Aaaaaaaah. That first cup of coffee helps millions of us get going in the morning. But before it reaches our mugs, it goes through a long materials handling cycle.

S&D Coffee, located in Concord, N.C., is a family-owned commercial market supplier that has benefited from the love of java. In less than 10 years, S&D has experienced a 300% increase in production of coffee, tea and specialty products. This boost led to a facility expansion and an overhaul of its lift truck fleet.

With 42 lift trucks, the S&D fleet is moving tons of product from loading docks, to the warehouse, to the production lines and back to the docks for loading. Since it has a variety of needs, it has a variety of trucks.

Twenty-two rider pallet trucks—in constant motion—are used for low-level order picking and for loading trucks. They form the backbone of the fleet.

Seven double-reach trucks and six sit-down counterbalanced trucks move coffee through tight spaces in the warehouse.

Accuracy in the warehouse is critical when product is being pulled from new double-deep racks. The narrow aisle reach truck helped make a change from a drive-in rack system that hindered efficiency.

Charlie Frye, warehouse manager explains, “Because of the way our logistics have developed to accommodate our spike in growth, a conventional sit-down truck can't get the job done. Our reach trucks are working both shifts every day.”

Skyrocketing demand required S&D to create staging areas in space that had been solely used for lift truck traffic. And double reach capabilities were a necessity. Engineering manager Carl Teten says, “We're dealing with 12- and 13-foot aisles that at times are reduced to eight-foot aisles because we need space to stage product.”

Other lift trucks in the facility include counterbalanced models used in the lower level warehouse because space is too tight for four-wheel sit-downs; a stand-up counterbalanced truck; an order picking truck; and a narrow-aisle reach truck are used for stacking in the packaging area.

“Having a durable fleet with prolonged battery life, combined with a dedicated product technician working to keep our trucks performing at their best is tough to beat,” Teten says. “There's no other way our warehouse could keep up with such growth in such a short time.”

Crown, 419-629-2311, www.crown.com