Category: Invicta

Board24 manufacture corrugated sheetboard for a host of customers in a variety of specifications.

The emphasis on quality presents a number of logistics challenges for the large palletised loads.

With over 20 years’ manufacturing experience, the company makes the raw materials for its packaging and box company customers, from  100% recyclable, 100% biodegradable and 90% recycled or recovered paper.

Fifteen years ago, when corrugated services manager, Lee Bullen, was beginning his career at Board24 in Preston, he felt the attention to detail was a little extreme…

“Since the day I started here the forklift truck drivers have always been under pressure to make sure the board is in perfect condition,” says Lee.

“As a forklift truck operator I thought this was an impossible goal, lifting board with a forklift surely there are always going to be marks. However the management team were persistently setting very high standards for the business. Now, many years later, I’m running the department and we really do get the importance of striving for perfection.”

“We set high standards in terms of our product quality and environmentally friendly approach,” adds production manager, Andy Bridges. “We pride ourselves on an efficient, flexible service, helping our customers to meet deadlines and get the best specification possible.”

Towards the end of 2015, Board24 invested in excess of £7.5m in a new corrugator. The development of the site was in response to ever-increasing customer demand for Board24’s corrugated sheetboard, and a desire to improve productivity and use resources more efficiently. The following year the company received a commendation at the UK Packaging Awards 2016 for its Plant Investment.

Yet, when large sheetboards are stacked on overhanging pallets, and combined with the pressures of the 24/5 site, moving 2,500 packs in a typical day – enough for up to 60 wagon loads- that investment could be undermined were the stock to be damaged and customer feedback turn negative.

It’s more than just good practice – there is a reputation to maintain. “Our quality is known,” says Lee, “and damage to the product is unacceptable. That naturally meant that we were always trying to reduce wastage. The levels may be low, but we see it as vitally important that we deliver in a pristine condition.”

This, despite the fact that large cardboard loads inevitably come into contact with the forklift’s load guard. “We are discerning, with our own high standards, and this solution is very effective. If you took delivery of a new car and it was dirty, you wouldn’t like it! There’s nothing wrong with the car, but it’s just not right.”

For the past few years, Lee’s team wrestled with the problem. One fix was pipe insulation taped to the forklift load guard, but it wasn’t ideal. Not only would it wear quickly, but as team leader, John, comments “it’s time consuming and not a long-term solution.” One operator searched for a better option and came across Invicta’s load protection range. Invicta then carried out a site survey to determine the most appropriate product from the range.

The magnetically attached IDSA shock absorbers with pliable bristles are designed to cushion the impact of a load coming into contact with the fork uprights. The soft, fibrous co-polymer bristles spread the load impact and gently prevent damage to all manner of goods. A trial run soon demonstrated that the IDSA could be the perfect solution.

“The board was getting damaged – now it isn’t. It’s improved, full stop. Our previous efforts just didn’t work anywhere near as good in protecting the packs.” The pallets are also double handled, once to load or unload and once to store in the warehouse, so there is a lot of opportunity for damage. There are also 18 operators, but the solution is so simple and the results so good that not a single complaint has been raised about using them. Quite the opposite, they see the benefit. “It makes them look like better drivers,” says a smiling John.

For Invicta, the return on investment was never in doubt. Preventing damage to a single pallet every month is more than enough for many to justify their investment. Once Lee reached the point where he knew the kit had more than paid for itself, he stopped counting.

“In the first two months we’ve seen a tenfold improvement. We have massively reduced our damage costs. It’s a very low cost in any case, a small investment, for a big return. A marked improvement and a no-brainer… an unmarked improvement,” quips Lee. But the true measure is beyond mere cost-saving.

“We think the product looks better. The presentation of what we do is everything. The biggest gain is not the reduction in cost but the 99.9% improvement in presentation. It just looks better and customers tell us their operators love our board. Its general flatness and neatness – it makes their jobs easier.”

Invicta Forks & Attachments has recently revealed a new fork-mounted tipping skip in an effort to reduce the risk of accidents on site while improving productivity.

With the introduction of the Auto-Lok Tipping Skip, Invicta, the largest manufacturer of mechanical fork attachments in the UK, offers its construction customers a safer and more convenient tipping process.

Fully automatic engagement allows operators to stay in the comfort and safety of their cab for the whole duration of the tipping skip’s use. Just driving into the fork pockets and picking up the skip will see it ready to tip, while the automatic locking mechanism ensures the attachment stays in place during operation.

The high-quality water tight body and reinforced loading edge means the skip is suitable for the safe and simple tipping of all types of materials. The chassis provides four-way entry pockets to allow the skip to be positioned from all four sides, and two easily replaceable tensions springs means maintenance costs are kept to a minimum.

“Our new Auto-Lok tipping skip brings safety and simplicity to a whole new level,” says Peter Sharpe, managing director at Invicta. “We’ve designed the automatic locking mechanism to eliminate the need to get out of the cab. Our customers have immediately noticed the difference in the speed and safety of operation, allowing operators to get on with their work and not exit the cab, which is the safest place for them.”

The introduction of the Auto-Lok Tipping Skip comes after Invicta revealed their Auto Tipping Skip for the industrial market last year, in recognition of a safety hazard on standard tipping skips, which often saw operators standing on mud guards or climbing the side of the yard skip to reach the release mechanism.

“At its inception over a decade ago, the auto-tipping mechanism was a specific model, and welded in place,” Peter adds. “Today, as manufacturing procedures have developed and customers have seen the value of the feature, we are able to bolt it on to our standard skip range. It means our industrial customers can still add it at a later date, even if they currently don’t have the need for the high-level tipping function.”

Peter concludes: “Here at Invicta, we have a proven track record for providing solutions for both the construction and industrial markets, and I’m pleased we are able to achieve the same outcome of keeping operators safe without compromising efficiency for both trades.”

For further information on the Auto-Lok Tipping Skip, head to the product page or contact Invicta today to find out about the huge range of bespoke materials handling solutions your business could benefit from.

Businesses looking to take advantage of commercial waste incentive programmes may be creating conditions that endanger their employees, according to leading forks and attachment specialists, Invicta.

The use of roll-on roll-off skips, up to 36.5 metres in length and 2.5 metres high, means operators are routinely working at height in unsafe conditions, increasing the risk of falls.

Invicta managing director, Peter Sharpe, explains: “Most skips carried by forklifts require a forward tipping action to unload, but the height and design of these super-sized skips often sees operators standing on mud guards or climbing the side of the yard skip to reach the release mechanism.”

Invicta has been involved in the manufacture and supply of tipping skips for over 20 years and has developed various skip options, including a unique ‘4 way entry’ base, bottom emptying skip and was the first to design and manufacture an auto-tipping version.

The unique mechanism ‘unlocks’ the tipping action when the base is lowered to the edge of the receiving skip, with a secondary locking mechanism to prevent accidental discharge. A combination of gravity and truck movement returns the attachment to its original position.

“We’ve designed the auto-tip mechanism to eliminate the need to get out of the cab,” adds Peter. “Operators have immediately seen its potential, allowing them to get on with their work and not exit the cab, which the safest place for them. The option is now a standard feature on our tipping skip range. Manual release mechanisms will always be required, but the option of the auto-tip function improves efficiency as well as adding safety.”

Now the auto-tip function is available as a bolt-on item to the standard tipping skip, allowing customers to upgrade as their business grows.

Says Peter: “At its inception a decade ago, the auto-tipping mechanism was a specific model, and welded in place. Today, as manufacturing procedures have developed and customers have seen the value of the feature, we are able to bolt it on to our standard skip range. It means customers can still add it at a later date, even if they currently don’t have the need for the high level tipping function.”

Businesses committed to maximising recycling and minimising landfill have increased in numbers in recent years, with various providers offering comprehensive collection and recycling services to all types of industry groups and businesses throughout the UK.

Whilst the move towards a ‘zero waste economy’ has been generally welcomed by the government, injuries from falls are an increasing concern.

In June 2015, a Chichester company specialising in the recycling of waste plastic was fined £1,500 and ordered to pay costs of £1,043 following a worker’s fall of 2.5 metres from the top of a large roll on roll-off waste skip while manually tipping out non-recyclable waste plastic from a tonne bulk bag.

The company was found breach in of Section 3(1) of Management of Health & Safety at Work Regulations 1999 and Section 6 (3) of Work at Height Regulations 2005

HSE Inspector Suzanne Matthews said: “Had the company carried out a proper risk assessment of the work, they would have identified both the foreseeable work at height risk involved and how that risk could have been avoided by choosing a system of work which eliminated the need for employees to work at height altogether.”

Invicta Forks and Attachments is the largest manufacturer of mechanical fork attachments in the UK, stocking many product lines from tipping skips and work platforms through to lifting jibs and drum handling equipment. The new auto-tipping skip is now available from stock. For more information visit www.invicta-attachments.co.uk