Bonduelle stays cool under pressure

Gniewkowo, Poland: The Bonduelle vegetable factory in Gniewkowo, Poland, processes around 30,000 tonnes of vegetables every year, with the main output being frozen produce.

Local Yale dealer Emtor has worked with the Bonduelle vegetable factory managing 40 long-term rental Yale trucks operating in the cold environment and narrow aisles of the warehouse. Bonduelle’s main output at its Gniewkowo factory is frozen produce where vegetables undergo a long, complex process of washing, blanching, and tunnel freezing before delivery.

The factory’s current fleet consists of 40 long-term rental Yale trucks, supplied by national dealer, Emtor, which has provided Yale equipment to the factory for over 10 years. The working conditions onsite vary from refrigeration environments (0-4°C) to dedicated coldstores at -18°C, therefore customised solutions are needed to prepare the equipment for temperature-controlled environments.

The Yale trucks provided by Emtor have enclosed cabs fitted with heated double glazing, double skin insulation and in-cabin thermostatic heating, providing operators with a warm and comfortable workspace that also helping reduce the risk of fogging when moving between cold and temperate environments. But there is more to the specification than cosy cabs.

Paweł Łyczywek, logistics and supply chain director, Bonduelle, says: “In our factory, semi-finished products are stored in a block system warehouse, and only finished products migrate to pallet racking. We discussed the need to ‘slim down’ the width of the reach trucks that will work in this area with Emtor because the aisles in our warehouse are extremely narrow. They took up the challenge and prepared narrower versions in line with the Polish Office of Technical Inspection’s requirements especially for us, which are doing well in our narrow aisles.”

Reach trucks make up the majority of the Yale fleet onsite with loads being stored at heights of up to 8.5 metres. The reach trucks are also fitted with special HD masts and have a low lifting capacity, enabling them to lift the same load capacity over the entire lifting height. Electric trucks with a lifting capacity of 1.6 tonnes and higher capacity LPG trucks (1.8-2.5 tonnes) fitted with rotator attachments complement the reach trucks, undertaking tasks outside the warehouse.

Most of the equipment in the factory operates seven days a week in a three-shift mode and is equipped with side battery extraction to save time and reduce the disruption caused by changing batteries.

“In the past, replacing the batteries from the top and manipulating them at height was a difficult operation that came with certain risks. The range of trucks we use is very broad, from reach trucks through to warehouse trucks, that’s why unifying the battery exchange system and adapting it to the various models we use is an important element of security for us,” Paweł says.

The Bonduelle processes around 30,000 tonnes of vegetables a year, most of it frozenimage description

The majority of the trucks at the Bonduelle Gniewkowo factory operate on a long-term contract for a period of five years, after which they are exchanged for new ones. A shorter, three-year rental period covers the most intensively used trucks. “The shorter rental period for some trucks is due to the extreme pressure they are subjected to. Some of the Yale forklifts we use transport loads of up to 15,000 tonnes a year,” says Wiktor Kwiatkowski, transport manager, Bonduelle.

Paweł says: “This rental agreement helps us maximise the efficiency of our fleet. We are confident that for five years of operation we can work relatively trouble-free, and if necessary, we can count on an immediate elimination of defects or replacement trucks from Emtor, which provides us with uninterrupted continuity of work.” Emtor guarantees an on-site service in Gniewkowo by providing a dedicated mechanic. However, during the busiest period of the year when the most intense work is under way, the service team is increased with a further two technicians based at the factory.

In addition to the on-site service provided by Emtor, the Yale dealer also has a warehouse within close proximity to Bonduelle. “We have a very well-equipped spare parts warehouse, supported by an outstanding Yale spare part distribution centre, along with a host of replacement trucks, which is why we are able to efficiently repair or replace a forklift if necessary. Emtor is a family company in which the decision-making process is undoubtedly shorter than in a corporation, hence our ability to flexibly adapt to the needs of our clients,” says Dariusz Czaplicki, technical and sales consultant, Emtor.

“I am glad that we have the opportunity to implement such a broad cross-section of solutions for Bonduelle. Thanks to this, we are able to work together to test different options, build expertise, and provide valuable feedback to their factories, allowing us to constantly improve our service,” Czaplicki says.

Pix: Bonduelle Case Study 1
Caption:
The Bonduelle processes around 30,000 tonnes of vegetables a year, most of it frozen

Bonduelle Case Study 2
Caption
The factory’s current fleet consists of 40 long-term rental Yale trucks, supplied by national dealer, Emtor

Bonduelle Case Study 3
Caption
Reach trucks make up the majority of the Yale fleet onsite with loads being stored at heights of up to 8.5 metres

Bonduelle Case Study 4
Caption
LPG trucks (1.8-2.5 tonnes) fitted with rotator attachments complement the reach trucks, undertaking tasks outside the warehouse

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