Mobile Loading Ramps for E-Commerce Mega Warehouse in Manesar
⚠ The Challenge
The client operates a 2-lakh sq ft fulfilment centre in IMT Manesar — the Delhi NCR region’s largest industrial township. The facility was originally a single-level warehouse with only 4 permanent loading docks. Rapid e-commerce growth pushed daily dispatches from 80 to 200+ trucks, peaking at 350 during festive sales. The 4 fixed docks were the primary bottleneck. Civil construction of additional permanent docks would take 3-4 months and disrupt operations during the critical pre-Diwali build-up period. The client needed immediate, flexible dock capacity.
✔ Our Solution
Nio Equipment supplied 6 mobile dock ramps with 10-tonne capacity, adjustable height range of 900-1400mm and 8-metre ramp length. The ramps can be positioned at any point along the warehouse perimeter by forklift, creating instant loading bays wherever needed. Hydraulic height adjustment accommodates all truck types from Tata Ace to 40-ft trailers. Anti-slip surface grading handles Delhi NCR’s dusty conditions and monsoon rains. Each ramp features wheel chocks, safety chains and high-visibility markings.
Key Results
The Challenge
IMT Manesar in Gurugram is the logistics nerve centre of North India, hosting fulfilment centres for Amazon, Flipkart, Delhivery, Ecom Express and dozens of 3PL providers serving the Delhi NCR market of 30 million consumers. This facility ships everything from electronics to fashion, with dramatic volume swings — daily dispatches triple during festive sales. The 4 permanent docks, designed for the original 80-truck-per-day volume, became an impossible bottleneck as the business scaled.
Our Solution
Mobile dock ramps offered the perfect solution: immediate deployment without civil work, flexibility to position docks where needed, and the ability to scale up or down with demand. Each 10-tonne ramp supports a loaded counterbalance forklift driving up and down repeatedly at full speed. Hydraulic height adjustment takes 30 seconds to match any truck bed height. During non-peak periods, unused ramps are stored compactly against the warehouse wall, freeing up yard space.
Results
The facility went from 4 dock positions to 10 operational loading points overnight. During the Diwali Big Sale event, 350 trucks were dispatched in a single day — a volume that would have been physically impossible with only 4 fixed docks. The client’s logistics head noted that the ramps paid for themselves during the first festive season alone, and the portability means they can move to a new facility if the lease term ends — unlike permanent civil dock construction which is a sunk cost.
“During our biggest sale day, we dispatched 350 trucks using 10 dock positions — 6 of which were Nio mobile ramps. No civil work, no downtime, deployed in a week. This is how logistics infrastructure should work.”— VP Operations, E-Commerce Fulfilment Partner, Manesar