C the alternative
October 1st 2005

Heavy investment in production facilities and R&D has resulted in innovative new products from pallet racking specialist, Metalsistem

Italian precision engineering group Metalsistem is providing the UK’s material handling sector with rich pickings in the way of lightweight and strong pallet racking systems. And the company, whose UK subsidiary Metalsidac is based in Nottingham, is showing how Italy’s manufacturing industry can withstand the current economic slump as a result.

Italy’s post-war manufacturers, who have made the country the world’s fifth largest industrial economy, have been struggling in recent years to keep up with the competition posed by China’s cheap and vast labour force. Those weathering the storm are the ones that have continued to invest in research and development - creating products that are head and shoulders above those of their competitors - even at the expense of short-term profits.

With a turnover of 260 million euros, Metalsistem has fully embraced this survivalist strategy, bolstering its position as one of the world’s largest groups in storage equipment. Established in Rovereto, northern Italy, in 1968, and after more than 25 years of production, Metalsistem now has a network of subsidiaries and distributors stretching across 55 countries.

Stronger & more durable

Its economic clout and its 120,000m2 devoted to production at the Rovereto factory have enabled the company to invest heavily in the most up-to-date production facilities and into research and development. Metalsistem’s engineers have come up with two alternatives to the traditional C-shaped design of upright sections in storage systems, which are stronger, more durable and lightweight.

The first, used in the group’s Superbuild and Unibuild systems, is a closed, D-shaped design.

The second, used in the Super 4/5/6 system, is a closed box shape without holes or cut-outs. Each upright has eight location points for connecting beams or bracing.

These can be fitted in parallel on the same upright at the same height, providing a unique solution to any load requirement.

Metalsidac’s Andy Bufton, who is responsible for supplying major turnkey projects, said: "The design of the various components is the result of rigorous technical testing.

"The three pallet racking products are made of the prime quality high tensile steels engineered to provide maximum strength. This rational use of steel has enabled us to compete on price too.

"These cost savings are particularly beneficial for companies who are looking to install substantial storage solutions."

The components are made from layers of prime-quality, high-tensile, hot-dipped steel, layered together to obtain lightweight yet extremely strong structures. The frame loads of the flagship products, Superbuild, Unibuild and Super 4/5/6, vary from 7.5 to 35 tonnes. Superbuild is designed for general purpose applications while Unibuild is designed for heavy-duty or heavier use.

Metalsistem’s newest product, the Super 4/5/6 system, has been designed to interface with the group’s retail shelving products, responding to the greater flexibility demanded by today’s retail markets.

The beams of the Superbuild and Unibuild are profiled with quadruple flange thickness at points of maximum stress to increase the loading capacity.

The grooves on top of the beams are also used to locate the Metalsistem patented heavy-duty, steel shelf panels, pallet support bars and drum cradles thus providing a truly integrated solution.

The welded beam end connector has five anchor points, three of them operating in tension and two in compression, providing a better connection to the upright with increased load capability.

Superbuild and Unibuild are interchangeable, providing companies with flexible storage solutions. Every component of the three systems is produced at the Rovereto factory on fully automated production lines.

Finely tuned

Metalsidac’s national sales and distribution manager Nigel Rycroft explained: "The Italian manufacturing process is incredibly slick. The production line is a finely-tuned process, ensuring that we can turn around bespoke orders from stock quicker than other manufacturers.

"Whether you need a few bays of pallet racking or shelving, or a much larger system to fill a whole warehouse, we can deliver within days or weeks. Our distributors, in particular, have found it extremely advantageous to secure short lead-time orders."

And therein lies the pay-back for the group’s heavy investment in technology.

Customers are expecting more and Metalsidac is delivering it - and in doublequick time.