SAVING COSTS AND THE ENVIRONMENT THROUGH DOUBLE DECKING

As a consequence of the general economic downturn, coupled with anxiety over uncertain energy prices, the effective and efficient control of materials handling and transportation costs has risen rapidly up the management agenda. This is particularly important for the retail sector where, additionally, firms are also recognising the need to promote their ‘green’ credentials in response to the environmental issues that are now playing such a significant role in forming consumer opinions.

Transporting goods by double deck trailer provides a key opportunity for retailers to address these issues and enjoy substantial cost efficiencies. In the sector, typically, double deck trailers carry 67% more goods, per vehicle, than single deck models, reducing mileage operated and saving fuel costs. Indeed, the Energy Saving Trust website states: “Double-deck trailers can improve the efficiency of a business by increasing load volume, cutting unnecessary mileage and reducing fleet sizes”.

Double deck trailers haven’t always enjoyed the best reputation. This is mainly because of user experience with units incorporating a hydraulically-powered second deck. This configuration incurs significant operational limitations because the onboard hydraulics system can add up to five tonnes to the vehicle weight, thereby reducing the available payload. In addition, a powered double deck trailer typically costs around £35,000 more to buy than a trailer with a fixed second deck.

Mark Adams, managing director of Transdek, the double deck specialists says: “By opting for ‘fixed’ double deckers, operators enjoy much more flexibility. For supermarkets, these fixed second deck trailers can mean the difference between simply shipping watercress or having the ability to move mixed loads of every product in their ranges. At Transdek w e’ve developed a unique range of electro-hydraulic powered lifts for loading and unloading double deck trailers.”

The Transdek range provides lift capacities from 6.5 to 20 tonnes and each is a compact, fully equipped, surface mounted unit. Installation does not require any civil construction work - a feature that, in addition to delivering considerable up-front cost savings, often means that, if required, it is easier to gain any landlord or planning permissions. It also delivers maximum operational versatility, as relocation to another position or even entirely different site is quick and easily to complete.

Main structural sub assemblies are fabricated, load tested and quality approved off-site, which means that onsite installation and commissioning takes only one to two days with absolutely minimal disturbance to normal site operation.

Each lift is equipped as standard with internal floodlighting, traffic lights, hydraulic bridging plate, vehicle buffers and dock seals. The seals ensure the necessary environmental continuum between the trailer and loading pod for handling frozen or chilled product.

Transdek lifts are also able to accept deliveries from any type of double deck trailer. This includes standard trailers with a bottom deck height of around 400mm as well as Continental style double deckers – which have a bottom deck height of 220mm. This facility is not achievable with a standard scissors lift unless it is placed in a sunken pit.

Safety features include front and rear safety gates on the lift platform, with an electronic interlock which ensures that the platform only moves when operators have closed both gates properly. Movement of the lift platform can also be exclusively operator controlled through a simple, interlocked, push-button console. To ensure safe deck access and easy loading a hydraulic bridging plate lowers across the gap between trailer deck and lift platform, and in the raised position this plate also prevents the front gates from opening accidentally.

Extending hand rails are provided that automatically move into position and lock along the sides of the bridging plate, removing the danger of operators falling between the lift and the vehicle. A fully partitioned walkway is also provided across the lift platform to ensure access between the trailer and dock at all times.

The lifts are also specially designed to allow loading with powered pallet trucks. This not only increases speed of loading, thus saving costs, but also significantly reduces the manual handling strain on operators and the risk of injuries.

Tesco is the leading user of fixed double deck trailers, but the company is not alone. Superdrug, Halfords, and Boots have also realised the benefits of these vehicles.

Having previously trialled powered trailers, Boots decided to move to lighter weight, fixed double deck trailers, and commissioned Transdek to convert its network of regional distribution centres to double deck operations. Transdek installed 50, 6.5 tonne, 12 cage double-deck hydraulic lifts.

By focusing on rapid installation and a compact lift design, Transdek have greatly increased the number of places where fixed double deck trailers can deliver. To date, double deck trailers have rarely been used to deliver direct to retail outlets however, with the development of Transdek’s 6.5 tonne double deck lift, one of the largest supermarket chains in the UK is now installing lifts at store level. This opens up the possibility of savings across a much larger section of the retail distribution network.

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