Improving Animal Feed Mill Safety: Pallet Loading Gates for a Manual Tipping Station

Improving animal feed mill safety was at the heart of this project. The customer’s existing pallet loading setup used a racking system, with pallets loaded onto it with an on-site forklift. The pallets hold various ingredients, which operators tip manually into mixers via hand tip stations.

Each time an operator removed a pallet or bag, it left an exposed, unguarded edge and a real risk of falling. The existing racking had also sustained damage over time and was approaching the point where it could fail load testing.

To resolve the safety risk, address the structural concerns with the existing racking, and improve the overall efficiency of the loading area, with minimal disruption to production.

Following a detailed site survey and discussions between our project manager and in-house design team, we agreed a plan with the customer to remove the racking entirely and fabricate a steelwork extension to the existing platform.

Because the project involved load-bearing steelwork, we brought in a structural engineer to review our designs and produce structural calculations. A requirement under BS EN 1090 to confirm the steelwork could safely support the intended loading.

Our design team modelled the new loading gates using Autodesk Inventor 3D software, producing a detailed proposal for customer approval before any manufacturing began.

Once the customer approved the design, we manufactured all components in-house: cutting steel to size, marking and drilling connections, welding, and completing a trial assembly before sending the finished parts for powder coating at our approved supplier.

Before installation, we fitted safety lines along the exposed edge and cordoned off access to the existing platform to protect operators during the dismantling phase.

Our engineers completed the installation over a planned two-day shutdown, arranged in advance with the customer. They removed the old racking using a forklift and cherry picker, then assembled the new steelwork and platform extension.

The new layout delivered more than a safety fix. By reconfiguring the platform, we created additional space for forklift manoeuvring and loading, which the old racking had restricted, while keeping clear walkway access throughout.

The new gates feature a locking mechanism that prevents lifting during loading, keeping operators safe at all times. And despite accepting two standard pallets simultaneously, the gates are lightweight. The pivot point and weight distribution mean one person can operate them safely and with minimal effort.

The customer is delighted with the outcome. The project delivered clear improvements to both animal feed mill safety and day-to-day operational efficiency on site.