AISLE-MASTER UP THE SPACE AND PACE FOR CASTLECOOL

The delivery of a gas-powered Aisle-Master articulated forklift truck to integrated logistics provider Castlecool has enabled the company to maximise the storage density at its new warehouse complex in Dundalk.

Established in 1994 Castlecool whose head office is located in Castleblayney, Co. Monaghan have quickly become one of the countries leading 3rd party logistics and storage companies. Their range of services now includes fully automated cold stores to dry goods warehousing, including order picking, packing and distribution services.

With customer requirements ranging from one individual boxed article to 20,000 units per month, selective racking seemed to be the best solution on a number of accounts. “We calculated that it would free up space, and make location and picking of goods quicker and easier”, says Managing Director Paul Short.
Paul’s priority was to maximise the usable storage space in the new 22,000sq ft warehouse and ensure continuous movement of goods within the two shift pattern, therefore finding a very specific forklift around which they could establish the racking, was essential.

Having traditionally used a combination of reach and counterbalance trucks due to the need to work inside and outdoors when loading trucks; Castlecool were impressed with the flexibility offered by the LPG powered Aisle-Master. Lengthy battery charging has been eliminated and a bulk gas tank situated on site means that operators are never more than a few minutes refuelling.

By reducing aisle widths down to 2.2m, and racking up to top beam height of 8.5m the warehouse is operating at maximum capacity. An increase of 25% verses reach trucks (3.0m aisles) and 50% compared to counterbalance trucks means the Aisle-Master will pay for itself very quickly.

Another major benefit over reach or VNA (Very Narrow Aisle) forklifts is versatility. The Aisle-Master can operate both inside and out; offloading incoming trucks and taking deliveries directly to the racking, and vice versa. The articulated design and cushioned tyred wheels fitted to the Aisle-Master mean that gradients and uneven surfaces around the site are no obstacle to efficient operations, “a truck for all seasons” as Operations Manager Kevin McCusker puts it.

The problems often associated with the implementation of a completely new system were thankfully not encountered at Castlecool, and Kevin attributes the absence of any teething problems to the excellence of the product itself and Aisle-Master’s customer service: “ Not having used the Aisle-Master truck before, we put our faith in the reliability of the truck and a plus fact that it is manufactured locally in Clontibret, Co. Monaghan. Both have more than fulfilled expectations, enabling streamlined operations from day one. Aisle-Master provided us with a number of rack layout proposals which made our decision much easier”.

The Aisle-Master is the first truck of its type on the market fitted with a three-way catalytic converter and “closed loop” air fuel ratio control, which reduces emissions by more than 95% - well below current regulations. The system provides greater fuel economy and minimises maintenance requirements.

Not only have Castlecool been able to store more products than originally envisaged but what was traditionally a reach and counterbalance truck operation is now being done by one Aisle-Master.

Ten years on Castlecool who are ISO and EU approved have a growing customer base, which includes Glanbia, Unilever and H.J. Heinz. Continuous investment in technology including Radio Frequency Systems and additional delivery vehicles, point to a healthy growth pattern.

Aisle-Master Sales Director Joe O’Brien says, “Despite the fact that we have trucks working worldwide it gives us great satisfaction to have an Aisle-Master truck being utilised in a state of the art distribution facility, locally. The truck is maintained on a contract hire basis by Aisle-Master who now have trucks working in a wide range of applications which includes Builders Providers, Engineering Companies, Stationary Suppliers, Cash & Carry’s, Beverage Distributors, Furniture Imorters and Logistics Companies.

For more information
Sales Director Joe O’Brien
Phone: +353 47 80400
Fax: +353 47 80402
Email: info@aisle-master.com
Web: www.aisle-master.com