When leading stationery manufacturer Pukka Pads needed to relocate one of its modular loading docks from its site in Bingley to a new facility in Lutterworth, it turned to Thorworld Industries to ensure a smooth transition with minimal disruption to operations.
The original Thorworld docking station had been installed at Bingley five years ago, with a second unit added shortly after. After several units at Bingley were sold, Pukka Pads required a solution that would allow them to transfer the dock to their new site efficiently without compromising safety or productivity.
Darryl Corbin-Jones, Managing Director at Pukka Pads, explained: “We knew the dock was a valuable asset, so when the decision was made to relocate, we asked for Thorworld’s assistance to ensure that moving it would be as seamless as possible while maintaining the high levels of safety and efficiency we expect.”
A comprehensive site assessment was carried out by the company’s distributor Loading Bay Service, ensuring that the dock could be installed at Lutterworth in a position that was both safe for hauliers and operationally effective. The modular nature of the dock meant it could be disassembled, transported, and reassembled with ease, with the relocation completed without disruption to daily operations.
“Thorworld’s ability to provide tailored solutions stood out,” continued Darryl. “The dock was designed in such a way that it could be broken down into sections and transported to the new location with minimal fuss. Once on-site, it was simply reassembled and bolted into position, making it ready for use almost immediately.”
Now in place at Lutterworth, the dock is being used more frequently, handling up to three loads per day as Pukka Pads receives incoming goods from China. The efficiency of the system has allowed the company to streamline its unloading process and make cost reductions, lowering the number of personnel required from five to three. Two operators load onto the dock while a forklift truck takes over, providing a safer and more efficient workflow.
Unlike older conveyor-based systems, which require regular maintenance and costly repairs, the Thorworld dock is designed for durability and reliability. The unit at Lutterworth is housed indoors, further improving working conditions and eliminating the risk of product damage due to the weather.
“The experience with Thorworld has been excellent,” added Darryl. “The relocation was efficient, cost-effective and executed without any headaches. As we continue to grow, we’ll be looking at Thorworld again for future projects.”
