Shuttle Racking Transforms Capacity for UK’s Leading Food Producer

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One of the UK’s leading food producers has transformed the capacity of one its warehouses by moving from APR Pallet racking to shuttle racking to deliver a solution which more than doubled the number of pallet positions in the same floor space.

Thistle Systems

276

Pallet positions created

Thistle Systems

19

pallets deep stored in racking

Thistle Systems

2

Lanes dedicated to largest products stored

Pallet Shuttle Racking

The company had been considering building an additional warehouse to increase the storage capacity on site, however, after discussing their challenges with Thistle Systems, recognised the biggest issue on site was space utilisation and identified pallet shuttle racking as a potential solution.

Thistle Systems have been working with the client for a number of years to deliver various racking projects and had been discussing the power of shuttle racking and the benefits it could achieve.

Like many food and drink companies, they had relied upon APR racking for fast moving stock and Drive in Racking for high density storage. However, they were looking to improve the efficiency of their operations to gain a competitive advantage in the sector.

After analysing the SKU profile and stock movements, the project team identified the large batch SKUs would be better stored in a high density storage system and proposed a few options to demonstrate potential capacities and number of picking faces.

The optimum solution for the project was a First in Last Out (FILO) shuttle racking solution which completely transformed capacity, enabling the customer to store a total of 736 pallets.

Thistle Systems Food and Drink specialist team designed the solution which was 10 lanes wide, 4 pallets high and up to 19 pallets deep, depending on the overhang of the pallets.

The flexibility of the solution, which can handle both CHEP and EURO pallets, was demonstrated with 2 of the lanes being dedicated to the largest products being stored, enabling the client to accommodate a greater overhang on the load with wider frames and achieving 16 pallets deep.

As well as the additional capacity, the shuttle racking solution also delivered significant improvements in the operations, including a dramatic reduction in forklift travel times.

This has improved picking times of pallets, reduced the standing times of the waggons being loaded as well as reducing the demands being placed on the operators.

And with Thistle Systems’ superior aftersales service, the client had the peace of mind that in the unlikely event of any issues with the shuttles, Thistle could be on site within a matter of hours to rectify the situation.

Click here to find out more about our pallet shuttle racking solutions or contact us now to discuss your requirements.

What we did

  • FILO (first in last out) Shuttle Racking solution installed providing capacity for 736 palletsFILO (first in last out) Shuttle Racking solution installed providing capacity for 736 pallets
  • Solution is 10 lanes wide, 4 pallets high and up to 19 pallets deep depending on overhang of palletsSolution is 10 lanes wide, 4 pallets high and up to 19 pallets deep depending on overhang of pallets
  • Shuttle Racking solution can accommodate both CHEP and Euro pallets Shuttle Racking solution can accommodate both CHEP and Euro pallets
  • Solution reduced forklift travel times, improved picking times of pallets, reduced the standing time of wagons being loaded as well as reduced the demands being placed on operators Solution reduced forklift travel times, improved picking times of pallets, reduced the standing time of wagons being loaded as well as reduced the demands being placed on operators

Solutions Used

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