Floor it without polluting
June 1st 2007

A move to LPG lift trucks featuring Nissan's exclusive Tri-Cat low emissions system is delivering materials handling savings for a major UK manufacturer of raised access flooring

Kingspan in Hull is one of the world's largest producers of the systems used to raise floors in office buildings for the installation of cabled services.

A typical system comprises floor pedestals supporting chipboard panels that are encased in galvanised steel. With three lines at the Burma Drive site turning out over 150,000 finished panels every week, the pace of production means the materials handling requirement is intense.

Fifty lorryloads of high density chipboard in 2.4 x 1.8m panels are received each week, together with palletised drums of adhesive and 50 tonnes of steel coils.

Operating on a just-in-time basis, and with temporary storage at goods inwards limited to just half a day's stock, Kingspan needed lift trucks to work in an efficient and environmentally friendly manner – both inside and out.

"The previous fleet comprised 7.0 tonne diesel and 3.0 tonne gas trucks," explains purchasing manager, Graeme Craggs. "The diesel trucks weren't ideal for inside working and because the gas trucks were operating from bottles, there was considerable downtime when changing over." With a rapidly expanding business, Kingspan's criteria were for a new lift truck fleet that was solely gas-powered – even up to 7.0 tonne capacity – and for bulk gas storage to contribute to maximum uptime.

First of the new trucks to enter service were two 7.0 tonne Nissan FX models, specified to offload chipboard panels and transfer them two packs at a time in loads weighing six tonnes through storage and on to the automatic cutting lines.

Trucks with solid tyres were essential because of the need to maintain stable loads and to avoid punctures. "With those requirements, it's not always easy to find a truck that's comfortable at the same time," says Craggs. "We involved our operators at every stage of the selection procedure and the feedback about the Nissan trucks was very positive." Second stage of the replacement programme at Kingspan involved the acquisition of eight 3.0 tonne gas trucks to remove finished product from the line, transfer it into storage and then on to transport.

Once the decision to run an all-LP gas fleet was taken, Nissan's DX models fitted with Tri-Cat engine management systems as standard were the "the only choice," according to Craggs.

The system is an advanced combination of three-way catalytic converter and computerised technology which reduces harmful exhaust emissions by up to 98 per cent and guarantees maximum fuel economy.

Believed to be the only lift truck installation of its type with a catalyst which addresses all three of the toxic substances produced when LP gas is burnt, it reduces carbon monoxide by 91%, hydrocarbons by 96% and oxides of nitrogen by 98%.

A further feature of the Tri-Cat is to provide optimum fuel economy through constant engine management. Electronic sensors continually monitor engine output, controlling and supplying just the right airto- fuel ratio for the truck's operational requirements.

Regardless of the composition of the LPG fuel, environmental conditions and the condition of the engine, the system always provides optimal combustion.

As well as ensuring minimum gas pollution and maximum fuel economy, the 'closed loop' air fuel ratio control helps to minimise maintenance.

Conscious of the need for greatest operator comfort and consequently higher levels of productivity, Nissan's 'floating cab' delivers further advantage at Kingspan: The design isolates the operator's compartment from the truck's chassis to minimise vibration.

Installation of a bulk LP gas storage facility has driven down materials handling costs at the site even further. "Not only have we seen major savings simply by moving to bulk storage, we no longer have downtime through operators constantly having to change gas bottles," says Cragg.

The new lift truck fleet at Kingspan Access Floors is supplied on contract hire with maintenance by Nissan's exclusive network location for the area, Malcolm West-Nissan. With shift requirements often extending to 24-hour working, the programme has been specially tailored to allow for earlier replacement of the most heavily used trucks.

As of June this year, the enhanced Tri- Cat system is rolling out as standard across the entire Nissan LP gas range.

More details next issue.

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