Andrea True’s disco song “More, More, More” details a person professing their love and wanting to give more as she harmonizes, “More, more, more/How do you like it? How do you like it?” In beverage warehouses, adding more, more, more beverages is shaping how facility managers navigate a growing portfolio within fixed space.

Stu Jacover, general manager of national accounts at Mitsubishi Logisnext, Houston, explains that this growth has shaped lift trucks operations as they accommodate this growth.

“A significant impact has been with the SKU explosion with so many specialty beverages and creative packaging,” he says. “The additional SKU have impacted how pallets are stored and have included slotting products above the bottom bay in rack. This results in utilizing low-level order pickers to compliment traditional order pickers and reach trucks that can store pallets up to 400-plus.”

Christopher Grote, general manager of product management at Crown Equipment Corp., New Bremen, Ohio, also sees the effects SKU proliferation is having on lift trucks as well as eCommerce habits.

“eCommerce and wholesale locations are handling more bulk product skids and experiencing continued SKU proliferation,” Grote says. “This means that the beverage industry needs to accommodate more SKUs and higher throughput demand all within the same footprint, requiring beverage suppliers to look for new and scalable solutions. This trend is causing a shift in the beverage industry toward a variety of solutions designed to handle more SKUs within a limited footprint.”

To support these trends and more, forklift manufacturers continue to invest in software and additional capabilities.

“Object detection is an emerging operator-assist feature, and companies are trying to identify which system works best for their operation and operator network,” Grote explains. “Features such as Crown’s ProximityAssist System, can provide beverage operations with added support in the effort to reduce incidents involving product, facility, or lift truck damage.  

“Crown’s ProximityAssist System is a LiDAR-based, integrated operator assist technology designed to aid operators in the operation of material handling equipment,” he continues. “When it detects an object in the vehicle’s expected path of travel, it automatically slows the forklift. The operator maintains complete control of the forklift to respond to the object in the forklift’s path. Lift trucks equipped with Crown’s InfoLink 7-inch Touch Display or the Gena operating system’s 7-inch touchscreen will also provide visual and audible alerts when an object is detected.”

Mitsubishi Logisnext’s Jacover explains that the company uses technology as a differentiator on its forklifts.

“Our Warehouse Navigation option found on our turret trucks and order pickers provides customers with operational efficiency by directing the user to take the most productive path to the desired product every time,” he says.

Labor support

Beyond the advancements, when it comes to lift trucks, it circles back to how best to support the personnel operating this equipment.

“First and foremost, the key to safe lift truck operation is attentive operators who follow their training,” Crown Equipment’s Grote says. “Consequently, training is the core of forklift safety programs and is fundamental to building a strong safety culture. Additionally, Telematics systems like Crown’s InfoLink operator and fleet management system, can play a vital role in enhancing safety by providing insight with respect to equipment performance, operator behavior, and safety procedures.

“Managers are continually looking for technologies that can enhance operators’ training and confidence levels to help ensure productivity goals are safely and efficiently achieved,” he continues. “Object detection systems, and active warning and passive systems are continuing to draw interest. However, it is important to remember that these technologies can only take you so far. They do not replace training and a constant awareness of the surrounding environment by pedestrians and lift truck operators.”

Mitsubishi Logisnext’s Jacover also highlights the investments that the company has made within its portfolio to support a safe working environment with lift trucks.

“Curb Control is an example of one such option that automatically adjust the truck speed when corning depending on the load and steering angle,” he says. “Additionally, Lidar and Zone Control provide superior detection of objects, pedestrians, and other forklifts significantly lower the risk of injuries and property damage. These technologies are integral part of our overall strategy for operating a safe and efficient warehouse operation.”

Although safety is a top priority for forklifts, manufacturers also understand that operators need comfort support when operating this machinery.

“At MLA along with our strategic partners we have made a significant investment focusing on ergonomics and providing best in class solutions to ensure our forklift users can maintain a high level of productivity throughout their shift,” Jacover says.

When it comes to ergonomics, Crown Equipment’s Grote explains that it’s “about designing a vehicle that supports how operators work rather than forcing operators to adapt their work habits to the vehicle’s design.”

“The more operators have to compensate for inadequate design, the more they are likely to experience unnecessary fatigue, which can ultimately lead to an increased risk of accidents,” he says. “An ergonomically friendly lift truck can help increase operator comfort, reducing physical strain and increasing productivity.

“For example, for electric sit-down counterbalance lift trucks, the operator compartment should be designed to avoid excessive reach or lean with pedal placement, allowing the operator to pivot between foot controls easily,” Grote continues. “All contact areas, including armrests, floor mats, and seats, should provide the support required to counter stresses confronted throughout a shift. Greater visibility is also key, giving the operator confidence with their moves and helping them stay productive in a fast-paced environment.”

As lift truck manufacturers invest in advancements to address safety and work comfort, suppliers do recognize it comes as warehouses are dealing with labor retention and recruitment challenges.

“Coming out of Covid, labor has become a critical challenge for many warehouse operators to address,” Mitsubishi Logisnext’s Jacover says. “With significant shortage in the labor market we have seen a rapid rise in our customers looking for semi and fully automated solutions to run their distribution centers. These products enable our customers to level the playing field with a less tenured workforce while maintaining a high level of productivity.”

Crown Equipment’s Grote notes that operator training and safety are key components of employee turnover, prompting interest in automation solutions.

“Companies are also identifying areas of the operation that align with automation capabilities (typically transport) due to workforce challenges,” he says. “Retaining experienced operators is a priority for many employers. Companies are looking for lift trucks with features that prioritize safety, efficiency, ergonomics, and productivity to support operator retention.

“Operators today are more involved in the purchasing process as warehouses have realized that the ‘buy-in’ from the operators contributes to the long-term success of their operation,” Grote continues. “Some employers also see automation as a way to reduce their dependency on what can at times be a challenging hiring market.”

Despite this challenge, lift trucks and operators remain a vital part of a successful beverage warehouse, and original equipment manufacturers are working to ensure the next generation of equipment is designed for success.