Flooring manufacturer eliminates risk of injuries with electric handling tugs

Forbo's plant in Ripley, Derbyshire, is the group's global production centre for Flotex sheet and tile flooring, producing approximately 3.2 million sq m product each year, of which 92% is exported. There are several production lines at Ripley. Raw materials are converted into 2 m-wide sheet flooring or into half-metre square tiles. There are lines for flocking, printing and cutting, with other departments that cut, prepare or mix the raw materials that are fed into the lines. Once sheet flooring has been flocked, it is rolled and placed on a chariot to be moved to the next stage. At any one time, up to 12 chariots are moving rolls – each weighing up to 2.5 tonnes – around the plant. Use of steam and water in the production process means the floor is sometimes wet, despite best attempts to keep it dry. This meant wheels on the chariot tugs were slipping which, production manager Ian Theyer explains, was an injury risk for workers. "We had a number of near misses. We therefore decided to look for an alternative solution for moving the chariots that would eliminate the risk of injuries or accidents to the staff." Forbo selected the MasterTug MT5-400 electric-powered tugs from MasterMover. "As soon as we saw a demonstration of the MasterTug at Ripley, we were convinced that this was the right solution," says Theyer. "The unique weight transfer system on the machine and wet condition drive tyres meant that there was no risk of slippage on the wet floor. We even demonstrated this by pouring buckets of water over the factory floor and using the MasterTug to move a chariot." The machines were fitted with audible siren and new drive wheel tyres for additional grip. Custom couplings were also added to connect the MasterTug to the chariot. "Since taking delivery of the two MasterTug machines, we've had no near misses and the staff are extremely pleased with how easy the machines are to use," reports Theyer. Forbo has since invested in another electric-operated handling tug from MasterMover. The SmartMover SM100 is being used on the flocking lines to move smaller rolls on chariots – a task which previously required two people to move rolls manually distances up to 12 metres.