Hyundai Motor Manufacturing AL

Hyundai Motors announced its $1.7 billion assembly plant in Montgomery, Alabama in 2002 and commenced production in May, 2005. In 2012, Hyundai added a third shift and moved to round-the-clock production to keep up with demand for Elantra and Sonata sedans. By 2013, the plant employed approximately 3,000 workers, and was attracting additional investment of $500 million by suppliers (who were also expected to hire 5,500 workers) to supply the plant with components on a “just-in-time” basis.
From the beginning, Hyundai and its sister company Kia Motors, as well as their web of suppliers, have been loyal Pack Mule customers. They have deployed a wide range of Pack Mule vehicles, including the SC-775 stock chaser style burden carrier, the SCT-7750 stand-up tow tractor, and the BC-620 sit down burden carrier. All of these vehicles are employed in the transport of materials within the manufacturing environment. The newest addition to their Pack Mule fleet will be the industrial battery version of Pack Mule’s SCT-7750, which Pack Mule developed at the request of Kia to take advantage of the high frequency industrial battery chargers that Kia had installed primarily for opportunity charging of its fleet of lift trucks. Soon, Kia recognized that opportunity charging would allow for charging during breaks and thus be a great way to keep their fleets of electric tow tractors running 24/7 to meet the exploding demand.

General Motors

General Motors has been using Pack Mule® PMT-4500 electric tow tractors at its assembly plants in San Luis Potosi and Silao Mexico for over twelve years to deliver components from satellite supplier warehouses to the main production line at the center of the campus over a route of about ¼ mile. As of 2010, GM had several hundred of these units in service and by 2011 was again running three shifts.
About that time, GM installed high frequency charging stations in these facilities to allow for opportunity charging of their forklift fleet. Soon thereafter, they asked Pack Mule whether Pack Mule could offer an industrial battery version of the PMT-4500 tow tractor. This led to the cycle of innovation that resulted in creation of Pack Mule’s BCG-6200 tow tractor employing 36 volt industrial batteries that GM’s employees can opportunity charge during breaks to keep them running for the full three shifts. The result it that GM has been able to run its Pack Mule tow tractors for three full shifts per day without having to take out of service for charging, resulting in considerable capital and operating cost savings.


In the Fall of 2006, Kia Motors America announced its new $1 billion plant located in West Point, Georgia, and the plant opened in early 2010, employing 2,500 KIA employees and over 3,000 employees of its component suppliers.

Since that time, KIA has become a very loyal Pack Mule® customer, relying heavily on Pack Mule’s SC-775 model for towing materials to the production line.  In addition, substantially all of KIA’s component suppliers have followed suit as well.

Then, in 2013, when KIA learned that Pack Mule had developed a sit-down tow tractor (the BCG-6200) for General Motors, it asked Pack Mule whether we could develop an industrial battery version of the SC-775.  Within a matter of a few weeks, Pack Mule had developed a prototype for KIA to try.  KIA used the unit for an extended period and then provided constructive feedback, which led Pack Mule to implement these suggestions, resulting in Pack Mule’s new SCT-7750-IB, which can be opportunity charged with the high frequency chargers KIA is using to keep its forklifts running through all three shifts.