including split systems and cabinet units – using AGVs in a tightly controlled warehouse environment.

Standard Carton Clamps weren’t suitable for the load dimensions, batch requirements, or the automation platform, so Cascade developed a custom AGV-compatible Carton Clamp capable of clamping up to 18 units at once, with a total load weight of approximately 950 kg (2,090 lbs).

Key design elements included:

• Custom arm length, height, and opening range
• Automatic force control system to prevent product damage
• Full compatibility with the customer’s AGV system

“With automation, precision matters even more,” says Whiting. “You can’t rely on operator input, so the attachment has to manage force, alignment, and repeatability on its own.”

The customized clamp allowed the customer to streamline transfers between production and storage while protecting delicate products and maintaining consistent throughput.

High-Throughput Milk Crate Handling for Dairy Operations

In fast-paced dairy environments, efficiency depends on moving product quickly and consistently. For a large Australian dairy operation, that meant rethinking how milk crates were handled on the warehouse floor, as handling them one at a time was limiting throughput and adding unnecessary handling steps.

Cascade’s Custom Products Division developed a custom milk crate handler designed to lift 30 crates in a single load, arranged in five rows by six columns. With each crate weighing approximately 18 kg (39 lb), the attachment allows operators to move high volumes of product in one stable, controlled lift – significantly reducing cycle times and improving overall flow.

“This was a case where fewer lifts made a bigger difference than faster lifts,” says Whiting. “By handling more crates with every load, the customer was able to streamline movement across the operation without adding trucks or labor.”

The attachment was engineered in two configurations to match the customer’s equipment and workflow. A Class 2 hang-on version provides flexibility for conventional lift trucks, while a welded configuration was developed for use on a walkie stacker where stability and compact design were critical.

Both designs balance load distribution, visibility, and durability, with overall dimensions optimized to handle large crate bundles while remaining maneuverable in tight production and storage areas.

“When you’re lifting that much product at once, stability and visibility matter just as much as capacity,” Whiting explains. “We designed the frame to give operators confidence during every lift.”

A Global Process with Local Expertise

Every Cascade custom attachment starts with a conversation - and a hands-on site visit. Regional sales and engineering teams work directly with customers to understand the application, the load characteristics, and the operational constraints before a design is finalized.

With more than 30 locations worldwide, Cascade combines global engineering resources with local, on-the-ground support. In one recent project, a custom tissue roll clamp for AGVs was designed in the U.S., manufactured in Italy, and delivered to a customer in Japan, with local, boots-on-the-ground service available in case it was needed.

“One of our strengths is staying connected throughout the entire process,” Whiting explains. “From design and manufacturing to delivery and after-sales support, we’re involved every step of the way.”

Built Around the Customer. Every Time.

Customer conversations are central to Cascade’s custom attachment process, as direct input from end users helps ensure no critical details are missed and that the solution performs exactly as intended.

Once a Cascade custom attachment is in operation, the results speak for themselves. In the mining application above, the customer went on to order additional units for other locations. In the automated warehouse example, the custom carton clamp delivered reliable, damage-free handling from day one. In the milk crate application, the solution improved throughput while minimizing truck wear and operator fatigue.

“Custom doesn’t just mean different. It means better for that specific job,” says Whiting. “When the attachment fits the application, everything downstream improves.”