Once material enters a recycling facility it may be moved a number of times. Forklifts fit the bill when it comes to moving and positioning the material. Whether used indoors or outside, forklifts can be an effective piece of equipment for recyclers.
Forklifts are almost ubiquitous in warehouse and materials handling settings. Small enough to be used at many of the smallest warehouses, yet often large enough to move some of the heaviest loads, this piece of equipment is one of the most popular pieces of equipment at many recycling facilities.
While forklifts provide a basic function, their applications vary at different types of facilities. A paper stock dealer may use a forklift to stack bales of paper and paperboard in a warehouse and then load up a box car or truck trailer with the bales.
A handler of scrap metal, especially in an external setting, may use a forklift, along with attachments, to pick up flattened automobiles and other inconsistent- sized loads, move drums or pallets of material, and load and unload material from varying heights.
Built to Last
For scrap processors handling thousands of pounds of recyclables, constantly larger forklifts are often required. These lifts, then, also would be more likely to be exposed to a harsher environment, including inclement weather; dirt covered surfaces and heavier material. Because of this, many forklifts geared to rough terrain may vary quite significantly from forklifts dedicated primarily to internal operations.
When a potential customer is shopping for a forklift the first step typically taken is determining whether the machine will be used exclusively in interior settings, a combination of outside and inside, or exclusively outside. Differences range from the weight capacity, tires used, wheel base, engine type and type of fuel used to operate the machine.
With such an inconsistent product as scrap being handled, one of the key factors when purchasing a forklift is the durability of the equipment. Being able to move the most material is an advantage, but as one scrap processor notes, if the equipment is broken nothing moves. To ensure the equipment meets the requirements of the harshest environments, both inside and outside, forklift manufacturers have taken significant steps to build equipment that will not only produce on a regular basis, but also will last.
Durability is the goal with Daewoo’s recent introduction of its G5 Series lift truck. The new line has load carrying capacities of 4,000 to 6,000 pounds. They are available with diesel, gas or liquid propane engines. Further, the engine has seen design improvements that have increased power while reducing noise and fuel consumption.
Covered with Steel
A key for forklifts designed for exterior use is having the undercarriage covered with steel. Covering the bottom of the forklift is especially important at a scrap yard, where loose pieces of metal could puncture essential engine parts, causing damage. Typically, most, if not all forklifts, are made from heavy-duty steel, which holds up better in a harsh environment.
Along with the heavy metal construction, the equipment used has a number of designs, which improves the operations of the equipment in both exterior and interior settings.
Capacity Differences
One of the biggest differences is in the general capacity levels both classes may hold. Interior forklifts can handle several thousand pounds of material in a standard pickup maneuver. Forklifts designed for exterior operations can handle up to 100,000 pounds, and for many recycling companies they are used to do everything from moving flattened automobiles to picking up palletized loads of baled scrap. For most scrap processors, rough terrain forklifts used typically lift loads from 5,000 pounds to 11,000 pounds.
The weight capacity of forklifts varies significantly. One reason is that forklifts are the generic workhorse in the materials handling industry. Also, because of the basic concept behind forklifts, industries ranging from defense operations to grocery store operations use forklifts to load and unload material. That wide range of industries and applications is why forklifts’ weight limits can range from several thousand pounds up to around 100,000 pounds, according to Mark Rossler, with Linde-Baker Material Handling Corp., a manufacturer headquartered in Summerville, S.C.
In the recycling industry, a number of scrap metal recyclers note that their standard forklifts move around 6,000 pounds at a time. Rossler says that in a recycling facility the common capacity is between 6,000 and 10,000 pounds. However, some recyclers use forklifts that far exceed this weight classification.
Safety First
Designing a forklift with maximum safety features is one of the biggest keys for manufacturers. Safety features being installed in forklifts run the gamut, from improved interior designs to exterior devices that reduce damage to the machine. Because forklifts often are being used in environments where thousands of pounds of material are being handled, the need to avoid an accident makes designing and building a safer forklift that much more important.
Equipment that is designed for safety goes hand-in-hand with operator safety standards that are issued by the Occupational Safety and Health Administration (OSHA). The federal administration is publishing modifications in industrial truck safety standards that have been three years in the making. Mandated training programs for operators of forklifts and similar equipment is the aim of the revised OSHA safety standards. The agency is also in favor of periodic evaluations of forklift drivers, with remedial training offered to drivers demonstrating skill deficiencies. A range of national and regional educational organizations are offering courses designed to comply with the revised OSHA standards.
But even the most experienced driver can best be helped by equipment that is designed to help prevent mishaps and help protect in the event of a safety incident.
John Zamora, chief instructor in the training department for Clark Material Handling Co., a Lexington, Ky. manufacturer of forklifts, notes their company has a winged seat on the forklift as well as putting two brackets on either side.
Other companies also mention features that add to the overall safety of the equipment. For Komatsu, it includes a hard overhead guard, hand grips on both sides of the compartment, slip resistance floorboard and low back rests. Steps taken to improve the ergonomics of many forklifts include tilt steering wheels, more room in the operator compartment and greater visibility in the front.
Dave Helmstetter, with Crown Equipment Corp., headquartered in New Bremen, Ohio, stresses that the forklifts manufactured by Crown are all ergonomically designed to provide a proper working environment for the operator. Further, the company manufactures almost 90% of the product itself, which allows the company to keep the quality control in house. Helmstetter notes that the company’s 5000 series allows the operator to sit, lean or stand while operating the machinery.
Schaeff Inc., Sioux City, Iowa, has implemented a host of features that improve the safety aspect of their forklifts. These include positioning the brake pedal to eliminate inadvertently placing both feet on the brake. The Warehousing Series forklifts also have an optional right foot detect floor switch that will stop the forklift if both the operator’s feet are not in the compartment.
Les Williams, director of communications for Clark Material Handling, notes that in addition to his company being one of the first to have a safety belt installed in forklifts, Clark makes its forklifts with vertical wings on the side that restrain the driver in case the lift tips over.
An example of the safety of the Clark forklifts came in a real life incident when an operator in a Clark forklift fell more than 100 feet and was buried under concrete and steel. However, the operator survived the accident with only modest injuries due to the safety wings and seat belt that kept him in the protective cage.
Forklifts designed for interior use have another concern: fibrous debris that could be ignited by heated, exposed engine parts. To prevent this, a number of forklift manufacturers have built-in screens and other devices to reduce the possibility of fires. Interior settings also have a greater amount of floating particulates in the air that can ignite. To reduce these possibilities, many forklifts designed for interior use have devices to screen out the problem materials.
In fact, most forklift manufacturers point out that with the amount of time operators spend in the lifts, it is imperative that the trucks are more comfortable. This could include padded floors, a larger compartment and the ability to stand and sit during the workday.
Ergonomics and operator safety are not just buzzwords for a more enlightened workplace. Because many operators may operate the lifts for hours at a time, there is a greater need to reduce operator fatigue. And reducing operator fatigue lessens the chance of accidents in the workplace.
Many manufacturers note the importance of overhead covers designed to prevent falling debris from falling into the cab. Along with this, high visibility is essential, since operators may often be moving thousands of pounds at any one time.
For exterior use, forklifts are being designed to handle a much more rugged environment. For Clark, this includes having both single and two-speed transmission, depending on the type of surface being used. Zamora points out the single speed transmission is ideal when dealing with a flat surface. When a forklift has to go over rougher terrain a two-speed transmission is ideal.
A Mixed Bag
Which forklift features are of key importance for recyclers can be a mixed bag. For Eric Brown, Komatsu manager of training and dealer development, durability is one of the biggest factors. "Forklifts take an enormous beating," he says. And, with margins at recycling facilities razor thin, it is imperative for scrap companies to have their equipment running as much as possible. One service that Komatsu is promoting is the use of long term rentals of the forklifts, which allows the processor to use the maintenance staff to work on other equipment.
Linde-Baker’s Rossler echoes this statement. "The number one priority is durability. It has to last." With forklifts typically used in harsh environments, it is important for the machines to consistently deliver what is required.
A key for Linde-Baker is the hydrostatic drive system. Normally used for heavy machinery in off-road applications, "the drive system is the single most critical factor in the truck’s durability," says Rossler. The advantage of the hydrostatic drive is that it replaces high wear components that may break down and are prone to wear and tear, Rossler adds. One of the biggest selling points, he notes, is that with the hydrostatic drive system "You never have to do a brake job." The system uses ‘dynamic breaking,’ which uses fluids as a breaking mechanism, as opposed to pads or other methods to brake.
Choice of Power
A wide range of fuels and engine types powers forklifts. Electrically powered, liquid propane, diesel, natural gas and gasoline are all used to drive forklifts. The decision on which type to use depends to a large degree on the application in which the forklift will be used.
Electrically powered forklifts are typically found in enclosed settings. Two big advantages to the use of electric forklifts are the lack of emissions and the relative quiet of the lift’s operation. The electric-powered vehicles, according to several manufacturers, do not sacrifice weight capacity for reduced emissions. Another big advantage to electric forklifts is the relative inexpensive cost to run and maintain the equipment.
Several negatives for using electrically powered forklifts in an outdoor setting is the need to charge the battery for an extended period of time, which may incapacitate the machine for a period of time. Also, in an outdoors setting battery-powered engines may be trickier to operate during inclement weather.
Forklifts powered by propane are more flexible, and can be used in both indoor and outdoor settings. Natural gas as a fuel for forklifts is more limited, with some manufacturers saying only a small percentage of forklifts are powered by natural gas.
For exterior use the choices are more varied. Many forklifts geared to rough terrain have diesel engines. According to Komatsu’s Brown, diesel engines are more rugged and sturdy. The advantage is partly offset by a diesel forklift’s "balky" operation in cold weather. "Diesel engines also are more expensive to fix than other engines," Brown adds. However, diesel fuel is much less expensive than other forms of fuel.
Diesel also offers that diesel engines give more horsepower, a key when toting thousands of tons of material day after day.
Ken Timmings, general manager of Clark Equipment, adds that diesel engines produce better torque than other engines. And, with these trucks moving thousands of pounds of material constantly, sturdiness is essential.
Another difference between indoor and exterior models is the wider wheel stance. David Sellick, with Sellick Equipment Ltd., Detroit, says that a wider wheel stance prevents the lift from toppling over. The wider wheelbase also makes the ride much smoother, an added benefit for an operator using the equipment for hours on end.
Additionally, rough-terrain lift trucks are higher off the ground, which prevents any damage from being incurred in the outside settings. Since these vehicles often are passing over uneven ground, there are always concerns that material lying on the ground could damage the underbelly of the machine. A forklift with a higher ground clearance greatly reduces the chance of that happening.
Along with the weight limits, forklifts have a number of other features that make them an effective way to move material. Loads are able to be tilted to place or dump the load into a location. Additionally, many forklifts are able to side shift material.
While interior usage forklifts and exterior forklifts have many of the same characteristics, there are a number of structural differences to make them stand apart. Along with the type of engine used in interior usage, forklifts used in enclosed settings have a lower ground clearance. This gives the forklift operator greater maneuverability. Since many interior forklifts are used for stacking bales, the need to move down narrow aisles is a major benefit.
Interior forklifts also typically have solid tires, which improves the turning radius of the machines.
Rough terrain forklifts, while belonging to the same family, are quite different. First, because many exterior use vehicles operate in an environment where there isn’t a consistent floor, there is a higher ground clearance to prevent any rupturing of the undercarriage of the vehicle.
Secondly, because of the uncertainty over the outside, tires are more often pneumatic tires, akin to tractor wheel. In a scrap yard especially, where loose metal may be scattered about the yard, pneumatic tires reduce the chance of permanent damage to the tire. The pneumatic tires may be foam filled, air filled or have a rubber coating to prevent punctures from ruining a tire.
The Future is Now
As for innovations, the concept behind forklifts may be the same—an ability to pick up and place material—but there are a host of innovations, some modest, others ambitious, which could help make the forklifts of the future even better. Lift King, Youngstown, Ohio, for one, offers a powershift transmission with shift on the fly capabilities. Also, some of the forklifts have side shifts, which can shift the fork assembly right or left, as well as the fork positioner, which allows an operator to adjust the fork on the carriage.
Lift King is one manufacturer that offers exterior forklifts in both two wheel and four-wheel drive. The company also offers crabbed steer, which allows the forklift to travel back and to the side. This is helps prevent a forklift from getting stuck in ruts that may be located at the site.
Schaeff, which builds interior forklifts, has designed and manufactured a forklift that gives the operator more control over the environment through closed loop control. The system allows the forklift to control the speed over a dock plate and into an included trailer; controlled deceleration with regenerative braking every time the truck is stopped; and same speed empty or loaded.
Most forklifts have the capability of tilting a minimum of 10%, while most can tip at least 15%. The maximum level is 45 degrees. The tilting angle depends on the application for the machine. In exterior environments the angle for tilting is much greater, due to the functionality of the equipment. For interior use, the angles are much less.
For All Types of Jobs
Forklifts are found in many plants and yards. For scrap processors, other equipment may be essential for converting raw material into a viable product. But the flexibility of forklifts is one of the ways for companies to keep the material handling aspect of their operations functioning efficiently and effectively. RT
The author is senior editor of Recycling Today.
Sidebar:
Four out of Every Five Recyclers Recommend . . .
Forklifts may not be the first machine that comes to mind when moving scrap is being considered, but the numbers show they are more common than skid steers or wheel loaders.
A 1997 survey conducted by the Recycling Today Media Group produced answers from 120 scrap and recycling facility managers about the equipment used on their premises. Four out of every five respondents (80%) used one or more forklifts to move materials as part of their operations. While 45% had only one forklift truck on-site, another 41% owned a small fleet of two-to-five, and another 12% owned from six to ten lift trucks. Yet another 2.2% owned 11 or more forklifts. (Actually, "owned" would not be the most appropriate term to use, since 48% of those responding said they typically rent or lease their mobile material handling equipment.)
At the time of the survey, 17% of the recyclers questioned planned to shop for one or more new forklifts within the next year, while another 10% would be in the market for pre-owned forklifts.
Less than 20% of those responding to the survey keep a regular trade-in or vehicle replacement schedule for their equipment. Those that did kept forklifts an average of four years or about 5,500 operating hours.
The forklift market is a competitive one within the recycling industry, although Clark had a 28% market share, followed by Caterpillar (20%) and Toyota (15%). Other manufacturers represented include Yale, Mitsubishi, Daewoo, Komatsu, Nissan and Baker.
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