Client: T&G
Location: Hastings, Hawkes Bay, NZ
T&G (formerly known as Turners and Growers) originated from humble beginnings as a fruit auction business based in Auckland, New Zealand. An impressive 125 years later, T&G now grows, sells, markets and distributes fresh produce to customers in over 60 countries worldwide. From apples to tomatoes, citrus, and blueberries, the team partners with growers across New Zealand, Asia, Africa, the Americas, and further afield.
Client Challenge:
With a far-reaching international network of sites and over 2,000 employees, maintaining staff safety and ensuring efficient operations is critical. So when T&G decided to build a brand-new packhouse in Hastings, having the right safety solutions in place to protect people and assets and mitigate area-specific risks was a must.
Packhouse environments are notorious for being short on space. Working in tight areas where forklifts, other material handling equipment (MHE), and pedestrians are present—in this case, up to 100 staff in the same building—presents significant health and safety risks. If these risks are not adequately managed, there is a high risk of collisions, potentially resulting in severe damage or injury.
Our team at Vanguard worked closely with T&G’s Project Manager and the layout team at Napier firm Bluefruit Design, reviewing and discussing the plans, identifying key challenges, and developing fit-for-purpose solutions to improve site safety and efficiency.
The challenges identified were:
- Protecting staff, structures and equipment in high-risk operational zones where forklifts, other material handling equipment (MHE), and pedestrians coexist.
- Preventing pedestrians from entering areas, such as packing lines, where forklifts and other MHE frequently access simultaneously.
- Creating a physical barrier to encourage pedestrians to stop and pause in high-risk zones before walking into the line of vehicles, forklifts and other MHE.
- Protecting the structure of the tunnel linking the old packhouse facility to the new site, where forklifts regularly travel in and out of.
- Preventing damage to the outdoor canopy area from vehicle, forklift and other MHE impact.
- Creating a clear walkway for pedestrians in and outside of the packhouse to keep them separate from the path of moving vehicles.
Solutions Offered:
Following our plan assessment, we recommended that T&G install a mix of steel and flexible safety controls to address area-specific risks. While T&G originally planned to use only steel solutions, they decided to invest in both to ensure they had the protection they needed across the entire site.
The reason for using both steel and flexible controls was that different areas required different levels of impact protection. The installation of both types of solutions was influenced by the kinds of vehicles in the area and the likelihood of them being hit.
T&G watched our flexible impact video and saw the value that flexible barriers and bollards could add to their facility alongside steel alternatives—despite the higher upfront cost of the flexible options. Providing the T&G team with a visual representation gave them the assurance they needed that incorporating flexible options would ultimately lead to better site protection and reduced long-term maintenance costs.
Protecting Staff, Structures and Equipment in High-Risk Operational Zones
One of the most vital areas requiring protection at the T&G site was the packing line. As previously mentioned, space is extremely limited in this environment, and forklifts and pedestrians often work in the same area.
Due to the space’s size and the high risk of collision, T&G needed to install a barrier system that could safely separate staff and MHE, while also providing sufficient impact protection in the event of a crash. For this reason, the decision was made to install Boplan TB400 Plus flexible barriers around the entire perimeter of each packing line.
All Boplan solutions are made from Extrilene®, a flexible, energy-absorbing polymer material designed to withstand various impacts and then return to its original shape.
The TB 400 Plus, in particular, is designed to withstand repeated impacts of up to 20.1 kJ. Due to its high impact resistance, the barrier won’t rip out of concrete floors during impact, protecting the flooring and reducing maintenance costs.
To develop a seamless flow between each TB400 Plus barrier, Boplan BO200R flexible bollards were installed at 45-degree angles at the corners, eliminating the need for multiple end posts. The Boplan BO200R bollards are designed to withstand repeated impacts up to 10.2 kJ.
Keeping Pedestrians Out of Shared Areas When Forklifts Are Present
With forklifts and pedestrians operating so closely together on packing lines, preventing them from intersecting was a high priority for T&G. In areas where both need access, this can be particularly challenging to navigate.
To provide access for both, T&G installed a mix of single and double Boplan SG Swing Gates to integrate with the TB400 Plus barriers. While the single gates were ideal for areas where only pedestrian access was required, the double gates were manually locked into place once opened. As a result, they created a physical barrier along the pedestrian path to prevent people from walking into the forklift’s path.
Encouraging Pedestrians to Stop Before Crossing Danger Points
At office doorways and at rapid-door pedestrian entrances and exits, it is easy for pedestrians to overlook that forklifts may be approaching when they are distracted or busy.
By installing Boplan HP PLUS flexible barriers in these risk-prone zones, a safe walkway was created to separate pedestrians from forklift areas and prevent them from crossing.
The HP Plus is Boplan’s strongest pedestrian handrail, featuring three rails and a heavier post to effectively screen pedestrians in high-traffic areas. Also energy-absorbing, it is designed to withstand repeated impacts of up to 5.50 kJ.
Installing Wall Protection for Tight Areas Where Vehicles Enter and Exit
At T&G, a tunnel links the new facility with the old packhouse. Vehicles regularly travel through this thoroughfare, increasing the risk of veering off and contacting the tunnel walls.
To protect these structures, ForkSafe 400-A steel barriers were installed along the walls. The ForkSafe 400-A is a compact, heavy-duty steel barrier designed to protect walls, machinery, and equipment from low-height forklift and MHE impacts up to 5.85 kJ.
At the foot of the rapid doors, Boplan BO200R flexible bollards were positioned for added wall protection against vehicle and forklift impact, and are designed to withstand repeated impacts of up to 10.2 kJ.
With two vehicles able to travel through the tunnel at a time, a Boplan TB400 Plus handrail barrier was installed between the two rapid doors to prevent forklifts from colliding when entering or exiting the tunnel.
In the canopy area outside, T&G installed RhinoStop Single Steel Guardrail along the walls for enhanced impact protection. A surface mount barrier, it’s designed to protect assets from low-speed, low-centre-of-gravity vehicles.
Compliant with AS/NZS crash testing standards, these barriers feature energy-absorbing support posts with crumple zone technology. The crumple zone technology minimises the force on bolts when hit and the risk of concrete damage as a result.
Creating a Clear Walkway for People to Get From A to B
Inside the facility, staff needed a dedicated walkway to guide them from the office to their workstation without intersecting forklifts or other MHE. To achieve a high level of impact protection, Boplan HP PLUS flexible barriers were utilised in this area.
Outside, however, pedestrian walkways were created using ForkSafe 950-A steel barriers. A highly popular walkway protection barrier, the 950-A is designed to protect pedestrians from forklift and light truck impact up to 11.75 kJ.
The decision to use steel rather than flexible barriers in this situation came down to the purpose they needed to serve. With limited forklift activity in the area, the barrier was required as a guide, rather than for impact protection, making it an appropriate solution for the situation.
The Outcome:
Following the installation, T&G’s Project Manager shared extremely positive feedback on the decision to use a mix of steel and flexible bollards and barriers. While flexible options were initially more expensive, he believed they were well worth the investment due to their durability and aesthetic benefits.
With the right safety solutions in the right areas (based on risk levels and the types of traffic in the area), the safety and efficiency of the packhouse have been significantly enhanced. As a result, the T&G team now has the confidence and assurance that their people and assets are kept safe, forklifts and MHE are protected from impact, and traffic can flow uninterrupted, ensuring maximum efficiency.
