A filling or packing line consumes bottles, caps, labels, cartons and shrink film non-stop. If each pallet of supplies is carried separately by forklift, internal roads get crowded and forklifts drive back empty most of the way. An electric tow tractor for a food plant solves this by combining several carts into one tugger train running on a fixed route and timetable.
When does a tugger train make sense in a food plant?
A tugger train pays off when the plant has many consumption points with a steady rhythm, a long enough distance between store and line, and supplies that fit on carts or trailers. Beverage, confectionery and instant noodle plants with several parallel lines are typical examples. Main benefits:
- Fewer forklift movements in production areas with many pedestrians.
- Cyclic line feeding: each round delivers new supplies and collects empty packaging and pallets.
- Linking buildings: moving goods between production, packaging stores and finished goods stores in separate blocks.
Concept, configuration and sizing are covered in electric tow tractors and tugger trains.
Choosing a STILL tow tractor by distance and load
STILL LTX 20: narrow aisles in the plant
The STILL LTX 20 tows up to 2 tonnes, is only 600 mm wide and reaches up to 8 km/h. That size lets it manoeuvre in narrow aisles between machines. In food plants, the LTX 20 suits delivering labels, caps, additives and maintenance supplies to each station.
STILL LTX 50: the main line-feeding tugger train
The STILL LTX 50 pulls trailers with a total weight up to 5,000 kg through narrow aisles at up to 14 km/h. Optional Li-Ion technology allows round-the-clock availability, together with the Blue-Q energy-saving mode. This is a common size for trains carrying empty bottles, cartons and film to several lines.
STILL LTX 70: between buildings, indoors and outdoors
When the packaging store and production are in separate areas, the STILL LTX 70 tows up to eight tonnes indoors or outdoors at up to 20 km/h. The automatic parking brake engages as soon as the truck stops, the STILL Ramp Indicator shows the current gradient, and service intervals are up to 1,000 operating hours.
STILL LXW 20/30: heavy towing over long distances
For large sites or several trailers at once, the STILL LXW 20/30 offers 6000 kg towing capacity, 3000 kg load capacity and 23 km/h. Descent Speed Regulation adjusts travel speed to gradient and load.
Tow tractor selection table
| Stage | Type/model | Reason |
|---|---|---|
| Small supplies to each station | STILL LTX 20 | 600 mm wide, tows 2 tonnes |
| Packaging train for several lines | STILL LTX 50 | Tows 5,000 kg, optional Li-Ion |
| Transfers between buildings | STILL LTX 70 | Tows eight tonnes, indoors and outdoors |
| Large sites, slopes | STILL LXW 20/30 | 6000 kg towing, descent speed control |
See more in the tow tractors category.
Designing tugger routes in a food plant
- Separate clean and dirty flows: plan the supply route and the route collecting empty packaging and waste so they do not cross high-hygiene areas.
- Turning circle of the whole train: longer trains need wider bends; survey actual aisles before choosing the number of trailers.
- Pedestrian safety: Safety Light 4Plus projects blue spots about 5 m in front of and behind the truck, useful at blind corners between machines.
- Handover points at the line: standardise stopping positions and cart sizes so line staff can take supplies quickly.
Other truck groups for stores and docks are summarised on food & beverage solutions.
Frequently asked questions
Does a small plant need a tugger train?
With one or two lines and the store next door, electric pallet trucks are usually enough. Tugger trains pay off with many delivery points, long distances and a steady feeding schedule.
Can an electric tow tractor run outdoors between buildings?
STILL describes the LTX 70 for indoor and outdoor use, with an automatic parking brake when stopping on slopes. Road surface and covered routes should be checked.
Does a tugger train fully replace forklifts?
No. Forklifts are still needed in the store to load trailers and at the dispatch dock; the train only replaces horizontal transport between store and line.
Need a tugger route designed for your plant? Send the layout and number of lines via the quote page or call 0902 63 79 70.