This large integrated toy manufacturer integrates injection molding, assembly, packaging, warehousing and shipment. Order volume fluctuates sharply all year round, with 3–4 consecutive months of peak production around Children's Day, Christmas and cross-border e-commerce shopping festivals. All workshops and warehouses run under standard normal temperature, while the factory faces long-standing logistics challenges:
High pallet load weight: Plastic raw materials and full cartons of finished toys reach nearly 2 tons per pallet, exceeding load limits of small stacking forklifts, while heavy-duty manual forklift operators are hard to recruit.
Diverse mixed materials: Plastic pellets, metal accessories, packaging cartons and finished toys are stored in separate zones, and manual inbound & outbound sorting easily confuses product batches.
Severe labor shortages in peak seasons: Temporary forklift staff incur high training costs, and idle workers raise operating expenses in slow seasons.
Easy scratch & collision damage: Rough manual handling leaves heavy scratch marks on toy surfaces, resulting in high finished goods rejection costs.
Safety risks: Mixed pedestrian-vehicle flow in workshops and warehouses, with high risks of toppling over overstocked pallets.
The toy factory deployed batches of the REEMAN X-ant 2-ton heavy-duty autonomous forklift, establishing a full-chain automated logistics system linking raw material warehouses, injection molding workshops, assembly lines, finished vertical warehouses and shipping docks. With 2-ton rated load and stable lifting performance, the model is fitted with soft fork protection pads to prevent scratches on plastic and toy pallets, supporting multi-vehicle cluster dispatching.
Project Implementation Workflow
Raw Plastic Material Inbound Stacking: Pallets of plastic pellets delivered by trucks are automatically transported by X-ant forklifts for layered storage in high-bay raw material warehouses.
Timed Material Feeding for Injection Molding Lines: Linked with production MES systems, forklifts deliver raw material barrels on schedule based on injection machine rhythms and recycle residual materials.
Semi-Finished & Finished Goods Storage: Fully packed toy pallets after assembly are automatically transported to finished warehouses for zoned layered stacking.
Cross-Border Order Outbound Shipment: After e-commerce orders are issued, forklifts accurately retrieve pallets of corresponding toy models and deliver them to loading docks for truck shipment.
Circular Auto-Charging Operation: Multiple forklifts work shifts for 24-hour nonstop production, automatically charging at low battery without manual attendance during peak seasons.
Measurable Customer Benefits
7 full-time forklift operators removed from warehouse transit posts, eliminating temporary seasonal recruitment and saving RMB 360,000 annual labor costs.
Scratch & collision rejection rate of finished toys dropped by 92%, drastically cutting product loss expenses.
Warehouse space utilization improved by 45%. The 2-ton heavy-load stacking capacity avoids costly warehouse expansion.
100% accurate inbound & outbound sorting, eliminating batch confusion of toy models and completely resolving cross-border order shipment delays.
24/7 uninterrupted logistics operation lifts factory peak production capacity by 30% and shortens order delivery cycles by 20%.
Core Advantages of REEMAN X-ant
Standard heavy-duty stacking autonomous forklift with 2-ton load capacity, perfectly suited for mass pallet transit in light manufacturing including plastic, toy and home goods factories. Equipped with soft fork guards to avoid surface scratches on plastic and paper packaging. IP54 dust-proof body adapts to slightly dusty normal-temperature injection molding workshops. Supports cluster collaborative dispatching for dozens of vehicles. Seamlessly integrates with WMS and MES production management systems to realize full digital traceability of orders and materials.
Free survey consultation for unmanned logistics solutions for toy & plastic light manufacturing factories