A Combilift forklift still in operation after 28 years is being highlighted as an example of how purpose-built handling equipment can improve safety, efficiency and long-term performance.
The first-ever Combilift C-Series remains in use at J.G. Kelly Supplies in Monaghan, Ireland, nearly three decades after it was first put to work.
The story has been shared as National Forklift Safety Day draws attention to safe material handling practices and the importance of using the right equipment for the job.
J.G. Kelly Supplies said the multi-directional forklift had helped transform how the business handles long loads, particularly lengthy PVC stillages.
Before the company introduced the Combilift, moving those products created significant operational and safety challenges.
The stillages, measuring up to six metres, had to be moved through a doorway only four metres wide.
Conventional counterbalance forklifts could not carry out the task safely or efficiently, particularly at a site located on a busy road.
Operator Tony McManus said the business previously had to rely on more awkward handling methods.
“Before, we just used to use counterbalance trucks,” he said.
“We had to reverse a lorry in here and were on a main busy road in the town.”
The C-Series allowed operators to move long loads sideways, giving them greater control and stability in tight spaces.
Mr McManus said the change had made deliveries safer and reduced disruption.
“But now, it just pulls up in the loading bay,” he said.
“We can offload it safely, both sides if needed, with minimal obstruction to traffic.”
The machine’s multi-directional capability has helped the company improve site operations, shorten unloading times and reduce risks to operators, pedestrians and passing vehicles.
“With the C-Series, it’s less labour intensive than it used to be,” Mr McManus said.
“It would take a lot of people to offload containers before, but now, one operator can offload a container in a short space of time compared to before.”
The forklift’s integrated platform has also improved load stability when transporting long products.
Combilift said the platform allows operators to support lengthy stillages more securely, reducing the risks linked to oversized loads and making handling more controlled.
Mr McManus said: “We know that it’s a lot safer, once you get the load on the platform, you can sort of relax almost.
“You've got that stability of it being on the rest beds.”
Alongside the safety benefits, the longevity of the machine has also stood out.
Paul Kelly, managing director of J.G. Kelly Supplies, said he had not expected the original forklift to remain in service for almost three decades.
“I never expected we'd still be using the same forklift nearly three decades later,” he said.
“But it’s a testament to the build quality of the machine as it's still running after 28 years.”
While several conventional forklifts have been replaced over the same period, the original C-Series remains part of the company’s operation.
Its continued performance has been linked to robust engineering, regular preventative maintenance and local support.
Mr McManus said the machine had required relatively little major work.
“It doesn't really take much maintenance,” he said.
“We have changed filters or timing belts over the years, but it’s still got the original engine from when it arrived here.”
Routine checks on oil, coolant, hydraulics, tyres and greasing have helped keep the forklift reliable.
Major repairs have been rare during its 28-year working life.
Mr McManus said downtime had also been limited, which was important for the business.
“In 28 years, it's very rarely had to be taken away for repairs,” he said.
“Any issues we've had have usually been fixed on site, and quickly.
“That's the main thing, because if the machine is out of action for any length of time, we're in trouble.”
The long-term performance of the original C-Series led J.G. Kelly Supplies to add further Combilift products to its fleet.
These include other Combilift models, a pedestrian Combi-CS and an Aisle Master at the company’s Limerick warehouse.
Mr Kelly said the business valued Combilift’s ability to tailor equipment to specific operational requirements.
“Combilift are very good at having a look at what you need and then they can tailor the product to suit you,” he said.
“We had the height of the mast and weight limit tailored to what we needed in our Combi-CS.”
Nearly three decades after it first entered service, the original C-Series continues to support productivity, safety and storage efficiency at J.G. Kelly Supplies.
Combilift said the machine showed how the right handling solution, backed by quality engineering and preventative maintenance, could continue delivering returns over the long term.