Airbag Man Case Study

Airbag Man Case Study

The new Airbag Man case study is now live, showcasing how a tailored two-machine Bendi solution transformed warehouse operations following a move to a new facility. As an Australian-owned family business specialising in air suspension systems, Airbag Man needed a more efficient way to handle growing stock volumes while maximising available warehouse space.

By replacing traditional materials handling methods with Bendi articulated forklifts, the company significantly improved storage capacity, reduced manual handling and dramatically increased container unloading efficiency. In this article, we highlight the key outcomes from the project and the lessons other warehouse operators can take away from the experience.

The Story Behind the Success

After relocating to a new warehouse, Airbag Man wanted to make better use of its available footprint while supporting future growth. At the time, the business relied on a counterbalance forklift and pallet jacks, with container unloading often taking almost a full day and requiring two workers.

To optimise operations, Airbag Man redesigned its warehouse layout with 2.1-metre aisles and introduced two specialised Bendi forklifts:

• Bendi B30 with a 4-stage mast for unloading shipping containers directly inside the warehouse
• Bendi B314 for efficient operation within narrow warehouse aisles

The result was a more streamlined workflow from goods receival through to storage, with greater capacity and less manual handling.

Why the Two-Machine Solution Worked

Every warehouse faces unique challenges, and a single forklift isn’t always the most suitable solution.

For Airbag Man, the B30 was selected to handle container unloading, while the compact B314 was ideally suited to navigating narrow aisles and placing stock into racking. By assigning each machine a dedicated role, the business created a more efficient and productive operation without expanding its warehouse footprint.

The case study demonstrates how matching equipment to specific operational requirements can unlock significant productivity gains and improve overall warehouse performance.

Faster Workflows and More Storage Capacity

The most striking result was the reduction in container unloading times.

What previously required two people and could take almost an entire day can now be completed by a single operator in as little as 40 minutes. This improvement not only saves labour but also allows stock to be received and stored much faster.

In addition, Airbag Man was able to double the amount of stock stored per aisle, helping maximise capacity within the same warehouse footprint.

As Morris Lovito, Warehouse Receivals Lead at Airbag Man, explains:

“Switching to a Bendi has made a huge difference. We can now unload a container in just 40 minutes compared to two people doing it manually and taking all day.”

Key Takeaways for Warehouse Operators

While every operation is different, the Airbag Man project highlights several important principles for businesses looking to improve warehouse efficiency:

• Aisle widths reduced to 2.1 metres
• Faster container unloading with the Bendi B30
• Efficient narrow aisle operation with the Bendi B314
• Container unloading reduced to approximately 40 minutes
• Stock capacity doubled per aisle
• Reduced manual handling requirements
• Improved workflow from receival to storage

The case study also showcases the benefits of Bendi’s 220° mast rotation technology, which enables operation in exceptionally narrow aisles while maintaining safe and efficient pallet placement.

Could Your Warehouse Achieve Similar Results?

Many warehouses struggle with limited space, inefficient workflows or time-consuming container unloading processes. The Airbag Man case study demonstrates how the right combination of equipment and warehouse design can deliver significant gains without requiring a larger facility.

At Bendi Australia, we work with businesses to assess their current operation and identify opportunities to increase storage density, improve productivity and optimise materials handling.

Read the full Airbag Man case study to see the complete transformation and discover what a Bendi solution could achieve for your warehouse.

Download Case Study