Distribution of beverages is a high-volume proposition that puts a premium on speed. And as one of the oldest, most successful independent bottlers in the country, Ab-Tex Beverage Ltd. understands the importance of streamlining warehouse productions to ensure maximum efficiencies and customer service. After all, it operates 13 distribution centers, each about 40,000 square feet, which supply Pepsi and other beverages to two-thirds of Texas.

Unfortunately, both throughput and efficiency come down quite a bit when Ab-Tex has to build pallet loads with different product on each layer. Until recently, most of that work was done by hand with less than 300 cases handled each hour.

That has changed with a 6,000-pound propane lift truck outfitted with a layer picker mast attachment. Now, 1,200 cases an hour are handled by the attachment that builds pallets layer by layer. What used to take 14 hours is done in five. Orders that used to take seven to eight people to fill, now require only one forklift operator.

Operators of the truck praise it or the increase in day-to-day productivity and its ease of use. They are also satisfied with its upgraded, comfortable seat and overall ergonomic design.

Another important feature of the truck and attachment is the ability to operate within a minimal amount of floor space. Operators easily swing the layer picker to the right and left of aisles lined with floor-stored product. The attachment telescopes out to the cases, clamps down, lifts the layers and places them onto waiting pallets. Sometimes workers build the rest out by hand to complete a specific pallet. The completed pallets are then removed from the building area, wrapped and taken to transport vehicles for distribution.