Retrofit in a Fruit Warehouse: Telescopic Fork D3/2-75-174-ZK-1600 Replaces Third-Party Unit Without Modifying the Existing System

Replacing the Old Load Handling Devices Without Modifications to the Chain Conveyors

At one of the largest fruit warehouses in Germany, several telescopic fork units from a third-party manufacturer had reached the end of their service life and needed to be replaced. The system stores and retrieves special pallets with fruit in a double-deep configuration, with the existing chain conveyors handling the fast transfer of load carriers to and from the conveyor system. Replacing the stacker crane was not an option. The requirement was clearly defined: our telescopic fork units had to fit into the existing installation space as a 1 by 1 replacement, without requiring any modifications to the chain conveyors already in place. At the same time, the new solution had to be designed for the 24/7 operation that a fruit warehouse of this scale demands.

On-Site Measurement as the Basis for a Precise Design

Before engineering began, one of our technicians carried out a detailed on-site measurement at the customer’s facility. The old load handling device, the interface to the chain conveyor, and the lifting frame of the storage and retrieval machine were all fully recorded. On this basis, our telescopic fork unit D3/2-75-174-ZK-1600 was engineered and designed: geometrically compatible with the old load handling device, mechanically configured for double-deep storage and retrieval of fruit, and robust enough for demanding continuous operation. Installation at the customer’s site was also part of our scope of supply and services, giving the customer a complete solution from a single source.

Higher Availability Through Modernised Technology

The new telescopic fork unit integrates seamlessly into the existing system. The chain conveyors remained completely unchanged, and operations could resume after installation without any additional modifications. The modernisation delivers a noticeable improvement in both performance and system availability. Maintenance intervals become more predictable, and the technology meets the standard required for continuous 24/7 operation in a warehouse of this size.

Are you planning a similar retrofit project or looking to replace a third-party telescopic fork unit with a tailored AFB solution?

Contact our sales team. We will assess your existing system, carry out on-site measurements, and develop a solution that integrates without structural modifications.

Technical data:

• Load weight: 1,300 kg

• Stroke 1st position: 1,650 + 35 mm

• Stroke 2nd postion: 3,250 + 35 mm

• Acceleration loaded / unloaded: 0,4 / 1,2 m/s²

• Speed loaded / unloaded: 40 / 92 m/min

• Length of the top fork: 1,350 mm

• Length of the unit: 1,600 mm

• Self weight of the complete unit: approx 1065 kg