Irish forklift manufacturer Combilift has introduced a new product designed to address the issue of forklift overloading. The company’s new Combi Safe-Lift is an anti-overload device that aims to help forklift operators better understand and manage the loads they are lifting, reducing the risk of accidents and injuries associated with exceeding a forklift’s rated capacity.

“Forklift operators who are insufficiently aware of the load they are lifting and the risks that come with exceeding the forklift rated capacity not only compromise their own safety, but also place everyone working around them at serious risk,” Combilift said in a statement.

There are several factors that can contribute to a forklift becoming overloaded, including the load center, weight of the load, lift height, and the type of load being carried. The load center, which is the distance from the face of the fork to the center of gravity of the load, is a particularly critical factor. The position of the load center can vary based on the type of load, such as liquid loads or non-uniform loads.

In addition to understanding load factors, forklift operators must also be aware of a forklift’s rated capacity and how to assess whether a load exceeds that capacity. The new Combi Safe-Lift is designed to help operators navigate these challenges by providing real-time feedback and alerts related to load weight and position.

The device incorporates a strain sensor on the forklift’s mast section and a lift cut-out valve on the hydraulic line. If the sensor detects a potential overload situation, the lift cut-out valve will disable further lifting. The device also includes an audible alarm to warn operators of an overload, as well as a load moment indicator on the forklift’s dashboard.

“The operator can instantly see from the green, amber and red ‘traffic light’ signalling when there is a risk of overloading or when the forks are not fully engaged for example, and take appropriate action,” Combilift explained.

While the Combi Safe-Lift is currently offered as an optional add-on for Combilift’s line of counterbalance forklifts, the company sees potential for the device to become an industry standard.

“We believe that this simple and cost-effective system should become a standard option on all counterbalance trucks in future,” said Combilift MD Martin McVicar. “Fitting a straightforward device such as the Combi Safe-Lift is an effective way to reduce risks for the operator and other personnel, and also to avoid product damage as well as costly repairs.”

According to the Occupational Safety and Health Administration (OSHA), forklift overturns are a leading cause of forklift-related fatalities, and these incidents are often the result of the forklift being overloaded or carrying an unbalanced load. OSHA regulations require employers to provide forklift operators with training on load capacity and load handling, as well as to ensure that operators are competent to operate a forklift safely.

Combilift is a global provider of forklifts and warehouse equipment, with distribution in more than 85 countries. The company specializes in the manufacturing of multidirectional forklifts, straddle carriers, and other materials handling solutions.