How does the cargo affect the tail lift and its equipment?
The type of goods to be transported significantly determines the requirements for the loading process. What is a routine and efficient process for standardised Euro pallets or roll containers requires special care and specific safety precautions when dealing with high-value goods or dangerous goods. The tai lift is more than just a lifting platform – it is the crucial link between the unloading point and the vehicle, making a smooth and safe flow of goods possible in the first place. Its proper use and the equipment fitted to the tail lift are decisive for safe transport and, ultimately, for cost-effectiveness.
Every type of load presents its own challenges:
Pallets »
require sufficient load capacity, as they can only be moved using pallet trucks.
Trolleys »
require a roll-stop, which is available in a variety of designs.
High-value goods »
such as pharmaceutical products require additional security measures to protect them from theft.
Hazardous goods »
are, in turn, subject to strict legal regulations that also apply during the loading process.
Below you will find an overview of the specific requirements for loading and unloading different types of goods and the safety aspects to be observed depending on the type of load – from correct positioning and the choice of suitable equipment that complies with legal requirements.
» Safe loading and unloading of pallets:
The foundation of modern goods transport
Pallets are the backbone of modern logistics. Whether beverage crates, foodstuffs, building materials or electronics – the vast majority of all goods are moved through the supply chain on standardised pallets. But what does this palletised transport mean for safe loading and unloading, and what demands does it place on the tail lift?
What goods are transported on pallets?
The Euro pallet (1200 x 800 mm) and its variants carry an impressive variety of goods. In the food industry, these include beverage crates, tinned goods, frozen goods and sacks of flour. The construction industry transports cement, tiles, insulation materials and paints on pallets. In industry, machine parts, chemicals in drums and electronic components are transported in this way. Even sensitive goods such as pharmaceutical products or high-value consumer goods benefit from standardised palletisation, as it offers protection and facilitates handling.
The load weights vary considerably: whilst a pallet with a light load such as toilet paper weighs a maximum of 200 kg, building materials or metal goods can easily reach 1,000 kg or more. This range clearly illustrates why a robust and reliable tail lift is indispensable.
How are pallets moved?
In practice, manual and electric pallet trucks as well as forklift trucks are mainly used. The pallet truck – also known as a hand pallet truck – is the workhorse for lighter loads and short distances. It is pulled or pushed by hand and is particularly manoeuvrable – ideal for tight loading areas and inner-city delivery routes. Electric pallet trucks make the work easier when there are frequent stops and heavier loads. It should be noted that the industrial truck adds extra weight to the tail-lift during the lifting process – for manual pallet trucks, a maximum of 100 kg of additional weight should be expected, and for electric pallet trucks around 500 kg.
This is precisely where the problem lies with forklifts: their own weight is significantly higher. Therefore, neither driving onto nor over the tail-lift platform is permitted! This can lead to severe damage – so-called impact damage – which permanently weakens the tail-lift. Further information can be found in the practical tips on using tail lifts ».
Requirements for palletised transport on the tail lift
Sufficient load capacity of the tail lift: Sufficient load capacity of the tail lift: A tail lift for palletised transport must be able to safely support the combined weight of the goods, the pallet and the pallet truck. Whilst the pallet itself weighs only around 25 kg, the goods on it can weigh between 200 and over 1000 kg, depending on the type. Added to this is the weight of the pallet truck required for handling. And: the larger the platform, the more space it offers for the load.
The MyCargolift online product finder will help you choose the suitable Cargolift, as will your contact at BÄR.
You can also find important information on correct handling in the practical hints for using tail lifts ».
Reinforced platform systems: The mechanical stresses caused by repeated use of pallet trucks and the concentrated forces acting on the platform require a robust design. Reinforced platform systems with more substantial platform profiles and special end profiles are specifically designed to withstand these stresses. It is particularly important to adapt the system to the specific load capacity and platform height: at BÄR, all these parameters are already incorporated into the development of its Cargolifts.
High-performance power unit for frequent work cycles: Palletised transport is characterised by high throughput rates. Delivery vehicles often have to manage numerous stops per journey. This requires a powerful hydraulic power unit with an output of approximately 3 kW, which enables rapid lifting and lowering movements and operates reliably even under intensive use. An undersized power unit would not only reduce the working speed and thus prolong delivery rounds but could also overheat and wear out prematurely during continuous operation. The higher engine power also ensures that the tail lift operates swiftly and smoothly even when fully loaded, without delaying operations.
The heavier the load, the more important it is to have trained specialist staff who are aware of the risks and hazards. For those who also want to know whether the Cargolift is being overloaded (e.g. too much load is being unloaded via the lift), BÄR has developed the Bär CargoWarn overload detection system. It enables fleet management to detect overloads and take appropriate measures, such as additional training for the lift can be used safely for as long as possible. Please speak to your contact person about this.
Select a different type of cargo by clicking on the image or heading or simply scroll down to roll containers and roll-off safety devices.
» Roll-container transport with tail lift:
Efficient, safe and economical
Roll containers, also known as roll-off containers, trolleys or colloquially as ‘Rollies’, have become an indispensable part of modern logistics. Those who deliver to supermarkets, bakeries or clothing shops on a daily basis do not transport individual containers, but several trolleys per trip. The tail lift is the critical interface between the vehicle and the recipient – and poses different challenges to those encountered in pallet transport.
Trolleys are standardised transport containers on (steerable) rolls that can be moved by a single person without technical aids. Their mobility makes them particularly efficient for certain industries and product groups. In addition, rolling boards are used to move machinery. However, loading and unloading several rollable loads simultaneously places specific demands on the tail lift and load securing.
Which industries transport which goods in roll containers?
The key advantage of roll containers is that goods can be moved directly from the warehouse via the vehicle to the point of use without the need for re-stacking. This is why trolleys dominate in sectors where speed and frequent goods handling are required:
- Retail and food logistics: Supermarkets and discounters receive daily deliveries in trolleys – bread and baked goods, fruit and vegetables, dairy products, frozen goods or drugstore items. Transport from the central warehouse to the branch and directly to the aisle and onto the shelf (“from lorry to shelf”).
- Postal and parcel services: Sorted items are efficiently bundled in roll containers and transported to distribution centres or branches.
- Healthcare: Krankenhäuser und Pflegeeinrichtungen nutzen Rollbehälter für Wäschelogistik, sterile Güter, Medikamente oder Verbrauchsmaterialien.
- Hotellerie, Gastronomie, Catering: Hospitals and care facilities use trolleys for laundry logistics, sterile goods, medicines or consumables.
- Laundries: Transport of soiled and clean laundry in hospitals or hotels.
- Pharmaceutical trade: Supplying pharmacies with pre-picked boxes.
- Textile and fashion industry: Garments and clothes on hangers can be transported hanging, whilst shoes and folded goods are stored safely. These flexible containers are indispensable, particularly in the fast-paced world of fashion logistics with frequently changing collections.
- Industry and retail: Small parts, spare parts stock, returns or picked goods benefit from standardised handling.
What impact do trolleys have on the tail lift?
The mobility of roll containers is both their greatest advantage and their greatest challenge during loading and unloading: unlike pallets, which can only be moved using a pallet truck, trolleys are permanently mobile. This fundamental characteristic determines the requirements for the tail lift: in accordance with the European norm for tail lifts EN 1756-1, roll containers must be secured on the platform. As a rule, so-called roll-off restraints (roll stops / trolley stops) or, alternatively, wheel recess are used.
Would you like to receive information on trolley stops straight away? Then BÄR has have a shortcut for you:
The platform website presents an overview of securing systems for roll containers ».
When selecting the right securing system for your trolleys, there are various questions to consider:
Trolley weight – How heavy are the loaded roll containers?
The weight of a loaded roll container depends largely on the type of goods being transported, but in logistics practice it usually ranges from 150 kg to 500 kg. Whilst shipments containing bulky, lightweight goods (such as toilet paper or clothing) often only reach a total weight of around 100 kg to 200 kg, containers with heavy items (such as drinks, tinned goods or magazines) can often fully utilise the maximum load capacity of 500 kg or more.
With regard to the tail lift, it should be noted that so-called trolley stops are almost always located at the tip of the platform. Every tail lift has a defined load moment – that is, a specific load capacity at a fixed load distance (see glossary entry on load capacity). For example, a load capacity of 2,000 kg has a load distance of 1,000 mm from the vehicle loading floor. The greater the load distance at which the load is placed, the lower the permissible load capacity. This is illustrated in the load diagram shown here: the centre of gravity of the roll container is at a load distance of approximately 1,800 mm (with a platform height of 2,410 mm). The permissible load capacity is just over 1,000 kg. However, a trolley rarely comes alone.
All roll-stops from BÄR feature a double floor. This ensures maximum roll-over resistance. For reasons of robustness, some roll-off safety devices are only available for specific load capacity levels and the associated platform systems. Further information can be found in the product portfolio brochure (linked on the product group websites), on the platform website or from your contact person.
Number of trolleys – How many filled roll containers do you wish to place on the platform simultaneously during a loading operation?
Most Bär platforms are equipped with a roll-stop for two roll-off containers. A trolley is placed on a flap or a pair of wheel recesses. Generally, BÄR offers trolley stops for:
- two trolleys
- three trolleys
- four trolleys
- five trolleys
Up to three roll containers are placed at the front of the platform. For four or five trolleys, either
- additional roll-stop flaps (as shown in the diagram),
- so-called roller cavities (one pair on the left in the direction of travel or two pairs – i.e. on the right and left) or
- a narrow roll-off safety flap along the left-hand side of the platform for one container – the so-called Type L.
At BÄR, the name of the trolley stop indicates how many trolleys it is designed for. Thus, the designation “2ad” stands for a trolley stop with two flaps for two trolleys of type ad (see explanation of trolley stop types below).
The availability of the trolley stops and the width of the flaps depend on the platform type and the platform dimensions. This is because multiple trolleys on the platform require a corresponding amount of space – the same applies to roll-stop flaps. At this point, BÄR would like to recommend the product finder MyCargolift to you: MyCargolift takes into account the carrier vehicle as well as the load and suggests only suitable Bär Cargolifts to you. The product finder considers both the minimum platform dimensions and the permissible load capacity at the roll-stop (as the higher the platform, the lower the load capacity). However, MyCargolift does not recommend a specific trolley stop system.
The flaps are opened via a toggle switch on the rear of the flap – except for the 3Rs: two flaps open simultaneously, one flap individually.
The flaps are opened individually via a toggle switch next to the flap – except for the 3Ax: two flaps open simultaneously, one flap individually.
The side flap is opened via a toggle switch next to the flap.
Other roll-stops allow the opened flap to reopen automatically after a trolley has passed over it. This is advantageous when loading goods from the ground into the vehicle in trolleys or on roll-off boards. There are two positions for the control lever or switch:
- "Loading" position: The flap opens automatically after the roll container has passed over it, allowing the roll container to roll back easily against the open flap.
- "Unloading" position: The flap locks in place after being pressed down, allowing the trolley to be rolled off the platform unhindered. This position of the control lever or switch is shown in the following photos.
In this context, BÄR often refers to "switch positions". The following trolley stop types feature this additional function – or second switch position:
Trolley stop rd / ad
The flaps are opened individually via a control lever for each flap. If the control lever is locked in the vertical position, the flap remains closed after being pressed down.
All flaps in a row are opened simultaneously via a toggle switch. This switch (also known as a butterfly switch) keeps the flap closed when it is tilted outwards.
Generally, trolley stops differ in the opening angle of the flap or, in other words: in the type of roll-off container securing and the maximum recommended roll diameter.
For roller diameters up to 110 mm, BÄR offers the following types of roll-stops, in which the flap acts as a barrier for the roller with an opening angle of approximately 43°:
With the operating lever in the ‘Loading’ position (centrally engaged) – consequently, the flap opens automatically after the rolls have passed over it.
The flap remains closed after being pressed down.
With the toggle switch in the ‘Loading’ position (tilted inwards) – consequently, the flaps open automatically after the rolls have passed over.
For roll diameters up to 200 mm, the following roll-stop types are available, into which the roll can roll as if into a wheel recess:
With an opening angle of 110° and the control lever in the loading position (locked in the middle) – the flap therefore opens automatically after the roller has driven over it.
With an opening angle of 90°. The flap remains closed after being pressed down.
The flap remains closed after being pressed down. Can be combined with roll-stops Rs, Rx and Ax.
In addition to trolley stops with flaps, BÄR also offers wheel recesses for securing trolleys:
Machined from a single piece. Available as two pairs, positioned at the tip of the platform.
With double floor. Available as one pair on the left-hand side in the direction of travel or two pairs (right and left). Can be combined with wheel recesses as well as with roll-stops Rs, Rx and Ax.
Delicate loads – How can sensitive trolley loads, such as ready-to-serve soup, be loaded and unloaded without damage?
When transporting sensitive, fragile or “top-heavy” goods, it is not just a matter of lifting and lowering, but of a loading process with maximum control and smoothness. In 2024, BÄR presented a development project entitled “CargoSpeed”. By this, BÄR means speed regulation as well as the stepless regulation of the speed of all functions of its tail lifts. Please ask your contact person about this patented equipment.
All Bär Cargolifts come as standard with "automatic tilting up and down at ground level". Bär Cargolifts with four cylinders (two lifting and two tilting cylinders – see the lexicon article on product names) usually have a mechanical link. This joint not only enables smooth tilting up and down, but also remembers the original platform position and returns to it when tilting up.
In weight-optimised Cargolifts with four cylinders – specifically the BC 1000 S4 and BC 1500 S4L – tilting up and down at ground level is controlled electrically in an innovative way. When loading very delicate cargo – such as ready-to-serve soups – the “Soft tilting upwards of the platform” option can be added to these products.
Prefer a different type of cargo? Just click on the image or headline! Or use the arrow to go right to the top. Valuable cargo follows.
» High-value goods – Loading and unloading valuable cargo safely at its destination
Precious, valuable or high-value cargo refers to goods with a particularly high material or market value, such as medical and pharmaceutical products, luxury goods, jewelry or high-quality machinery. When transporting such goods, protection against theft plays a central role. In addition to careful route planning and secure temporary storage, technical measures on the vehicle are crucial. The aim is to prevent unauthorised access and to secure the transport chain without any gaps.
When transporting these goods, the tail lift forms part of the security chain. To prevent cargo theft and unauthorised access whilst parked or during loading and unloading, Bär Cargolifts can be fitted accordingly.
Lock the lift tube!
The robust support tube cover allows access to the main beam to be secured with a padlock. This is because, in addition to high-value lift components, the support tube also houses the emergency control mechanism.
Define the unloading location and time
All Bär Cargolifts can be connected to your telematics system via the standardised data interface. This not only allows you to receive real-time information about the lift but also enables geo- and time-fencing for Cargolift operations.
Protect against unauthorised operation
Fixed control elements such as the Bär Control EVO control unit are usually switched on and off from the cab. It is also possible to activate or deactivate the control elements via a control command – i.e. by moving a lever or pressing a button – known as SwitchKey. SwitchKey can be configured in the diagnostic software. A PUK is also available for emergency operation. Your contact person berät Sie gerne.
Stay safe during operation
The Bär SmartControl Plus radio remote control detects the distance between the lift and the handheld transmitter. If the handheld transmitter moves out of the defined working range, the lift automatically locks all its controls.
This is a selection of the options available to you, thanks in particular to the "eBC Controller" electronic control system. Discuss your requirements with your contact person.
Is your high-value cargo transported on rollers? Then click on the roller image or heading of the trolley for more information! Or start at the top using the arrow. Information on the transport of dangerous goods follows.
» Ensuring dangerous goods are loaded and unloaded safely
When transporting dangerous goods by road, people, the environment and property must be protected from damage caused by these substances. That is why the European ADR Agreement (Accord relatif au transport international des marchandises Dangereuses par Route) regulates this with requirements regarding classification, packaging, labelling, documentation, vehicle technology and equipment. In Germany, the ADR provisions are transposed into national law by the Ordinance on the Transport of Dangerous Goods by Road, Rail and Inland Waterways (GGVSEB, formerly GGVS), which sets out specific requirements for both domestic and cross-border transport of dangerous goods by lorry.
For the use of tail-lifts, this means that when transporting dangerous goods, not only must load securing and operation of the taillift be carried out in accordance with safety requirements, but all ADR and GGVSEB requirements regarding labelling, equipment and the qualification of driving personnel (ADR certificate) must also be complied with, so that risks to people, the environment and infrastructure are minimised. BÄR offers various Cargolifts with ADR certification for packaging group III (ADR EX/III). Your contact at BÄR will be happy to advise you.
You can use the headings and images to view other types of cargo or find out more about other safety components.
Conclusion: The goods being transported also affect the tail lift
Well-designed tail-lift safety concepts minimise the risk of accidents and ensure efficient workflows. General safety equipment, additional warning signals and special protective devices ensure that Cargolift operations can be carried out safely and reliably for the driver and everyone in the working environment, as well as for the goods being transported. The safety equipment of modern Bär Cargolifts is therefore a key component of successful transport operations.
However, this equipment not only meets safety requirements but also offers further benefits in the operation and installation of tail lifts. The following lexicon article therefore cover the following topics:
