Lift Truck Tips: Linking equipment, operators and business objectives

Lift truck attachments like clamps, paper roll handlers and layer pickers come with a lot of strings…well, attached. A precise marriage between the attachment’s hydraulic system and the lift truck is not guaranteed. Operator training might cover the proper operation of the lift truck, but often lacks detailed instruction on the attachment and how much hydraulic flow it needs to work efficiently. Too much flow from the truck can result in overheating, excess fuel consumption and reduced longevity for both pieces of equipment. As product presentation becomes increasingly important, even a small crimp or smear of lubricant can require repackaging.

The challenges increase when an application requires clamping, when the operator must think about how much force to apply to the load so it doesn’t drop or squeeze and damage the product. Clamping scrap bales of cardboard doesn’t have to be as precise as clamping six big screen TVs. The fundamental need to carefully pair the right tool with the right job remains a challenge for many users of lift truck attachments. Keith Miller, director of sales for Cascade Corp., suggests that the right mix of technology and education can eliminate—not just reduce—unnecessary product and equipment damage.

“Reliability, uptime and damage mitigation are all tied together,” Miller says. “It’s important to ask a lot of questions about the specific application, like a physician, to assess the patient. Each customer has their own pain threshold, but it doesn’t have to get to that point.”
Applications that consistently handle one product all day might benefit from a simple mechanical solution, Miller says, like a single-setting pressure relief valve to prevent applying too much or too little clamp force. When there’s an emphasis on product appearance, a simple change to lubricant-free polyethylene bearings can help product stay clean and cut maintenance costs.

More complexity has resulted from the recent growth of layer-picking applications as stores ask DCs for more customized product mixes. Attachments like carton clamps can split off one or two layers as well as a larger cube of product as needed. To further simplify operation, Miller says some attachments feature sensors that automatically detect the size of the load and use a wireless power and communication system to apply appropriate clamp force.

Despite recent technological advances, Miller says one of the biggest remaining challenges is the learning curve for entry-level operators. “An inexperienced operator in a large, complex and powerful piece of equipment can create a lot of havoc,” he says. “It’s essential to educate them about load engagement, not just safe operation.”

Solutions using force control accessories can further enhance productivity by using preset parameters to determine the proper amount of pressure to produce a precise amount of clamp force for each load. Some solutions can even be preconfigured for the handling characteristics of hundreds of SKUs, with special allowances for packaging variations and whether product is stacked. Using these solutions, Miller says, it is possible to bring a new clamp operator up to speed within an hour.