Mansfields modernises Kent fleet with 15 Hyster forklifts and six powered pallet trucks

Mansfields has completed a fleet investment comprising 15 lithium-ion Hyster forklifts and six powered pallet trucks at its Kent operation. The equipment is intended to increase materials-handling capacity, support the use of vertical warehouse space and improve control of vehicle and pedestrian movement in busy packing and storage areas. The order combines different forklift mast heights with ride-on pallet trucks that can be adapted for more than one operating configuration. ^[1]

The mixed fleet supports several stages of fresh-produce handling

Mansfields operates a fresh-produce business covering growing, packing and storage. Its Kent site also handles produce from partners and importers, creating a materials-handling environment in which fruit, packaging, pallets and finished orders move between several operational areas. The company states that it has storage capacity for more than 1,500 pallets and can pack 812 different items. ^[2]

That operating profile requires more than a single type of warehouse truck. Forklifts are suited to lifting and placing palletised loads, while powered pallet trucks support horizontal movement, staging and loading tasks. Mansfields has therefore combined 15 forklifts with six powered pallet trucks rather than specifying one standard machine for every activity. The fleet composition reflects the different handling requirements found between storage locations, packing areas and dispatch operations. ^[1]

The announcement does not disclose the value of the investment, the charging infrastructure, the fleet’s utilisation rate or any measured productivity improvement. Those figures are important when assessing the commercial performance of a materials-handling project, but they cannot be calculated from the published information.

Two mast specifications address different storage positions

Two of the 15 forklifts have a mast height of 5.5 metres, while the remaining 13 have mast heights of 4.6 metres. This specification allows the fleet to serve storage positions with different lift-height requirements. Mansfields’ stated objective is to make better use of vertical warehouse space without relying only on additional floor area. ^[1]

Vertical storage can increase pallet capacity within an existing building, but it also makes truck selection and operating discipline more important. Rack geometry, aisle width, pallet dimensions, clearances, floor conditions and the required capacity at height all influence whether a particular truck is suitable. Mast height alone does not determine the effective performance of a storage system.

In this deployment, the two taller forklifts appear to be intended for locations requiring additional lift height, while the larger group of 4.6-metre trucks covers the more common handling requirement. This is an interpretation of the published mast-height mix and the company’s focus on vertical storage, rather than a detailed description of each truck’s assigned area. ^[1]

Lithium-ion forklifts extend the electric equipment specification

The forklifts are electric and use lithium-ion batteries. They can lift loads of up to 2,000 kilograms and have a tight turning radius intended to support manoeuvrability in busy pack-house and warehouse environments. ^[1]

For fleet managers, lithium-ion technology has to be assessed against the actual duty cycle rather than treated as an independent performance measure. Shift length, truck utilisation, charging opportunities, battery access, maintenance procedures and the availability of suitable charging points all affect the operational value of the equipment. The Mansfields announcement does not provide details of its shift pattern, charging layout, energy consumption or total cost of ownership.

The electric configuration is relevant to a food-handling site where vehicles operate around packing and storage activities. Mansfields describes rapid chilling, grading, packing and pallet storage as connected parts of its fresh-produce process. ^[2] A fleet working across these areas must therefore be specified for predictable handling performance, suitable dimensions and reliable availability as well as for its battery technology.

Pedestrian detection and automatic slowdown support site controls

Pedestrian protection was a central part of the forklift specification. The trucks include pedestrian-awareness technology that can detect pedestrians up to 5 metres away across a 110-degree field of view and provide an alert to the operator. Improved mirrors are also intended to support visibility and situational awareness during manoeuvring. ^[1]

Hyster describes pedestrian-awareness functions as systems that alert operators when people are detected near a forklift. The warning can give an operator more time to reduce speed, adjust direction or stop, depending on the circumstances and the site’s operating procedures. ^[3]

The forklifts also include automatic slowdown. Hyster’s technology information describes speed-control functions that can reduce travel speed automatically in defined situations, including aisle ends, intersections or designated areas where a lower speed is appropriate. ^[3] The presence of these functions does not remove the need for traffic management, operator training, site rules or physical separation between vehicles and pedestrians.

In a working warehouse, detection and slowdown systems need to be configured for the layout in which they are used. Warning zones, speed settings, maintenance routines and operator responses all affect how the technology performs. The published information confirms the specified features but does not provide incident rates, near-miss data or evidence of a measured reduction in collisions at Mansfields.

Ride-on pallet trucks add adaptable horizontal transport

The investment includes six A2 ride-on powered pallet trucks. These machines can be converted into A1 multi-functional trucks, allowing the equipment to be adapted for different tasks and working environments. ^[1]

An adaptable pallet truck can be useful where loading, replenishment, staging and internal transport requirements change during the working year. That flexibility may be particularly relevant to a fresh-produce operation with varying volumes and handling patterns. The announcement confirms that adaptability was part of the specification, but it does not describe the exact conversion procedure or the operating limits of each configuration.

The pallet trucks include keypad access, power steering, automatic slowdown and protective arms that can be raised or lowered according to how the truck is being used. Keypad access replaces conventional keys, while power steering is intended to support easier handling and manoeuvring. ^[1]

The protective-arm arrangement gives the operator a configurable physical safeguard, although the appropriate position depends on the task, the surroundings and the manufacturer’s instructions. As with the forklift safety functions, the equipment features should be integrated into site procedures rather than considered a substitute for risk assessment or operator competence.

Fleet selection must reflect the complete warehouse layout

The Mansfields deployment links several equipment decisions to specific operational requirements. The mast-height mix addresses vertical storage, the 2,000-kilogram lifting capability covers pallet-handling requirements, and the tight turning radius is intended to support movement in confined areas. Pedestrian awareness, improved mirrors and automatic slowdown address the interaction between trucks and people. ^[1]

For procurement and operations teams, a comparable project should begin with a map of actual workflows. Relevant information includes load weights, lift heights, rack dimensions, aisle widths, turning areas, pedestrian routes, loading points, charging opportunities and seasonal changes in activity. These details help determine whether the selected equipment is suitable for the complete process rather than only for its most demanding individual task.

Higher-density storage also requires coordination between racking, pallet dimensions, truck clearances, traffic routes and operating procedures. A taller mast can help use available volume, but the result depends on safe clearances, stable loads and consistent operating practices. The equipment can support a more effective use of existing space; it cannot by itself guarantee higher storage density or improved throughput.

Measured results will determine the project’s operational value

The published announcement identifies the equipment and its intended benefits, including stronger operational capability, improved safety, greater efficiency and better use of warehouse space. ^[1] It does not disclose a purchase price, a productivity baseline, post-installation throughput, energy consumption, maintenance costs or a financial payback calculation.

For UK fleet managers considering a similar investment, those measurements should be established before commissioning and reviewed after the new equipment has entered service. Useful indicators may include truck availability, battery-related downtime, travel distances, pallet movements per shift, charging performance, recorded near misses and maintenance expenditure. The appropriate measures will depend on the site’s workflows and safety objectives.

Mansfields’ fleet provides a specific example of an electric materials-handling package for a fresh-produce environment: high-lift forklifts for pallet handling, adaptable powered pallet trucks for horizontal movement, and integrated warning and speed-control functions for mixed traffic areas. The extent to which those features improve performance at the Kent site will depend on deployment, configuration, training and operating data that have not been published.