Perhaps the greatest accolade a fork truck company could have is a world-renowned competitor placing an order. And that’s just what happened to Combilift Ltd of Ireland: household name JCB has three Combilifts operating in its factory.

The reason is that the Combilift – the world’s first engine-powered, all-wheel drive, multi-directional forklift – is designed for long loads, such as timber – and it is ideal for JCB to handle its telescopic arms.

Combilift managing director Martin McVicar and technical director Robert Moffett both worked for Moffett Engineering Ltd, the manufacturer of the Moffett Mounty truck mounted forklift, until 1998 when Mr McVicar formed Combilift Ltd and the two men set about developing a forklift for the long load handling sector.

The multi-directional capability of the Combilift means that it can operate in aisles as narrow as 2m and it removes the need for a combination of sideloaders, counterbalance and narrow aisle trucks.

“Some of our customers have said that if the Combilift had existed 30 years ago, why would anybody buy a sideloader when you could buy a forklift that goes sideways,” says Mr McVicar.

When the two men started work on their invention, they assessed what was already on the market. The forward and back forklift could be used for long loads but it used a lot of space. While the side loader carries long loads, it drives only sideways and cannot carry cube loads. The four-wheel electric unit has manouverability but it is not designed to work outside and recharging can create downtime.

In contrast, the Combilift can carry both bulky and long loads, the LPG or diesel engine enables it to work outdoors, and it can operate on semi-rough terrain. The multi-directional capability means that aisle widths can be reduced, providing more warehouse space, and the low platform allows stock to be stored at a lower level.

“Even with small material there are space savings to be achieved because it reduces the aisle width,” says Mr McVicar. In the case of very narrow aisles, guide rails can be used.

Keeping it simple

The engineering philosophy behind the machine is ‘keep it simple’. It has a hydraulic drive, no gear box and no electronics so service costs are reduced. The capacity ranges from 2.5-9 tonnes and a wide frame attachment with a hydraulic outer fork is designed for long, flexible products and can carry lengths of up to 12m long.

Despite efforts not to embark on any “hard marketing” until the product was developed, word of mouth has helped the company to sell 1,200 of its multi-directional Combilifts worldwide in the past four years.

However, with sales growth from 18 units in 1998 to 450 last year, and the launch of the mark II model this year, Combilift is now ready to spread the word – and even become the word: “We hope Combilift will become the generic name for sideloaders,” says Mr McVicar.

Distributors worldwide

The company has distributors in “nearly all European countries” and dealers in the Canaries and further afield in the US, New Zealand, Australia, Canada and the Dominican Republic. In Norway, which has a population of 4 million, 46 machines have been sold. The UK is Combilift’s biggest export market and the company expects to sell 200 units here this year.

“We are going to expand all our markets but our UK volume is increasing rapidly so for the next few years it will account for 33% of our export market,” says Mr McVicar.

And in the UK, Combilift has found a willing market in the timber industry. Among its customers are Travis Perkins, James Latham, Timbmet, Finnforest, Arnold Laver, S Silverman, Century Homes, Magnet, Boise, International Decorative Surfaces, Stewart Milne, Space4, Torwood2, Richard Burbidge, Ridgeons and Amdega Conservatories – to name a few.

Warehouse solutions

Mr McVicar says that Combilift provides more than just forklifts – it provides warehouse solutions and has two staff who work with customers to design warehouse layouts.

At James Latham’s new depot in Hemel Hempstead, Combilift worked with racking specialist Rack Stor to design the storage configuration. Rack Stor installed a high impact guide rail system with reinforced aisle radius lead-in sections in five of the six aisles to guide and speed up operations. The resulting aisle widths of 2.47m and racking heights of 8.3m increased stock density by 60%.

The three Combilifts – which replaced the initial notion of buying two forklifts and two sideloaders – were supplied in James Latham’s livery and fitted with extra high masts to enable them to handle a load of two tonnes at the top storage level. The company is now converting all of its branches to Combilifts.

Operations director Andy Duffin says that using the Combilift has reduced the company’s overall outlay on trucks while increasing flexibility.

“The combination of the racking guide rails and the Combilift trucks has increased our picking volume enormously and significantly reduced loading times,” he says.

At Timber Store’s Crawley outlet, the low platform of the four-tonne capacity Combilift has allowed an extra metre of stacking space in the lower racks, creating more storage space for packs of timber and roof joists measuring 5.4m.

Engineered wood products manufacturer Boise uses a 4.5 tonne Combilift to manoeuvre long loads of 15-20m and the company believes the unit has saved 40% on storage space.

Boise was one of the first customers to take delivery of the new Series II model which features a joystick directional control lever, a three-litre engine for faster travel speed and increased auxiliary hydraulic speeds. The LPG bottle has been repositioned under the driver’s seat for increased visibility and the option of attaching two LPG cylinders is a benefit for heavy use applications.

Heart of Oak Buildings Ltd, which designs, manufactures and constructs large oak framed structures, uses a four-tonne Combilift to carry long lengths of oak along the 1.5 miles of uneven track between its storage depot and the workshop.

The Oxfordshire company handles oak in lengths up to 7m and as the Combilift has freed up space, it can take on larger projects and order timber direct in full loads. It has also reduced unloading time and the company can now stack 20m3 of timber in 30 minutes.

Entrepreneur of the Year

Combilift’s efforts won it the DHL Exporter of the Year award in 2001 and Mr McVicar was a finalist in the Ernst & Young Entrepreneur of the Year award Ireland. But he not only won the Young Entrepreneur title, he was also awarded the overall Entrepreneur of the Year 2001. In May he attended the world finals in Monte Carlo.

Mr McVicar says that Combilift remains the only one of its type on the market and the company expects growth of around 50% this year. And the manufacturing set-up will help to achieve this growth. All prototype work is done by Combilift but for the machines being rolled out for the market, all material is supplied pre-cut and drilled by local subcontractors.

“Prefabrication means we can grow very quickly,” says Mr McVicar.

Cell assembly, where one person assembles an entire machine, also aids a smooth production line.

“It means people take responsibility and if one person is off sick, production is not held up. People feel accountable and don’t get bored,” says Mr McVicar.

Also, cell assembly enables machines to be customised, which would be difficult on a production line.

The long-term aim is to develop the UK, the US and Germany as Combilift’s main markets and, although others may try to imitate the design, Mr McVicar is not concerned.

“We will stay ahead of any competition – and, to date, we have four years on them,” he says.

And that’s not all: the machine’s ability to work inside and outside and the company’s warehouse design expertise are further advantages.

“We look at the Combilift as more than a fork lift; it’s a warehouse solution,” says Mr McVicar.