Case Study - Fibercill, Dudley.

Company Overview

Based in Dudley, West Midlands, Fibercill has established itself as a significant player in the door systems manufacturing industry. Operating from their facility at The Moorings, the company has built a reputation for innovation and quality in the production of door kits and engineered solutions. As part of the Masonite group, Fibercill represents a crucial component of one of the industry’s leading manufacturing networks.

The Challenge

In keeping with their commitment to sustainable operations and operational efficiency, Fibercill faced the challenge of modernising their materials handling fleet. The company’s existing diesel-powered Baumann sideloaders, whilst reliable workhorses, no longer aligned with their environmental goals and increasing operational demands.

The Solution: Baumann EGX 60 Electric Sideloaders

After careful consideration, Fibercill made the strategic decision to invest in a fleet of Baumann EGX 60 electric sideloaders. This transition represents a significant step forward in their commitment to sustainable operations and workplace efficiency.

Implementation Impact

The introduction of the EGX 60 fleet has already begun to show positive results across multiple areas of Fibercill’s operations:

1. Workplace Environment

• Improved air quality in indoor operating areas

• Reduced noise levels, enhancing communication and worker comfort

• Better operator visibility and control

2. Operational Efficiency

• Enhanced manoeuvrability in tight spaces

• Improved precision in load handling

• Reduced downtime for maintenance

3. Environmental Metrics

• Significant reduction in carbon emissions

• Lower overall environmental impact

• Alignment with corporate sustainability goals

Key Features and Benefits

The new Baumann EGX 60 electric sideloaders offer several advantages over their diesel predecessors:

1. Environmental Impact

• Zero direct emissions during operation

• Significantly reduced noise pollution

• Lower carbon footprint across the operational lifecycle

2. Operational Excellence

• Advanced hydrostatic transmission system

• Automatic deck levelling capability for enhanced load stability

• Superior visibility for operators

• Heavy-duty components designed for demanding applications

3. Cost Efficiency

• Reduced maintenance requirements

• Lower operating costs compared to diesel alternatives

• Decreased energy consumption

• Extended service intervals

Enhanced Safety Features

The safety of operators and pedestrians was a paramount consideration in Fibercill’s transition to the new electric fleet. Working with Forkway, Fibercill have implemented a comprehensive suite of safety technologies:

Blue Pedestrian Awareness Lights

These specialised LED lights project a bright blue beam onto the floor several feet ahead and behind each vehicle, providing an early warning system for pedestrians. The blue spot technology is particularly effective in:

• Alerting pedestrians to approaching vehicles at blind corners
• Providing clear visual warnings when vehicles are entering or exiting trailers
• Enhancing visibility in dimly lit areas of the facility.

SEEN Safety System

The SEEN Safety pedestrian detection system provides an additional layer of protection through:

• Advanced proximity detection that reliably identifies high-visibility safety vests
• Audible alerts when personnel enter high-risk zones around the vehicles
• Real-time warning systems for operators
• Simple, low-maintenance operation that ensures consistent protection

FTC Optafleet Integration

The implementation of FTC’s Optafleet system brings advanced fleet management capabilities:

• Real-time monitoring of vehicle movements and operator behaviour

• Comprehensive driver license management and automatic expiry tracking

• Streamlined pre-use safety checks

• Enhanced warehouse efficiency through GPS tracking

• Detailed performance analytics for ongoing optimisation

Looking Forward

Fibercill’s investment in the Baumann EGX 60 electric sideloader fleet represents more than just an equipment upgrade – it’s a statement of their commitment to sustainable manufacturing practices and operational excellence. This transition serves as a model for other manufacturers seeking to strike a balance between productivity and environmental responsibility. The success of this implementation demonstrates that sustainable solutions can deliver both environmental and operational benefits without compromising on performance or reliability. As Fibercill continues to grow and evolve, their new electric sideloader fleet positions them well for the future of manufacturing.