Explosion-proof electric stackers, automated AGV forklifts and counterbalance trucks together digitize raw-material intake, process feeding and finished-goods storage at a fine chemical plant — drum handling accidents down 95%.
Chemicals & Hazardous Goods
The client is a large fine chemical manufacturer producing organic solvents, chemical powders and liquid intermediates. The site is divided into a production/process zone, a hazardous raw-material stereoscopic warehouse and a finished-goods warehouse, handling 200 L drums of hazardous liquids, IBC totes of solvents and bagged chemical powders.
Manual handling of hazardous materials carried three major risks: tipping and leakage of hazardous drums, mis-storage and mixing across chemical categories, and difficulty staffing hot or night-shift operations — plus handling damage to raw materials. MightyCargo deployed a combined solution of counterbalance forklifts, explosion-proof electric stackers and fully automatic AGV forklifts, covering raw-material intake, process feeding and finished-goods putaway for a safer, digital, more efficient chemical warehouse.
Equipment deployed: Counterbalance forklifts + explosion-proof electric stackers + fully automatic AGV forklifts
Reactor support tanks need a constant supply of drummed organic solvents; 200 L chemical drums are stored as whole pallets and transferred from the raw-material yard to process feed points. The MightyCargo explosion-proof counterbalance electric forklift features explosion-proof electronic control and a flame-retardant hydraulic system for flammable atmospheres: forks center precisely on standard chemical drum pallets, and a cushioned mast prevents drum cracking and liquid leakage from travel bumps — eliminating solvent-leak fire risk. For outdoor, all-weather duty, sealed motors and wear-resistant tires suit rough yard surfaces, moving bagged powders (calcium carbonate, additives, etc.) whole-pallet from the yard to the dosing workshop — replacing aging fuel trucks and removing exhaust corrosion and explosion-compliance concerns.
The finished hazardous warehouse uses multi-level heavy racks with IBC totes and drummed chemicals stored by zone at 6 m heights in narrow aisles. The MightyCargo walkie explosion-proof stacker is the zone's main equipment: a compact body works narrow aisles and a multi-stage lift mast puts totes and drums at high levels, maximizing stereoscopic storage; solvents are segregated by type (alcohols, esters) to eliminate chemical-mixing reaction hazards. Explosion-proof electricals and spark-proof wheels meet the fire code for Class A hazardous warehouses — human-supervised duty that removes the risk of sparks igniting volatile vapors.
A newly built clean intermediate-materials warehouse stores food-grade IBC totes and must tightly control dust and personnel entry. Multiple MightyCargo underride-lifting AGVs plus stacking AGVs are integrated with the WMS: raw materials are palletized at unloading, AGVs pick them up automatically, follow mapped routes into the rack area and complete autonomous high putaway; on production feeding orders, the system picks the matching totes and transfers them to the outbound dock — with no personnel entering the clean zone. Multi-vehicle zone dispatch plans paths automatically, avoids congestion and collisions, and supports 24-hour continuous feeding with unattended night shifts — solving the chemical industry's night-shift staffing problem.
−95%
drum handling accidents
Explosion-proof equipment plus automation cut chemical drum tipping/leakage accidents by 95%; mis-storage and mixing hazards are basically eliminated, and the site passed the regulatory hazardous-warehouse compliance review.
12 → 2
staff on site
The original 12 forklift drivers across warehouse and workshop were reduced to 2 equipment O&M staff — saving over 300,000 RMB a year in labor.
+180k RMB/yr
materials recovered
Automated stable picking cuts drum damage, recovering about 180,000 RMB a year of raw-material losses.
15 → 5 min
per pallet in
Manual single-pallet inbound took 15 minutes; automation shortens it to 5 minutes, lifting daily warehouse throughput 50% — matching the plant's 120,000 t/yr capacity expansion.
The explosion-proof forklift plus intelligent AGV package can be replicated widely in petrochemical, coatings, pharmaceutical intermediates and agrochemical manufacturing — with models selected by Class A/B/C hazardous-warehouse ratings. It is the standardized blueprint for chemical warehouse intelligence and safety upgrades.
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Read the caseTell us about your warehouse, factory or port challenge — our engineers will recommend the right MightyCargo solution for your loads, aisles and duty cycles.