Tresse Métallique reduces manual handling injuries with MasterMover electric tug

Tresse Métallique Forissier used to move dozens of heavy trolleys by hand, every day. Repetitive pulling caused back and shoulder pain for the team, risking development of MSDs. Switching to a MasterMover electric tug cut handling time by 20% with a single machine handling fifteen different trolleys.

Tresse Métallique Forissier, part of the International Wire Group, manufactures flexible copper electrical connections for the energy sector. Its products supply industries including automotive, aerospace, power distribution, and electrical engineering; and safety sits at the centre of how the company operates, leading HSE Director Séverine Planche to find a permanent and scalable fix for heavy trolley handling.

The challenge

MSD-causing manual trolley handling

Before working with MasterMover, every trolley at Tresse Métallique was moved by hand and the physical toll of that builds over the course of a shift.

The risk was clear and exacerbated each day, Séverine noted that: "We were moving dozens of trolleys manually. People had to pull them rather than push them, and the weight was a major issue. We really needed to find a solution that would allow us to move them without excessive effort and without putting our people at risk of injury."

Pulling loads is harder on the body than pushing them, forcing awkward posture and added strain on the lower back and shoulders – a major cause of long-term musculoskeletal disorders (MSD) risk and something Tresse Métallique wanted to eliminate.

Why motorising trolleys didn't work

Before turning to MasterMover, Tresse Métallique trialled fitting individual trolleys with their own motors to relieve the strain from operators; however, this wasn't a reliable solution as Production Line Manager, Idriss Outaafroukte notes: "We tried motorising one trolley, but one day it worked and the next day it didn't."

Unreliable equipment isn't an option for safety-focused businesses; if operators can't count on a motorised trolley to work, the process reverts back to manual handling and MSD risk. Fitting a motor to each trolley also comes with additional cost and maintenance burden, which scales with any new trolleys added to the fleet.

Motorisation itself is the solution, but not in the form of individual trolley motors. A fleet-wide handling problem needs a solution that scales and adapts easily.

Watch the full project breakdown

The solution

Why Tresse Métallique chose a MasterMover electric tug

Tresse Métallique needed a solution that would solve the problem once, and then continue to scale as the operation grows. It also needed to remove the physical element of manually handling trolleys to cut out injury risk and fit into daily production seamlessly; the SmartMover SM100+ electric tug ticked all three boxes, as Séverine explains: "That's what led Tresse Métallique to work with MasterMover. Their electric tugs fully met everything we wanted to achieve in terms of production and material handling."

A MasterMover technician carried out an on-site demonstration of the electric tug moving Tresse Métallique's trolleys in real time. Operators were able to try out the machine themselves before anyone committed to the solution.

When other departments try out equipment and start to request their own versions, it's a great indicator that the solution is working the way it should. Idriss explains that "the very first time we used it was in another department; we asked if we could try it, and we adopted it straight away."

The results

Faster handling with a fleetwide solution

Switching to a MasterMover electric tug has reduced trolley handling time for Tresse Métallique by 20%. A single electric tug can now move fifteen different trolleys up to ten times per day, eliminating physical strain for staff and the need to motorise individual trolleys.

One machine, fifteen trolleys, daily repeated use across multiple departments; for a company built around a safety-first culture, this combination has delivered on every front that matters. With less physical strain and less time spent moving trolleys throughout site, Tresse Métallique has prioritised staff safety and seen productivity benefits as a result.

Ongoing support even after delivery

At MasterMover, we believe a collaborative approach is key. Rather than just selling you an off-the-shelf product, we first set out to understand your exact challenges and specify a solution that we know will work for you and deliver real results – and the partnership doesn't stop there.

We continue to provide support long after your electric tugs have been delivered. As an international group, it was vital for Tresse Métallique to partner with a supplier who could also provide that support on a global scale, as Séverine explains:

"Tresse Métallique is part of an international group, particularly across Europe. One of the biggest advantages of MasterMover is that they are also an international company. If I need to work with Germany tomorrow, I'll have a local contact there as well. We were able to hand everything over to them, and MasterMover managed the entire project from start to finish, including every stage of the implementation."

That international reach gives Tresse Métallique confidence beyond a single site. If handling challenges arise at other locations, there's already a local contact to support.

"The relationship Tresse Métallique has built with MasterMover is based on trust, responsiveness, and excellent advice."