Case Studies
MULTI-MILLION POUND TESCO INSTALLATION PROVIDES EASILIFT WITH ITS BIGGEST EVER LOAD
8 August 2011
Easilift Loading Systems has recently completed the largest single order ever placed in the UK for loading bay equipment. The bespoke solution for Tesco's new state-of-the-art Grocery Distribution Centre in Daventry saw Easilift successfully deliver a project worth in excess of £6.5M
The 800,000 sq ft facility is a major investment designed to meet Tesco's long-term distribution requirements. Easilift, already an existing supply partner to Tesco, was recruited to take care of the Grocery Distribution Centre's widespread and complex loading dock requirements.
Working closely with Tesco and the main contractor Volker Fitzpatrick, Easilift project managed the installation of 40 double deck lifting platforms and 100 dock leveller bays, all housed in external loading pods. The high specification of the build together with the complex design issues and tight programme required the attention to detail that Easilift are renowned for.
"Easilift has proven its abilities in the past, and we knew that by involving them in the process from the start, we could maximise resources to deliver a robust loading bay environment on a scale never attempted before in UK distribution," explains Duncan Robertson, Project Manager at Tesco.
The design interface was critical to the success of the project and Easilift worked closely with the project team to overcome a number of technical challenges. Notably, spatial restrictions at yard level meant that the double deck bays had to be constructed in pairs. This innovative arrangement created a tandem pod around a single walkway to ensure safe and easy operator access / egress.
Each of the 40 double deck bays incorporates a heavy duty, surface mounted 16,000kg lifting platform, capable of carrying up to 30 roll cages. The lifts are located within external modular pods, manufactured and partially preassembled at Easilift's Huddersfield factory prior to delivery and final on-site erection using a 60-tonne crane. This approach equated to a 60% reduction in installation time for this particular element, when compared with previous lift installations.
The dock leveller bays comprised 96 Type 232 PoweRamp hinged lip units and 4 Type 233 PoweRamp telescopic lip units, with each bay comprising a modular loading pod, a Type 403 PowerShelter and a 601 PowerDoor.
Ancillary equipment supplied throughout all bays included environmentally friendly LED traffic and loading dock lighting, pod lights, fully integrated control panels and heavy duty "slider" bumpers.
Furthermore, in line with Tesco's commitment to improving site safety all "goods in" bays were fitted with the revolutionary new Dock Management System developed by Easilift and Traka. This innovative hi-tech management reporting and safety system is designed to prevent the premature departure of vehicles from the loading bay.
The system combines Easilift's dock door and associated control equipment with Traka's electronic key control system and was tailored to complement Tesco's existing safety processes, creating a high-tech solution to the problem of vehicle drive-off accidents.
The success of the project, which went live in May 2011, underlines Easilift's ability to achieve large-scale and technically demanding projects. The bulk of the installation was completed during the winter months of 2010/2011, where Easilift was able to fit equipment on time and within budget despite the extreme bad weather which plagued the UK.
"In terms of size and scope, the development of the Grocery Distribution Centre has been a huge undertaking, and Easilift has met our requirements every step of the way," confirms Duncan Robertson.
All Tesco distribution centres to install Easilift new Dock Management System
14 February 2011
An innovative hi-tech management reporting and safety system designed to prevent the premature departure of vehicles from the loading bay is set to be installed at the Goods In section of every one of Tesco's distribution centres across the UK.
The supermarket is investing in the Dock Management System, which was jointly developed by UK firms Easilift Loading Systems and Traka, after it impressed during a pilot scheme at Tesco's distribution centre in Hinckley, Leicestershire.
The system combines Easilift's dock door and associated control equipment with Traka's electronic key control system and was tailored to complement Tesco's existing safety processes, creating a high-tech solution to the problem of vehicle drive-off accidents.
The Dock Management System works by using electronic keys - known as iFobs -each containing a unique electronic chip, which is individually programmed to open or close one specific door when inserted into a control panel.
At Hinckley, the system is now an integral part of a robust protocol whereby drivers are required to hand in their ignition keys when they arrive at the Goods In office. The keys are clipped to an iFob, which is inserted into the main Traka control panel, allowing a corresponding iFob to be removed and handed to the driver.
Only then is it possible to open the bay door, when an authorised operative inserts their personal iFob into a secondary control panel located adjacent to each door.
Once loading or unloading is complete, the operative closes the door. This sends a message to the Goods In control box, permitting the removal of the driver's keys - but only after the deposit iFob is inserted back into the box.
Tesco trialled the Dock Management System at 26 Goods In loading bays at the Hinckley depot. The bays are used by between 300 and 400 vehicles each day, many of which arrive from overseas, representing a stern test for the new Easilift system.
"We have an excellent safety record at Hinckley, but worker safety is paramount and there is always room for improvement," said Joe Carthy, distribution health and safety manager for Tesco UK and Ireland.
"It was important therefore that the system was tested in the Goods In section, where we deal with a high volume of drivers, many of whom will be unfamiliar with the layout.
"If the system worked there, we knew that it would be able to achieve our objectives at other loading bays too."
Fitting the system involved surface-mounting cabling on the inside of the exterior walls and linking 26 individual boxes stationed next to each loading bay door with the control panel in the Goods In office.
"The Easilift Dock Management System was attractive to us because by using control boxes and indicator lights, it lessens the chance of human error," said Joe.
"This was a limited trial, but the results were fantastic. The system was easy to operate and to understand, and it took a huge amount of human element out of the process. Importantly, it made people feel safe and put them at ease."
Although the system was developed with a health and safety angle in mind, it has a whole range of other benefits. The system minimises the amount of time the door is open - which can save money and reduce carbon footprints for chilled distribution centres - and, furthermore, can provide an audit trail, logging who used what door and for how long.
This can not only improve efficiency and assist companies in tracking down any missing stock, but can also help with servicing costs. By using the information recorded within the system and the reports generated, a company can devise a servicing programme which takes into account how much the door is used over a set period of time.
The Dock Management System can be easily retro-fitted to virtually any loading bay door and will now be installed in all of Tesco's distribution centres, representing what David Whyatt, sales director at Easilift Loading Systems, described as an excellent way to launch the product onto the market.
He added: "We are thrilled that Tesco has agreed to roll out the Dock Management System UK-wide and by doing so has shown great foresight by investing in a solution which has the potential to cut out serious accidents.
"There could have been no tougher test for the system than to trial it at Hinckley, which is an extremely busy depot where any shortcomings in the system would have been very quickly highlighted.
"It is testament to the technology and expertise at Easilift Loading Systems and Traka that the system proved itself to be watertight and demonstrated that it goes further than any other system on the market to offer peace of mind."
With 35 years' experience in the design, manufacture, installation and maintenance of high quality loading bay equipment and industrial doors, Easilift Loading Systems is the UK's leading specialist supplier of total loading bay solutions to some of the biggest names in retailing, manufacturing, logistics, distribution, warehousing, building, construction and the service sector.
In addition to its unique new Dock Management - Anti Drive-Off System, the company provides a complete range of loading bay equipment, including dock levellers, dock shelters & seals, industrial & high speed doors, and lifting platforms, together with a wide selection of safety aids & accessories such as dock plates, dock bumpers, dock & traffic lights, wheel guides & vehicle restraints, and integrated control systems. Easilift also provides comprehensive service and maintenance programmes for all makes and types of loading bay equipment - irrespective of the manufacturer.
Easilift was also one of the pioneers in the design and installation of dock pod systems, which are complete stand-alone loading bay enclosures that can be installed directly onto the external face of a building. Suitable for new buildings, extensions and refurbishments, they can be quickly and easily re-positioned, if required, and are ideal for use with the increasingly popular and highly cost-effective double deck trailer units.
As the UK's leading loading bay specialist, Easilift was one of the first in its sector to achieve the prestigious SAFEcontractor accreditation in recognition of its excellent health & safety record and competence, confirming to prospective customers that effective policies and systems are in place.
Easilift is a member of the Loading Systems International Group, one of Europe's foremost manufacturers of loading bay equipment. The Group has over 450 employees across Europe and a total turnover in excess of 60 million Euros.
An active member of the Association of Loading & Elevating Equipment Manufacturers (ALEM) and the Confederation of Construction Specialists, Easilift operates to the International ISO 9001:2008 Quality Management Standard. The company has Investors In People Bronze status accreditation and is a participant in the Construction Skills Certification Scheme (CSCS), with all its engineers fully qualified under the CITB Site Supervisory Training Scheme.
NEW CONCEPT EASILIFT DOUBLE DECK SCISSOR LIFT DOCK POD PROVIDES A SPEEDY LOADING/UNLOADING SOLUTION FOR THE TIC GROUP
A new double deck scissor lift modular dock pod designed, manufactured and installed by Easilift Loading Systems has significantly increased loading/unloading efficiency for the TIC Retail Accessories Group.
The TIC Group is a major international business providing retailers and vendors with a range of innovative and world class services to manage the movement of merchandise backwards through the supply chain.
Often referred to as ‘reverse logistics’, the types of goods that are brought back include high-volume, re-usable retail accessories such as coat hangers and security tags.
TIC Retail Accessories pioneered the concept of hanger re-use, which is now becoming increasingly accepted internationally, particularly by more enlightened retailers, because of the financial and environmental considerations.
In addition to the supply of new ‘virgin’ hangers to the UK market, in early 2009 TIC Group Europe Ltd began to handle returns of used hangers that are then sorted, reprocessed and fed back into the supply chain – thus reducing the need for new hanger manufacturing.
In order to solve the loading/unloading problem with a new used hanger processing contract, on behalf of a major retail customer whose vehicle fleet was moving over to double deck trailers, the TIC Group approached two loading bay equipment suppliers, including Easilift, to advise on the most suitable double deck solution.
Click here to see our 8 step double deck pod installation presentation.
Now increasingly being used for goods transportation, double deck trailers provide significant cost saving and environmental benefits – optimising operational flexibility, increasing load volumes, cutting unnecessary journeys and mileage and reducing fleet sizes. It is claimed that, typically, a fixed double deck trailer operating in a retail environment can carry around 70 per cent more goods than a conventional single deck version, achieving up to 40 per cent transport cost savings.
The subsequent decision by TIC to choose Easilift Loading System’s purpose-designed double deck scissor lift modular dock solution was clear cut.
TIC Group Operations Manager, Mark O’Sullivan, said: "Selecting Easilift for this project was made even easier for us by the very positive approach of their people – they were highly professional, demonstrating integrity, enthusiasm and a real interest in what we were trying to achieve; as well as portraying an in-depth industry knowledge, together with an extremely strong belief in their product.
"During meetings with Easilift Sales Director, David Whyatt, and his team we felt that they made a real effort to determine exactly the right solution that would benefit us most. Cost for us was not the only factor to be taken into account," Mark O’Sullivan continued.
"Like Easilift, we wanted to develop a long-term relationship built on trust and mutual respect. We quickly discovered that they have a similar up-front ethos to ourselves and knew that we could work together," added Mark O’Sullivan.
The third party processor selected by TIC to undertake the refurbished coat hanger contract had to be in a position to make the earliest possible start at their premises in Sheffield and therefore needed a very quick project completion from Easilift. Due to its modular construction, the double deck scissor lift dock pod solution developed by Easilift took less than two days to install – far exceeding customer expectations and ensuring that the hanger contract was able to start on time.
Quick and easy to erect, without disruption to the company’s on-going business operations, it did not require any major civil engineering work or building modifications. Easilift was one of the pioneers in the design and installation of dock pod systems and is therefore highly experienced with an established track record in this specialist area, having supplied dock pods in all shapes, sizes and finishes to many discerning “blue chip” customers over a number of years.
A dock pod is a complete stand-alone loading bay enclosure which can be installed directly onto the external face of a building. Typically fitted with a dock seal, dock leveller or scissor lift and a sectional insulated overhead door, they are suitable for new buildings, extensions and refurbishments. They can also be quickly and easily repositioned, if required, and are a highly cost-effective retrofit option for an existing building.
In today’s challenging economic climate dock pods are experiencing ever increasing popularity. They do not take up valuable internal warehousing space and maintain the loading/unloading function within a separate and distinctly confined area. With no cross traffic to worry about, this is a significant health and safety benefit. Their lightweight but exceptionally strong structure provides an insulated, weatherproof enclosure – with resulting energy-saving potential and enhanced working conditions for the internal environment, making them ideal for ambient and temperature controlled buildings such as cold stores.
The TIC dock pod is equipped with an Easilift Double Deck PowerLift 12 cage 6,000kg capacity scissor lift loading platform – suitable for use with double deck trailers, smaller vehicles with low body height or conventional single deck trailers. The solid steel scissor lift is manufactured to the highest quality and safety standards to achieve maximum rigidity and provide superior platform support and guidance.
Also fitted with an Easilift PowerShelter 403016 collapsible curtain type dock shelter forming a seal between the loading bay and the docked trailer, the pod features LED low energy dock lights incorporating movement sensors.
The new concept double deck scissor lift dock pod developed specifically for TIC was based on well-proven, tried and tested Easilift technology, with design, installation and subsequent on-site training carried out by the company’s highly experienced in-house team.
Mark O’Sullivan said: "We would not have been able to meet the specialised loading/unloading requirements of this particular new contract without the double deck lift and it should now provide us with a very strong competitive advantage for any similar future business opportunities.
"The Easilift team just got on with the job, whilst always keeping us fully in the picture at all stages - but, importantly, without demanding too much of our valuable time," added Mark O’Sullivan. "Our processing partner was also extremely pleased with the speed and efficiency of the short two day installation process, which did not impact in any way on their business operations and they were able to continue completely as normal whilst the work was being carried out.
"The new double deck scissor lift dock pod is the perfect solution to our needs and the staff are now confident and very happy using it following an extensive day's on-site training from Easilift. It means we can now service any vehicles and trailers in our customer’s fleet. I would therefore have no hesitation in recommending Easilift and using them for any future projects," concluded Mark O’Sullivan.
As one of the UK’s foremost loading bay equipment specialists, Easilift was one of the first in its sector to achieve the prestigious SAFEcontractor accreditation. SAFEcontractor is a scheme which independently assesses the health and safety record and competency of contractors and, as such, confirms to prospective customers that effective policies and systems are in place.
Easilift Sales Director, David Whyatt, said: "Our continued successful development is due in no small part to our extensive experience and industry knowledge, together with the positive commitment of our staff and extensive resources available, including an in-house design team, working alongside experienced engineers, able to advise on the most productive and cost-efficient installation – whether for a new build or refurbishment project.
"These facilities are complemented by a full installation and after-sales support service, which incorporates the provision of preventive maintenance programmes designed to ensure compliance with statutory obligations under UK and European legislation, as well as avoiding costly loading bay down-time," he added.
"We work in close collaboration with all our customers, enabling us to develop an in-depth appreciation of their business, its processes and procedures, so that we are then in an ideal position to develop individually tailored total loading bay solutions," David Whyatt concluded. "This approach is reflected in the extremely high levels of customer satisfaction achieved, resulting in a significant extent of repeat business, with more than 60 per cent of new orders coming from existing customers."
Easilift’s loading system keeps environmental impact to a minimum
Client: Tesco
Project Title: Middlesbrough DC
Project Description: A new 90,000m2 distribution centre incorporating loading bay equipment designed, manufactured and installed by Easilift Loading Systems Ltd and the Loading Systems Group. The scheme comprised 76no “PoweRamp” dock levellers and 15no Double Deck Scissor Lifts all housed externally within Modular Loading Pods designed to support the “PowerDoor” Insulated Sectional Overhead Doors and “PowerShelters”.
Main Contractor: Bowmer & Kirkland Ltd
The new Tesco Distribution Centre in Teesport has achieved an exceptional level of air tightness. Built by Bowmer & Kirkland, test reports show that the building scored air permeability results of 0.41m3/(h.m2) and an air leakage index of 0.693/(h.m2) setting a new standard for already stringent Tesco targets.
Early in the design phase initial concerns were raised by the project team in respect of the scissor lift pods and the fact that the sectional overhead doors which, when closed separated the loading pod from the building had been omitted from the scheme. As a result, the loading pod became an integral part of the building envelope and a potential weakness in respect of air permeability.
In short, the loading pods would be subjected to the same stringent test procedures as the main building and by extension a potential cause of failure for the whole project.
Accepting the challenge, Easilift worked closely with the Main Contractor and the Project Team throughout the design and construction phase to identify and eradicate suspected areas. The full test results which were carried out by BSRIA revealed an exceptionally air tight building. Duncan Robertson at Tesco explains:
“Easilift has been a strategic supplier for many years, we are very happy with the performance of Easilift and their willingness to work with us to deliver bespoke solutions. The increased performance of the Easilift pods raises the bar and sets the benchmark for all future installations”
David Whyatt, Sales Director for Easilift adds:
“Our loading pods and sectional overhead doors are market leading products. To meet our client’s expectations on this particular project confirms not only the quality of these products but also our ability to deliver a cost effective workable solution which has helped reduce the environmental impact to a minimum.”
Gazeley Choose Easilift for G-Park Sittingbourne
Morrison's has opened a 920,000ft² warehouse and distribution centre in Sittingbourne, Kent. Located close to the M2, it will be used to supply the supermarket chain's expanding presence within the South-East.
The complex is split into two units and was built in conjunction with logistics distribution company Gazeley, which, under the terms of the sale, completed construction in 42 weeks.
The building has been designed to contribute to Morrison's sustainability objectives; and it aims to deliver 585,830kg of carbon dioxide savings through a range of eco-friendly technologies, including solar heating, a grey water system, vertical wind turbines and efficient lighting control systems.
Easilift Loading Systems provided a total of 111 loading bays to the two buildings, with 100 bays designed to accommodate traditional vehicles to both goods in and goods out operations and a further 11 bays designed to accommodate Morrison's new fleet of double deck vehicles by utilising Easilift's 403E collapsible dock shelter which is complete with a secondary roller blind system designed to provide total vehicle range flexibility.
James Brook, Development Surveyor at Morrison's, comments:
"This major new facility will enable us to better service our growing business. As one of the UK's top four supermarket chains it is important that we continually develop our infrastructure to enable us to continue to deliver exceptional service to our customers.
We selected this site primarily because of its strategic location and close links to the South East motorway network but also because of the unbeatable environmental credentials which Gazeley has been able to offer".
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