In injection moulding, extrusion and blow moulding plants, the electric forklift is the busiest machine in the plastics and rubber industry: it takes resin bags to the machines, clears boxes of parts from the line and moves pallets to the warehouse. This article looks at each step on the shop floor and how to choose between the STILL RX 20, RX 60 and RCE.
What does a plastics or rubber plant demand from a forklift?
Unlike a distribution warehouse, a forklift in a plastics plant works between moulding machines, extruders, mixers and packing areas. Aisles are often narrowed by resin dryers, vacuum loaders, conveyors and mould trolleys. Material flows to the rhythm of production: if the machines run day and night, raw material must arrive steadily and finished goods must be cleared in time, otherwise the line stops for lack of space.
Inputs are resin bags, bulk bags (jumbo bags), octabins, additives and masterbatch; rubber plants also handle natural rubber bales and compounded rubber. Outputs are usually light but bulky: boxes of moulded parts, bottles, cans, film rolls, seals. The truck must manoeuvre precisely and lift and lower smoothly so products are not dented or scratched. Because the work happens in enclosed halls next to machine operators, a locally emission-free electric truck is the natural choice for production areas.
Where electric counterbalance trucks are used
Receiving raw material and feeding machines
Pallets of resin bags are unloaded from trucks, put into the raw material store and supplied to the machines according to production orders. A counterbalance truck handles both jobs: it drives into the trailer over a dock leveller and lifts bulk bags onto a discharge frame or the platform of a feed hopper.
Clearing finished goods at the end of the line
Boxes of moulded parts, film rolls and packed rubber products accumulate continuously at the end of the machine. Electric forklifts take the pallets to packing, quality inspection or the warehouse staging area, keeping the floor around the machines clear.
Suitable STILL models and why
STILL RX 20 covers the 1.4 to 2 tonne range with a top speed of 20 km/h, and STILL presents it for narrow aisles in heavy-duty two- or three-shift applications. With the Li-Ion version, just 30 minutes of charging can add several hours of operation, which suits a plant running continuously: charge whenever the driver takes a break.
STILL RX 60 is for heavier loads such as compounded rubber pallets or bulk bags. The 2.5–3.5 t and 3.5–5.0 t ranges let you pick the right capacity; with STILL lithium-ion technology the truck can run three shifts without a battery change. STILL describes the RX 60 6.0–8.0 t as suitable indoors and outdoors, even in wet and dusty environments.
If the plant has adhesive mixing, solvent-based printing inks or a solvent store, assess the hazardous zones first. STILL sources show that the RX 20 and RX 60 have operating documentation for explosion-protected versions; the specific protection level must be determined through a site survey and area assessment under current regulations.
| Step | Type / model | Reason |
|---|---|---|
| Unloading resin bags from trucks | STILL RX 20 | Compact, precise manoeuvring, 1.4–2 tonne range |
| Shift-based feeding of moulding machines and extruders | STILL RX 20 Li-Ion | Interim charging between shifts |
| Compounded rubber pallets, heavy bulk bags | STILL RX 60 3.5–5.0 t | Right capacity range, three shifts with lithium-ion |
| Small workshops, low frequency | STILL RCE 15-20 | Simple, lithium-ion version with quick-charge access |
Points to watch in a plastics plant
- Spilled pellets: pellets on the floor reduce wheel grip. Set up a cleaning routine around the machines and choose tyres that suit the floor.
- Working height: measure the height needed to place bulk bags on hoppers and compare it with the specification sheet.
- Actual load centre: bulk bags and rubber bales have different load centres from standard pallets; see how to choose forklift capacity.
- Mould changes: if a forklift assists, check the mould weight and load centre against the load chart, with suitable attachments and safety procedures.
Other truck types for the industry are summarised on the forklift solutions for plastics & rubber page; the full range is in STILL electric forklifts.
Frequently asked questions
Can electric forklifts keep up with a plastics plant running three shifts?
Yes, with the right energy configuration. With lithium-ion the RX 60 can run three shifts without a battery change; the RX 20 Li-Ion uses short charges during breaks.
Should a counterbalance truck be used for mould changes?
Only when the weight, load centre and the way the mould is held fall within the truck’s load chart and suitable attachments are available. Have a technician survey the job first.
How do I choose a truck for areas with solvents?
Assess the hazardous zones first. The RX 20 and RX 60 have documentation for explosion-protected versions; the specific protection level is set after a survey under current regulations.
To find out whether the RX 20, RX 60 or RCE fits your plant, send a request via our quote page or call 0902 63 79 70 and a technician will survey your actual material flow.