Based in Dudley, West Midlands, Fibercill has carved out a strong reputation within the door systems manufacturing industry. Operating from their facility at The Moorings, Fibercill produces high-quality door kits and engineered solutions, playing a key role in the wider Masonite group, a global leader in interior and exterior door manufacturing.
As part of their mission to drive sustainability and operational excellence, Fibercill faced a familiar but pressing challenge: modernising their materials handling fleet to meet evolving environmental and efficiency standards.
The Challenge: Modernising Materials Handling for a Greener Future
Fibercill had long relied on diesel-powered Baumann sideloaders—robust and dependable machines that had served them well over the years. However, with tightening environmental standards and a growing internal focus on sustainability, the need to reduce emissions, noise, and maintenance overhead became impossible to ignore.
The company recognised that their existing equipment, while operationally sound, no longer aligned with their forward-thinking goals. They needed a solution that could maintain performance while supporting a cleaner, more modern work environment.
The Solution: Baumann EGX60 Electric Sideloaders
After thorough evaluation, Fibercill selected the Baumann EGX60 electric sideloader as the next evolution of their fleet. The decision marked a strategic investment in both operational performance and long-term environmental stewardship.
The new EGX60 sideloaders offer high performance with zero emissions, making them the ideal solution for handling long and heavy loads indoors and in tight manufacturing environments.
Implementation Impact: Measurable Improvements Across the Board
Since introducing the Baumann EGX60 fleet, Fibercill has experienced a range of tangible benefits in key areas of operation:
- Workplace Environment
- Enhanced indoor air quality thanks to zero-emission operation
- Quieter performance, improving overall communication and comfort
- Better operator visibility and ergonomic controls for safer handling
- Operational Efficiency
- Superior manoeuvrability in confined production spaces
- Greater precision and control in load handling
- Reduced downtime due to lower maintenance requirements
- Environmental Sustainability
- Significant drop in COâ‚‚ and particulate emissions
- Reduced energy consumption compared to diesel alternatives
- Full alignment with Masonite’s broader sustainability objectives
Key Features & Benefits of the Baumann EGX60
The Baumann EGX60 electric sideloader offers a wealth of features that enhance both performance and sustainability:
Environmental Impact
- Zero direct emissions during operation
- Near-silent performance for indoor use
- Substantially reduced carbon footprint over the machine’s lifecycle
Operational Excellence
- Hydrostatic transmission for smooth and responsive handling
- Automatic deck levelling for improved load stability
- Exceptional operator visibility and intuitive controls
- Heavy-duty components designed for rigorous, long-term use
Cost Efficiency
- Lower fuel and energy costs versus diesel models
- Less frequent maintenance and longer service intervals
- Reduced total cost of ownership over the fleet’s lifespan
Enhanced Safety: Putting People First
Operator and pedestrian safety played a central role in Fibercill’s fleet upgrade. In collaboration with Forkway, several advanced safety technologies were introduced:
Blue Pedestrian Awareness Lights
- Projects a bright blue warning spot ahead and behind the vehicle
- Ideal for alerting pedestrians at blind corners or trailer entrances
- Boosts visibility in low-light areas of the facility
SEEN Safety Detection System
- Detects high-visibility vests worn by nearby personnel
- Triggers real-time audible alerts when people enter high-risk zones
- Provides operators with instant feedback to reduce incidents
Fleet Intelligence: FTC Optafleet Integration
To further optimise their investment, Fibercill implemented FTC’s Optafleet system, which brings intelligent fleet management tools to the operation:
- Real-time tracking of sideloader usage and operator behaviour
- Integrated license management with automatic expiry notifications
- Digital pre-use safety checklists for compliance
- GPS tracking and detailed analytics to refine warehouse efficiency
Conclusion: A Future-Ready Fleet for a Leading Manufacturer
Fibercill’s adoption of the Baumann EGX60 electric sideloaders is more than a fleet upgrade—it’s a statement of intent. Their move toward sustainable, intelligent materials handling represents a significant stride in responsible manufacturing and operational performance.
This initiative proves that embracing green technology does not mean compromising on capability or reliability. Instead, it delivers measurable advantages in safety, cost savings, and environmental performance—setting an example for other manufacturers looking to balance productivity with sustainability.
As Fibercill continues to grow as part of the Masonite group, their Baumann electric sideloaders will be an essential part of a cleaner, more efficient future.
