In frozen-food operations, product damage is one of the most common causes of waste.  UK supply chains reportedly lose around 12-13% of perishable stock every year due to operational issues – including handling and storage inefficiencies – equating to hundreds of tonnes of wasted goods per business and significant financial cost.

Toppled pallets, crushed boxes, and/or punctured drums not only reduce stock levels but can also compromise food safety, customer satisfaction, and reputation.  Using the right forklift attachments and using them correctly plays a crucial role in protecting products, reducing waste, and keeping operations running efficiently.

Key considerations for reducing waste include:

1. Attachment / Load Pairing
   Different products require different handling solutions. Fork extensions, pallet clamps, drum handlers, and box grabs are designed for specific load types. Using the correct attachment prevents tipping, crushing, or over-compression, keeping items intact throughout their journey from storage to dispatch
2. Fitting and adjustment
   Attachments must be correctly mounted and adjusted for each load. Even the smallest misalignment can cause uneven lifting or unstable handling, which increases the risk of damage. Adjustable forks help operators position loads correctly for different pallet sizes and types of packaging.
3. Careful handling
   Cold-store conditions can encourage operators to work quickly to meet deadlines, but it’s important to balance speed with careful, controlled handling. Using attachments like tilting forks or spreaders allows smooth, controlled movement of heavy or fragile loads, reducing shocks or sudden impacts that can damage products.
4. Maintenance
   Worn forks, stiff hydraulics, or poorly lubricated joints increase the chance of goods being mishandled. Regular inspections, lubrication with cold-weather greases, and timely replacement of worn components are essential for consistent, safe operation.
5. Operator training
   No attachment, no matter how well designed, can prevent waste if operators aren’t confident in using it correctly. Contact Attachments offers on-site training covering:

• Correct attachment fitting and load handling
• Understanding how attachments affect forklift stability and load limits
• Techniques for delicate or irregular loads

Training is hands-on, typically 90 minutes, with a maximum of three trainees per session, ensuring operators gain practical skills that directly reduce product loss.

With over 50 years’ experience in designing forklift attachments for the food & drink industry, Contact Attachments supports frozen-food operations with bespoke solutions that are hygiene-safe, cold-store compatible and ergonomically smart.  They’re proud to work alongside BFFF members in helping make the chain of frozen-food logistics safer, cleaner and more efficient.

If you’d like to discuss how the right attachment can reduce manual handling in your chilled or frozen operations – or to conduct a review of your site – please contact the team on 01686 611200 or via their website at www.forklift-attachments.co.uk