Macfarlane Packaging
Dock Levellers

Macfarlane Packaging design and distribute protective packaging materials to businesses throughout the UK, Ireland and Europe, helping their customers to reduce total packaging costs, while enhancing their reputations.

Arrow were contacted by the Wakefield branch who were facing somewhat of a dilemma after having their three dock levellers condemned following a mandatory safety check. Unfortunately instead of jumping to resolve the issue, Macfarlane were left without a timely solution by their existing supplier.

With their operations heavily compromised, we moved our surveyors timetable around and were able to attend site two days later to assess the situation. 

Although the dock levellers were indeed in a state of disrepair and would need replacing, we proposed an interim solution to keep the site operational whilst we carried out the more extensive works. It was also noted during our inspection, there was an overlooked reason for some of the damage inflicted on the existing levellers ... the move to three wheeled forklifts trucks.

Across the UK more businesses, like Macfarlane, are switching to three-wheel electric forklifts. They're cheaper, compact, and ideal for tight warehouse environments.

But there's a problem we're seeing more and more on site ...
Most loading bays and dock levellers were never designed for them.

The Simple Science.
Dock levellers are engineered on the assumption that weight is spread across four wheels, over a wider footprint. Capacity ratings are based on evenly distributed loads plus expected dynamic forces as trucks move between dock and trailer. It's basic physics.

The Plan
After completing the "hot works" to help keep the site operational, it was full steam ahead to deliver a lasting solution. After a comprehensive survey and providing a detailed report to the customer, Arrow were commissioned to replace three dock levellers and provide accompanying GFA Control panels and dock lights.

As was highlighted in our original survey, the use of three wheel forklifts needed to be catered for and so we added to the spec a structural support beam which would add the necessary strength to make the leveller suitable for use of four AND three wheel FLT's.

In March 2026, over a period of 4 days, we systematically removed the condemned levellers, working on individual bays to allow the site to continue operating and started replacing with brand new products.

Along with the dock levellers, we added three new GFA control panels which were also connected to the dock lights, providing valuable illumination in a darkened space. These panels provided the controls to easily operate the levellers, quickly and safely.

In 4 days, our installation was complete and Macfarlane were back to full operational speed with new compliant dock levellers.

Customer Testimonial

"After being badly let down by my previous supplier, I put the call into Arrow who had worked on one of our sister sites and came heavily recommended. From my initial conversations with them to their speed of response, it was obvious Arrow would be able to support our urgent needs.

Arrow attended site two days after my initial call and carried out a very thorough survey. I was particularly impressed with their level of detail and how they identified our recent shift to three wheeled forklifts, may have contributed to some of the damage.

The installation was very smooth and because I was kept informed on expectations and timelines, I was able to keep my team abreast of when it was safe to work and when accommodations needed to be made. The handover was smooth and I was taken through the operating procedures face to face.

Due to the impressive nature of how Arrow worked, I didn’t hesitate in moving our complete door and loading bay maintenance needs over to them."

Matthew Greenwood-Field. Logistics Manager for Macfarlane Packaging Wakefield.