What matters at the dock
- Equipment and finishes that stand up to soil, dust, plant debris and water from washing produce.
- Insulated doors, dock seals and strip curtains that keep chilled produce cold between store and lorry.
- Separate intake and dispatch areas, with ground-level access for farm trailers and bulk bins.
- Pre-season servicing so idle doors and levellers are proven before harvest volumes arrive.
- Simple signals and controls that seasonal staff can follow safely from their very first shift.
What makes packhouse loading bays different?
Packhouse loading bays differ because they serve two very different flows: field produce arriving at ground level on farm trailers and in bulk bins, and packed, chilled produce leaving on refrigerated lorries for retail depots. Both can peak hard during harvest, then fall quiet for months.
- Intake is usually at ground level, with mud, soil and water on the yard.
- Dispatch runs to fixed delivery slots at customers' depots.
- Seasonal staff may be new to dock procedures and controls.
- Chilled stores hold produce between harvest, packing and dispatch.
Intake doors take the hardest knocks, from tractors, trailers and bin handlers, while dispatch doors need to seal and insulate. Packing lines may also run long shifts in season, so dispatch bays can be busy late into the evening.
We plan intake and dispatch separately so each gets the right doors, protection and equipment, rather than one specification for the whole building.
How do you protect dock equipment from dust, mud and water?
Dock equipment at a packhouse lasts longer when it has corrosion-resistant finishes, sealed motors and controls, and a cleaning routine that keeps guides, tracks and pits clear. Soil, dust and plant debris build up in door guides and leveller pits and wear moving parts.
- Choose galvanised steel and suitably rated electrical enclosures where equipment is washed down.
- Keep drainage in front of docks clear so water does not pool in pits.
- Fit bottom and brush seals that cope with grit on the floor.
- Protect intake doors with bollards against impacts from farm vehicles and bin handlers.
- Clean pits and guides between services when soil and debris build up.
Rodents and birds are attracted by produce and packaging, so the same seals that keep dust out also help with pest control. Where equipment is hosed down, keep water away from control panels unless they are rated for it.
Repairs caused by dirt and impact are chargeable, so regular cleaning between services is worth building into the site routine.
Which equipment keeps produce cold at dispatch?
Insulated sectional doors with close-fitting dock seals or shelters keep produce cold at dispatch, with internal doors or strip curtains separating chill stores from the packing hall. If the refrigerated lorries collecting your produce are a consistent size, dock seals give a tight fit at a modest cost.
Inside, PVC strip curtains are a low-cost way to reduce cold air loss at openings used by forklifts and pallet trucks. On the busiest openings, high-speed doors close quickly between movements and stand up to frequent use.
Insulated doors also limit condensation, which can drip onto produce and packaging near the dock and cause rejected loads. Where trailer sizes vary, a retractable or inflatable shelter suits better than a seal.
Dispatch to retail depots usually runs to booked slots, so a dock that fails at the wrong moment can mean a missed slot. Seals, doors and levellers on dispatch bays deserve the closest attention at each service.
When should a packhouse service and upgrade its docks?
A packhouse should service its loading bays before the season starts and plan upgrades for the quiet months, so equipment is proven before volumes rise. Doors and levellers that sat idle can develop faults that only show under heavy use.
- Book a pre-season service early enough to order any parts needed.
- Use the off-season for pit repairs, new levellers or door replacements.
- Brief seasonal staff on traffic lights, restraints and door controls.
- Agree how repair requests will be priced and booked during the season.
- Check that drainage and yard surfaces in front of docks are in good repair.
The off-season also gives time for groundworks or new docks, which are hard to schedule once harvest begins. Out-of-hours working can be arranged and priced in advance if work has to overlap with the season.
Our guide to upgrading loading bays without stopping the operation covers phasing work around a live site.
Equipment we recommend
Questions
Can you service our docks before harvest starts?
Yes, we can plan a pre-season service so doors, levellers, shelters and safety equipment are checked before volumes rise. Book early enough to allow parts to be ordered for any defects found. Servicing is chargeable at £85 to £180 per item per visit, excluding VAT, and any repairs are priced in the report for your approval before work goes ahead.
Do you cover rural and island packhouses?
Yes, we cover England, Scotland, Wales and Northern Ireland, including rural sites. Remote and island locations, such as the Highlands and Islands, Argyll and Bute islands, Orkney, Shetland, the Western Isles, the Isle of Wight and the Isles of Scilly, are covered by arrangement, with any travel costs shown in the quote.
Are PVC strip curtains suitable for chill stores?
Yes, PVC strip curtains are a low-cost way to reduce cold air loss at chill store openings used by forklifts and pallet trucks, at £180 to £1,100 per opening excluding VAT. Grades are available for low temperatures. On very busy openings, a high-speed door may last longer and seal better. Damaged strips should be replaced, because gaps reduce their effect.