A Cold Store Foreman’s Perspective on Modern Container Loading
At a Glance: Kainui Pack & Cool’s Dock Loading Upgrade
- Before: Manual pallet-by-pallet loading, repeated forklift trips to the back of the container
- After: Sensor-guided reversing, dock leveller deployed, forklifts load directly
- Biggest benefit: Safety – reduced risk of pallets shifting or falling during loading
- Bonus: Staff freed up for other cool store tasks, and loading now happens under cover
A slow-loading container can hold up a truck, delay dispatch, and tie up staff who could be doing other jobs on the floor. For New Zealand exporters, that’s the real cost of a manual loading process.
At Kainui Pack & Cool, a kiwifruit packhouse and cool storage facility, the team made the move to a dock loading system to change how containers are loaded on-site. We spoke with Robbie Franks, Cool Store Foreman at Kainui Pack & Cool, about what that shift has meant for his team day to day.
A dock loading system speeds up container loading by letting forklifts drive straight into the container once it’s docked and levelled, replacing manual pallet-by-pallet handling. At Kainui Pack & Cool, cool store foreman Robbie Franks says the switch made loading “easier and faster” and removed the risk of pallets falling during manual transfers.
Loading Containers the Traditional Way
Before the upgrade, container loading at Kainui was a manuaal, repetitive job.
When a container arrived onsite, the truck would disconnect from the container before loading could start. Staff would then manually feed pallets into the container one at a time, requiring repeated handling throughout the loading process.
According to Robbie, the process was repetitive and labour intensive.
“The truck would come in and then detach from the container. We would open the doors and feed pallets in one by one. The operator would take each pallet all the way to the end and then come back for another.”
The process worked, it required significant labour input and kept staff tied up with loading tasks that could otherwise be spent on higher-value activities.
A Faster and More Efficient Loading Process
Loading containers at Kainui today is a different job.
The driver reverses into the dock, guided by sensors that signal how far to come back. Once the truck is in position, the dock leveller is deployed, bridging the gap between the warehouse floor and the container so forklifts can drive straight in.
The result is a faster, more streamlined loading process with fewer manual steps.
“This is definitely easier and faster.”
Instead of relying on repeated pallet transfers, operators can now move product directly into the container. That cuts out the repeated handling and shortens the time a container sits at the dock.
For facilities managing high export volumes, these efficiency gains can quickly add up over the course of a season.
| Manual Container Loading | Dock Loading System |
|---|---|
| Truck detaches from container before loading starts | Truck reverses into the dock, guided by sensors |
| Staff feed pallets in one at a time | Dock leveller creates a direct floor-level bridge |
| Operator carries each pallet to the far end and back | Forklifts drive directly into the container |
| Risk of a pallet shifting or falling during transfer | Reduced handling lowers the chance of a pallet falling |
Improved Safety During Container Loading
For Robbie, the biggest change isn’t speed. It’s safety.
Manual loading methods can introduce additional risks when pallets are being transferred or moved through containers. The dock leveller creates a fixed, level connection between the building and container, cutting out most of that handling.
“Safety is the big one. You can never be too sure if a pallet is going to fall out or not when you’re loading manually.”
– Robbie Franks, Cool Store Foreman, Kainui Pack & Cool
With a controlled loading interface in place, operators can focus on moving product rather than managing the risk of a pallet coming loose.
Freeing Up Staff for Other Cool Store Tasks
Beyond faster loading, one of the most noticeable improvements has been the ability to reallocate labour to other tasks throughout the facility.
“It’s made our day a lot easier. Less time loading means doing other work that we could be doing.”
For a packhouse managing high export volumes through the season, that’s staff time that goes back into other jobs around the site rather than standing at the back of the container.
Working Out of the Weather
Loading through an enclosed dock also means operators aren’t exposed to the weather during the process.
“The good thing about working inside is you don’t have to deal with the elements.”
For a facility handling product through wet winters and busy export seasons, that’s a small but real change to the working environment.
Would Kainui Recommend a Dock Loading System?
“I definitely would recommend it to save time and for safety. It’s definitely a better process.”
– Robbie Franks, Cool Store Foreman, Kainui Pack & Cool
For Kainui Pack & Cool, moving from manual container loading to a dock loading system has changed the loading process on three fronts: speed, safety, and how staff spend their day.
FAQs
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What’s the difference between manual and dock-based container loading? Manual loading means staff feed pallets into a container one at a time while an operator carries each one to the far end and back. A dock loading system lets forklifts drive directly into the container once it’s docked and levelled, cutting out the repeat handling.
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How does a dock leveller make container loading safer? By creating a fixed, level bridge between the warehouse floor and the container, a dock leveller reduces the handling and repositioning that can cause a pallet to shift or fall during manual loading.
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Does a dock loading system reduce the labour needed for container loading? Yes – because forklifts can load directly rather than pallets being carried in stages, staff spend less time on the loading task itself and can be reallocated to other work in the facility.
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Can a dock loading system be used in cold storage and packhouse environments? Yes. Kainui Pack & Cool, a Bay of Plenty kiwifruit packhouse and cool storage facility, uses a dock loading system as part of its container loading process.
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What sensors are used to guide a truck into a loading dock? Vehicle-guidance sensors signal the driver how far to reverse and when to stop, so the container lines up correctly with the dock before the leveller is deployed.
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Does loading indoors protect staff from weather conditions? Yes. Loading through an enclosed dock system means operators work under cover rather than exposed to wind, rain, or sun during loading.
Looking to improve container loading at your facility?
Whether you’re running a cold store, packhouse, food processing plant, or distribution centre, Ulti Group can help you assess your loading dock setup.
Ulti Group designs and installs container loading systems throughout New Zealand, helping facilities create safer and more efficient loading operations.