The Manufacturing Outlook: Specials Magazine

Material Handling

Toromont Material Handling

Smart Warehouse Management With Electric Material Handling Models

As businesses race toward sustainability, rethinking supply chain strategies has become crucial. One of the most practical and cost-effective ways to reduce carbon emissions is by transitioning material handling fleets from internal combustion (IC) forklifts to electric models. This shift offers a powerful combination of lower emissions, improved efficiency, and significant energy savings—all while reducing downtime through enhanced reliability and fewer maintenance needs. Toromont Material Handling, a division of Toromont Industries valued at $5.02 billion, is a leading provider of material handling solutions in Canada. The company specializes in helping businesses transition smoothly to more efficient material handling systems. With expertise across all five forklift classes and experience serving industries such as manufacturing, automotive, food and beverage, government, logistics, and retail, Toromont is uniquely positioned to deliver results. “In our fleet, we proudly feature premium brands of electric forklifts, including CAT, Jungheinrich, Kalmar, Shuttlewagon, and more. Recently, one of our customers in the automotive industry successfully converted their entire fleet of 140 propane trucks to CAT electric forklifts. We are thrilled to support this transition to electrification,” says Sajith Manikath, Vice President at Toromont Material Handling. Electrification of Forklift and Material Handling Fleets Transitioning forklift and material handling fleets to electric models comes with its own set of challenges. Customers shifting to electrification may face inefficiencies, leading to increased downtime and higher costs. Unlike propane or diesel trucks, which only require a quick LPG tank replacement at the end of a shift, electric forklifts rely on a structured charging routine. The charging process varies depending on the energy solution and system in place, requiring operators to charge forklifts during breaks to maintain an optimal state of charge. The key to overcoming these challenges lies in selecting the right energy solution. Toromont conducts a comprehensive power study to analyze operator behaviors and operational challenges. This process helps determine the optimal energy solution, battery capacity, and charging system for each application. Additionally, the company provides training to ensure a smooth transition and effective change management. Its expertise in energy solutions enables customers to turn theoretical efficiency gains into real-world results.

Industrial Engineering

VG Engineering

Better Systems through Advanced Engineering

Vadim Akishin, President

The roar of jet engines in an aircraft testing facility. The hum of gas turbines powering energy plants. The vibration of industrial mechanical equipment. The background noise of heating and ventilation systems in commercial buildings. The din of traffic on highways. And the deliberate silence of NASA's research labs. Behind these advanced mechanical systems lie common challenges: excessive noise, disruptive vibrations, inefficient airflow, and poor exhaust flow dispersion that hinder critical environments. These issues don't just impact performance—they waste energy, reduce efficiency, and create less livable and workable spaces. From quiet gas turbines to airflow control in wind tunnels and noise management in defense facilities, industries face growing pressure to design systems that are efficient, precise, quiet, and sustainable. VG Engineering is the go-to destination for tackling noise, vibration, flow, and dispersion control challenges. “By blending decades of expertise with cutting-edge innovation, we ensure our solutions meet today’s demands while preparing industries for the possibilities of tomorrow,” says Vadim Akishin, President. Whether it’s silencing disruptive noise, streamlining airflow, or managing exhaust gas dispersion, VG Engineering delivers tailored solutions to meet the needs of the industrial, power generation, and aviation markets. The company’s seamless integration of advanced engineering with practical manufacturing makes it a top choice among clients. Unlike firms that specialize solely in consulting or production, VGE bridges the gap between design and execution. This synergy ensures every solution is technically sound, cost-effective, and manufacturable, reducing inefficiencies and ensuring a smooth transition from concept to reality.

Manufacturing Packaging

When a beverage brand launches a new product, its initial packaging strategy is often created to meet the broad needs of major retailers. Once the product hits the shelves, real-world consumer behavior starts to impact sales trends in ways that brands may not have anticipated. For example, a new sparkling water is introduced in 12-pack cases for grocery and big-box stores. Over time, convenience store chains may start requesting smaller four-pack and six-pack options to better cater to grab-and-go shoppers. This shift presents both an opportunity and a logistical challenge. Brands need to adapt quickly to capitalize on changing consumer preferences while ensuring their supply chain remains efficient. That’s where Alliance steps in. From custom repackaging to final delivery at the retail door, every aspect of the process is managed with precision. By optimizing packaging formats without disrupting production or distribution, Alliance empowers brands to capture new revenue streams while keeping pace with consumer demand. “They gain a single point of contact,” says Dario Lopez, president and VP of sales. “While we take care of the packaging and operational headaches, our customers can focus on what they do best—producing great products.” Making this level of efficiency possible is Alliance’s network of GFSI SQF-certified repack and warehouse facilities—three in the Greater Toronto Area, including Brampton, Mississauga, Milton and one in Montreal. Proximity to key hubs in Canada ensures faster turnaround times and nationwide distribution while reducing brands’ transportation costs and streamlining supply chains by eliminating unnecessary touchpoints. Operating six days a week, 24/7, these facilities handle peak demand and urgent repackaging requests without delays. Whether it’s routine fulfillment or last-minute orders, Alliance keeps products moving—on time. Each facility has a packaging unit that prioritizes customizing the product that fits the brand’s retailer’s specifications. Alliance runs a variety of paperboard folding cartons across different die-line structures, from compact four-packs (two-by-two cans) and 60-count packs to variety packs and single-SKU formats. Each carton is designed to maximize visibility and simplify handling at the retail level. Strength and durability are non-negotiable when it comes to packaging. Alliance’s corrugated cartons—available in 12, 24, 36 and 60-pack formats—are engineered to absorb impact and maintain structural integrity, ensuring products remain protected during transit and storage, arriving retail-ready.

IN MY OPINION

Industrial Coating

Motivating and Challenging Technical Professionals in a Manufacturing Environment

Scott Marcus, Process Engineering Manager, Flex-N-Gate

LAST WORD

Wire and Cable

The Role of Statisticians in Study Design and Why to Engage Them Early

Melanie Buitendyk, Sr. Director, Biostatistical Consulting, Allucent

IN FOCUS

How Advanced Material Handling Systems are Transforming Canadian Industries

Material handling—the intricate system responsible for the movement, storage, control, and protection of materials.

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Canada's Response to Evolving Packaging Solutions

Canada's custom packaging solutions sector has evolved into an innovation-driven industry that plays a crucial role in branding, supply chains, and advancing sustainability and technology.

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EDITORIAL

Engineering Progress with Smart Solutions and Green Goals

A quiet revolution is reshaping Canada’s industrial backbone—powered by technology that turns warehouses into intelligent ecosystems. Across the material handling sector, robotics, AI and IoT are streamlining operations with real-time data, automated guided vehicles and predictive maintenance. These innovations boost productivity and embed sustainability at the core, with energy-efficient systems and low-emission equipment redefining performance standards.a

This drive for smarter, greener operations extends into the packaging space. Custom packaging companies pair biodegradable materials with embedded tech like QR codes and NFC tags—offering transparency, waste reduction and richer customer engagement. Packaging is evolving into a digital touchpoint reflecting environmental and consumer priorities. Supporting these shifts is a new generation of industrial engineering services. With AI-led process optimization, digital twins enabling virtual prototyping and widespread adoption of renewable energy, engineering teams are now designing for agility, efficiency, and climate resilience.

Driven by these trends, the material handling industry in Canada is projected to grow at a CAGR of 3.87 percent from 2025 to 2030. Similarly, the flexible plastic packaging market is expected to expand at a CAGR of 5.26 percent between 2025 and 2030, growing from 0.92 million to 1.18 million tones.

The Manufacturing Outlook Canada magazine features a thought leadership article by Scott Marcus, Process Engineering Manager at FlexN-Gate, who highlights the critical role of leadership and communication in motivating and retaining technical professionals. It also features an article by Isaiah Lever, Manager of Composite Manufacturing at Airbus Helicopters, who sheds light on the modern gaps in the aviation industry that hinder manufacturing and production processes.

We also feature the stories of material handling companies delivering solutions that play a crucial role in driving innovation. One of them is Toromont Material Handling, which sells, rents and services a full range of forklifts and other material-handling equipment and storage solutions across Eastern Canada.

In this edition featuring the Material Handling Solution Company of the Year in Canada 2025, Top Custom Packaging Solutions Provider in Canada 2025 and Top Industrial Engineering Services in Canada 2025, we hope you find the right partner to meet your organization’s needs.

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