a big step forward for Bjelin with automated loading

Watch how we help Bjelin revolutionise its loading processes with Automated Loading Systems.

We dive into an extraordinary case study that will redefine the way you look at manufacturing production and warehouseing.

Witness how cutting-edge loading automation technology is changing the face of the industry as we unveil our groundbreaking solution that automatically loads pallets from the production line directly into the trailer. Say goodbye to labour-intensive processes and hello to streamlined productivity!

Bjelin’s primary challenge was to find an automated loading solution that could efficiently handle their diverse product range and streamline the transportation process. With a factory located in Viken, Sweden and a newly established warehouse in Helsingborg, Sweden, Bjelin needed a way of safely and efficiently loading and transporting raw material from their warehouse to their factory and returning pallets of finished wooden flooring to the combined warehouse and distribution centre.

Bjelin produces circa 200 pallets per day of various-sized palletised finished goods, which amount to between seven and ten trailer loads. Manually side-loading and unloading processes with forklift trucks took between 35-45 minutes at both the factory and the warehouse. Each trailer load is about 20 tonnes (20 pallets at one tonne each), so securing the loads in the trailer with ratchet straps is essential, however, this process was also time-consuming and labour-intensive.

Pallets are of various shapes and lead to another challenge: how to secure the load. Truck drivers were manually securing loads by threading and tightening ratchet straps to the trailer. A less time-consuming solution was required to reduce driver waiting times and allow them to get on the road quicker.

In the scenario that Bjelin hadn’t implemented an automated loading system, they would have required three forklift truck operators working three eight-hour shifts across 24 hours at both the factory and warehouse to keep up with the demand of the factory’s output.

Truck drivers would have needed to wait for trailers to be loaded (35-45 minutes) and loads secured (30-45 minutes) before making a 20-minute, 23km journey from the factory to the warehouse and then waiting for the trailer to be unsecured (five-ten minutes) and unloaded again (35-45 minutes). The full shuttle cycle time (load, secure, travel, unsecure, unload, load, secure and return) would have taken between three hours and two hours 45 minutes.

1. Fast and Efficient Loading: The system’s motorised conveyor-like slats move pallets in and out of the trailer, enabling a full trailer to be loaded or unloaded within 3 minutes. This reduction in loading and unloading time allows for more loads to be shuttled in a shorter period and improves their supply chain agility.

2. Robust and Safe Design: The system is a robust engineering solution and ensures a safe and reliable loading process. The automated system eliminates the need for manual intervention during loading, reducing the risk of accidents and injuries, and safeguarding both employees and products.

We also installed fencing around the loading docks in both the factory and the warehouse to eliminate the risk of accidents whilst the loading process is in operation. In addition, Bjelin also installed a pedestrian bridge across the two docks to reduce the risk of accidents between warehouse employees and forklift truck traffic.

Upon the successful installation of the system, in the Commissioning phase, we completed risk assessments to minimise the risk of accidents whilst the system was in use. Emergency stops, light guards and scanners were installed to protect staff from entering the system’s area before coming into contact while in operation. These safety features automatically shut off the system, should members of staff come into proximity whilst in operation.

1. Streamlined Operations between Viken and Helsingborg: With the automated loading system implemented, the transportation process between the factory and the warehouse became seamless; enabling operations to run efficiently in a significantly reduced time, with only a few members of staff.

The shuttle cycle (load, secure, travel, unsecure unload, load, secure and return) now takes approximately an hour, resulting in a minimum of 70% reduction in time than it would have taken.

2. Eliminating accidents in the loading bay: With no forklifts required in the trailer loading process, the risk of accidents in the loading bay has been fully eliminated, making it a safer working environment for all members of staff and visitors.

6. Factory and warehouse space optimisation: Palletised goods can be loaded onto alternate loading docks, meaning the space in the factory and the warehouse can be better optimised. Goods can be loaded onto alternative docks in preparation for the trailer’s return, meaning goods now don’t need to be stored near the loading bay doors ready to be loaded onto a returning trailer.

7. Indoor Loading: The loading operation now takes place within a sealed loading bay, which offers two advantages.

• Loading is now completed indoors, meaning none of Sweden’s cold or wet weather conditions can now interfere or risk goods sustaining damage whilst being transported to the trailer.
• Air conditions in both the factory and warehouse are easier to control and regulate without the loading bay doors open. With the doors open less, the solution ensures that minimum heat and air escapes the buildings during the loading and unloading process. As a result, less energy is required to maintain a consistent temperature level.

Supply Chain Director, Pär Jönsson, reflected on the processes and commented: “Our [Bjelin’s] expansion plan is quite immense and we could foresee future challenges with unloading and loading. We needed to find a solution to help the process become as swift as possible, whilst also taking out some of the [forklift truck] traffic from the loading bays.

“After we identified a solution, we got in touch with Joloda for a quotation and looked at the size and scope of the business to gauge whether they'd be a fit for us. One of the most important things was that we buy and use equipment from well-known suppliers that can provide a solution and a service that we can lean on going forward. They also had some interesting references in Sweden. 

“We are always looking for bigger companies that can grow, support and handle different challenges; Joloda ticked these boxes. We got a good connection with their staff and we liked that they showed an interest and came to look at our premises to find a solution that would suit us.

“Our project manager, Anton, had a lot of discussions with Joloda to agree on the scope of the work. Good communication was important to us as it was the first loading system we have bought. It was a good way of working as they were very supportive.”

The implementation of our Moving Floor system combined with the FIX Truck-Safe load securing system, proved to be the ideal solution for Bjelin’s complex logistics challenges. Their ability to automate loading and unloading processes and streamline its operations between Viken and Helsingborg resulted in improved operational efficiency, increased productivity, a more sustainable logistics operation and reduced costs and risk of accidents.

Through our commitment to innovation and engineering excellence, Bjelin now stands at the forefront of modern logistics, setting an example for others in the industry to follow.

Working with an automated loading system brings with it many advantages for your business. It gives you an opportunity to increase efficiency, enhance worker safety, make room for flexibility and add savings. 

There are a variety of reasons why it is of benefit to rationalise as to whether the investment and The Benefits of Automated Loading Systems is worthwhile for so many businesses. Automated loading systems also have a longer lifespan, which provides your business with a higher return on investment. We’ve drawn on some of our most popular benefits here…

Around the world, we’re known as the number one; the global leader in loading and unloading solutions. This is not only because we are the largest but also the first too; we've been pioneering loading solutions since 1962.

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