Case Study: Tip Top Bakery | Springwood, QLD

Products: Verge Lift Up Dock Pro · Eco Handrail
Location: Springwood, Queensland
Industry: Food manufacturing and distribution

About Tip Top

Tip Top is one of Australia’s most recognised bakery brands, supplying supermarkets and retailers nationally. The Springwood QLD facility is a key distribution point in their Queensland supply chain, with consistent daily truck movements supporting routes across the state.

The Problem

A high-volume bakery distribution facility runs on tight schedules. At Tip Top’s Springwood site, trucks are in and out of the loading docks twice a day, every day. That’s a lot of movement across 17 docks, and it doesn’t slow down.

The docks themselves had no fall protection. Workers operating at dock height had exposed edges and nothing between them and a drop.

The second problem was just as real but easier to overlook. Contract truck drivers, not Tip Top employees but people on site every day, had nowhere safe to stand while their trucks were being loaded and unloaded. They were waiting in the line haul area, sharing space with forklifts, trolleys, and moving vehicles, in an area that had never been designed with a stationary person in mind.

Two problems. Both needed fixing without interrupting one of the busiest loading operations in the region.

The Solution

Verge installed the Lift Up Dock Pro barrier system across all 17 docks. The gates sit in front of each dock opening and lift vertically when a truck backs in. Full access when you need it, full protection when you don’t. Workers on the dock floor are protected every time a truck pulls away or a bay sits empty.

At the same time, Eco Handrail was used to create defined driver waiting zones in the line haul area. Contract drivers now have a clearly marked, protected space to stand away from equipment and traffic while their loads are being handled.

The Outcome

• 17 loading docks with full edge protection
• Compliant fall protection installed across the entire dock face
• Operational flow unchanged. The Lift Up gate opens with the truck, closes when it leaves.
• Contract truck drivers given designated, protected waiting zones
• Both dock workers and visiting drivers covered in a single scope of work

Need fall protection for your loading docks? Contact Verge or call 1800 765 539.