Combilift’s expansion drive

Monaghan (Ireland)-based Combilift, which is recognised as one of the world’s most innovative companies when it comes to manufacturing equipment for the materials handling sector, continues to add new products to its portfolio.

The past year, which was its 25th year in operation, saw the launch of five products, including the Combi-LC Blade, Combi-CB70E, and Combi Connect telematics system. It was also a record year for the group with close to 9,400 machines delivered in 2023, up 5.8% on 2022’s output. Turnover of €500M was posted.

Martin McVicar, CEO of Combilift, expects another strong performance in 2024, citing a solid order book and improving trading conditions in two of its main export markets (UK and US). “We did see a softening in the UK market between September and December last year, but 2024 has seen a strong start with sales up 30% to the end of March.”

However, he is keen to expand sales in emerging markets with the company targeting countries such as Brazil and India, both of which he referred to as “substantial markets offering the company tremendous growth opportunities over the next five to ten years.” Overall, Combilift sells its products in 85 countries.

Offshore focus

While the Combi-LC Blade was developed jointly with Siemens Gamesa, a leading supplier of components for the offshore energy (wind) sector, McVicar stressed that sales of the machine were not restricted to Siemens Gamesa and that active discussions were taking place with other offshore wind companies. To date, eight or so machines have been built for use at sites in the UK, Denmark, France, and Taiwan, with Combilift expecting sales to exceed €50M a year by 2026.

The Combi-LC Blade has been designed to ensure that wind turbine blades and towers as large as 115m in length and 70t in weight can be transported safely and efficiently from their production sites to storage locations. The Combi-LC comprises two fully customisable remote-control units with low-level chassis beds that can work in tandem, master and slave operation.

In addition, the system encompasses a unique attachment that is designed to securely grip the cylindrical ends of the blades and ensures their stability during transport, and a tip-side carrier unit that manoeuvres beneath the blade and is supported by a hydraulic tilting table-mounted clamp. The design features 12 wheels, six of which are for multi-directional steering. It can travel at up to 14km/hr and has a range of about 5km.

According to McVicar, this year will see the group target additional industry sectors for its range of heavy-duty lifting machines. It also plans to allocate more space at its 46,000 m² manufacturing facility in Monaghan for the production of this type of equipment. Meanwhile, Combilift’s previous factory, which has mainly been used as a warehouse and storage facility since the company moved to its present premises in 2018, is to be used to refurbish and rebuild existing machines.

“The factory has a paint plant and we see it fitting into our thinking on the circular economy of rebuilding, reusing, and recycling as a means of keeping products and materials in service at their highest value for as long as possible.”

The group expects its engineers and research and development teams to be kept busy addressing bespoke solutions for various customers. Since its foundation in 1998, Combilift has gained a reputation as being one of the most innovative and customer-focused groups in the materials handling sector.

At the end of last year, following what the company referred to as a “comprehensive consultation, design, and delivery process,” Combilift supplied Melbourne-based FBT Transwest with a straddle carrier able to lift three containers high. It features eight wheels for greater stability while the cabin has larger windows for increased visibility and fingertip controls which make it easier to operate.

FBT had approached several companies to come up with a solution(s) that would allow it to optimise the use of its storage yard in Sydney while maintaining its high safety standards and improving its productivity levels. The facility handles a wide range of cargoes including dangerous goods, machinery, and perishable products.

“It was an easy choice in the end,” said Cameron Dunn, managing director of FBT. “It’s not all about the sale, it’s also about the partnership with Combilift and the quality they could provide. We were very impressed with their ethos and their commitment to safety, which primarily led to us choosing them.”

Jarad Wilson, Combilift’s Australia straddle carrier product manager, explained the process. “The key to developing a product in conjunction with the customer is understanding that customer’s functional requirements and their key concerns,” he said. “Then, it’s important to continue communicating with them through the process, so the end result considers the engineering constraints while still addressing the key functionality that the customer needs on-site.”

He added: “Our three-high straddle carrier epitomises the company’s dedication to its customers. Our philosophy is one of customer-driven innovation. It’s something that we’ve done for years and will continue to do. It’s why we have such an expansive range of equipment and solutions.”

Scott Major, FBT’s transport manager at the Sydney facility, said the new straddle carrier had “greatly increased storage capacity and speeded up the operation.” He added: “It’s a much faster and more stable unit than previously used and we’re finding that our turnaround times for trucks in and out of the depot have been greatly improved. By including eight wheels, the stability of the unit has made it a lot easier for the team to drive around.”

It is highly likely that FBT will place further orders with Combilift. “We see this as the machine of the future and we’re very proud to be the first site in the world to enjoy the three-high machine,” said Dunn.

Meanwhile, Combilift intends to work closely with FBT to see how the straddle carrier can be used to improve its operations and how refinements in the design might help this process. FBT operates storage and depot facilities in Melbourne, Newcastle, and Sydney.

Combi Connect

Of huge significance over the past 12 months has been the launch of Combilift’s telematics system, Combi Connect, a fleet management solution that provides operators with real-time information on key metrics, including a machine’s location and usage rates. It enables users to optimize their fuel, oil, and battery charging requirements while following more efficient predictive maintenance programs.

This helps companies streamline their components/parts supply chains, reduce inventory levels, and, most importantly, cut times needed for servicing and repairs. Moreover, by avoiding machine breakdowns, equipment is more productive and operations more reliable and productive.

McVicar explained that Combi Connect has been designed so that it can easily be integrated with other systems. It is also modular, with the type and number of sensors fitted and parts of the machine monitored determined by individual customers’ requirements.

Meanwhile, information captured from individual machines can be shared on request by any customer. Combilift believes its transparency on this front is an integral part of its ongoing relationship with its dealers and customers, while at the same time allowing any problems with equipment to be shared, mitigated against, and solutions promulgated.

He explained that about 300 pieces of equipment were installed with the Combi Connect system at the current time and that this would increase to 1,000-plus by the end of 2024.

Combi Safe

Ensuring its machines are operated safely is also of paramount importance to Combilift, hence its recent introduction of Combi Safe-Lift on its range of forklift trucks.

The anti-overload system incorporates a strain sensor on the mast section of the machine and a lift cut-out valve on the hydraulic line. It disables the machine’s lifting function, thus preventing operators from moving loads that are too heavy and might cause the machine to become unstable, potentially causing serious injury or even death to the driver and/or working colleagues.

An audible alarm warns the operator of an overload situation and a load moment indicator is fitted to the dashboard in the cab. An operator can immediately see from the green, amber, and red ‘traffic light’ signalling display when there is a risk of overloading or when the forks are not fully engaged, for example, and take appropriate action.

“We offer the Combi Safe-Lift as an option at the moment, but we believe that this simple and cost-effective system should become a standard option on all our counterbalance trucks in the future,” said McVicar. “Fitting a straightforward device such as the Combi Safe-Lift is an effective way to reduce risks for the operator and other personnel, and also to avoid product damage as well as costly repairs.”

He added: “At a time when many companies are finding it difficult to recruit experienced drivers, Combi Safe-Lift removes all guesswork by the driver and makes the operation safer. If the forks are not fully engaged or the load is too heavy, an immediate warning is sounded and the machine shuts down.”

Electric options

Like other manufacturers of cargo handling equipment, Combilift has seen an increasing demand for electric versions of its machines, and it has responded accordingly. Currently, approximately 70% of the company’s production comprises battery-powered units, while a massive 98% or so of its research and development resources are currently focused on this sector of its production.

“As a company, we’re inherently focused on sustainable solutions,” he said. “We’re focused on making vehicles that are more environmentally friendly to use, as well as vehicles that enable our customers to make their warehouse utilization more environmentally friendly.”

McVicar added: “The increased capacities that we are offering in our electric range will answer the demand for ever more powerful products, while at the same time helping companies to achieve their aims for more sustainable operations.”

Currently, its electric machines are installed with lead-acid batteries, whereas the industry as a whole appears to be moving towards the use of lithium-ion units, which have higher energy ratings and generally allow operators longer operating periods between charges.

McVicar explained: “Lead-acid batteries are highly reliable and of utmost importance to us as they are 98% recyclable, which is good for the environment. This is not the case with lithium-ion batteries, which present many challenges when it comes to recycling. Given that most lithium-ion batteries are sold on seven-to-eight-year warranties, which is not that long in the future and with no sustainable recycling solutions in place for lithium-ion batteries, we are concerned about what will happen to those batteries when decommissioned. But all of our electric machines are lithium-ion ready and can easily be converted from lead-acid units once a solution is found.”

McVicar exudes confidence about the future. “We have produced a total of 80,000 machines over our history with almost 10,000 of these units delivered in 2023,” he said. “Our aim is to double these numbers every five years, which means by 2028 we are expecting to be building 20,000 units per annum. We also plan to increase our investments to make our business more efficient and more sustainable.”