Clark electric forklift fleet helps power greener door production at Teckentrup

Electric trucks now move raw materials and finished doors throughout the plant

A fleet of 30 electric forklifts is helping one of Europe's largest door manufacturers cut emissions and improve efficiency as it ramps up production at its German factory.

Teckentrup has deployed the Clark electric forklift fleet at its Großzöberitz site in Saxony-Anhalt, where between 1,500 and 2,000 steel doors are produced every week along one of Europe's longest production lines.

The family-owned company, founded in 1932, manufactures garage doors, industrial doors and specialist steel doors for applications including fire, smoke, sound and burglary protection.

Around 250 employees work at the Großzöberitz factory, which produces approximately 100,000 steel doors and 5,000 roller shutters each year.

Peter Handrich, head of supply chain management at the site, said the company had continued investing in production capacity to meet rising demand for specialist door systems.

The factory expanded its powder-coating capacity in 2023 and is now planning two new frame production lines alongside a new manufacturing hall for fire doors.

Sustainability has also become a key focus, with the site generating part of its own electricity through a 1,000kWp rooftop solar PV installation.

When Teckentrup decided to renew its materials handling fleet, the company opted for electric forklifts as part of its wider environmental strategy.

Following trials of several competing machines, Clark secured the contract.

“We tested several competing vehicles, but I liked Clark's ‘green’ one best and it won us over – not because of the colour,” Mr Handrich said.

He added that the decision was influenced by the forklifts' performance and the support provided by Clark dealer P&H Gabelstapler und Baumaschinen GmbH.

Today, the fleet includes 27 Clark GEX 20-30 electric forklifts, one five-tonne GEX 50 model fitted with an 8.5m triplex mast, plus newly introduced SE20 and SE30 electric forklifts.

The trucks are used throughout the factory for unloading deliveries, transporting raw materials, feeding production lines, moving finished products and loading outbound vehicles.

Forklift operators also use tablet-based warehouse management systems to carry out paperless order picking before products leave the site.

Employee safety and comfort were also important factors during the procurement process.

“Our forklift drivers should feel comfortable on their forklifts, because good ergonomics increase productivity,” Mr Handrich said.

The vehicles feature ergonomic seating, intuitive controls and restraint systems designed to improve operator protection in the event of a rollover.

Despite the increasing popularity of lithium-ion batteries, Teckentrup chose to retain lead-acid technology.

Maintenance manager Marcel Krämer said the company's single-shift logistics operation meant there was sufficient time to recharge batteries, making lithium-ion systems less economical.

“The use of Li-ion batteries is not cost-effective in our factory,” he said.

He added that lead-acid batteries offered a long service life, often exceeding 10 years under the site's operating conditions, while high-frequency chargers ensured forklifts were ready when required.

Mr Handrich said the investment formed part of a broader strategy to improve efficiency while reducing the environmental impact of production.

“Our goal at our plant in Großzöberitz is to make industrial door and gate production as efficient and sustainable as possible – from resource-saving production and in-house power generation to emission-free and smooth logistics processes. Our partner Clark also makes an important contribution to this.”