Manufacturer saves storage space and streamlines handling

AT ITS facilities near Barcelona, ITW faced growing space constraints that limited its ability to expand storage capacity and streamline material handling. Traditional forklifts required 3.5 metre aisles and additional room for turning, which restricted storage density and efficiency.

To address this challenge, ITW reached out to its trusted local material handling dealer, Politractor, for expert guidance. After conducting a thorough site survey and a detailed analysis of ITW’s operations, it was determined that the Aisle Master from Irish material handling specialist Combilift would be the ideal solution to increase space utilisation significantly and enhance material handling processes.

This articulated forklift offered the ideal combination of versatility, compact design, and lifting performance to meet ITW’s needs.

ITW’s logistics manager Lourdes Mora, says: “We needed to maximise space utilisation as much as possible. Previously, we used conventional forklifts for both Euro and American palletised loads, which required wide aisles and wasted valuable space. With the Aisle Master, we reduced aisle widths to just 2.3 metres, increasing our storage capacity by 34%.”

In 2018, as ITW continued its growth in the region, the company relocated to a nearby, larger facility. The new facility was initially designed for manufacturing only, but was soon after adapted to include warehousing operations—a change made possible by the space and efficiency gains delivered by the acquisition of the new machines.

“Thanks to the space optimisation offered by the Aisle Master, the same facility now serves both manufacturing and warehousing functions,” said Lourdes. “This dual use has been key to maintaining operational agility while supporting business growth.”

Today, ITW operates five units with a 2 tonne capacity and lift heights of up to 10 meters.

“They’re ideal for working in confined areas and efficiently moving pallets in and out of racking,” Lourdes added.

Sustainability and operator well-being were key factors in ITW’s decision. As the Aisle Masters are used indoors, all five units are electric-powered, helping to reduce emissions and noise while improving operator comfort.

As a business that has the wellbeing and safety of its strong workforce at the heart of its ethos, safety around equipment and in the warehouse is paramount. Each Aisle Master is equipped with additional advanced safety features such as mast-mounted cameras, blue pedestrian safety lights, and red halo safety lights. These features ensure a safer working environment for all employees, while complementing their space-saving capabilities.

Additionally, ITW has also recently redesigned parts of its pallet-wrapping process to further improve ergonomics and operator safety, which “is the perfect combination alongside the Aisle Master,” Lourdes noted.

The use of Combilift equipment within the ITW group is not limited to Spain alone. Other subsidiaries of the company in countries such as the United States, and even Australia also use Combilift equipment.

At the company’s Spanish facility in Barcelona, Aisle Master has transformed ITW’s material handling operations—solving critical space challenges while enhancing efficiency, sustainability, and safety.

By reducing aisle widths, increasing storage capacity, and integrating advanced safety technologies, ITW has successfully expanded its warehousing capabilities without requiring additional space.

This long-term collaboration between ITW, Politractor, and Combilift stands as a powerful example of how the right material handling equipment, backed by expert support, can drive operational excellence and long-term business growth.