One of the UK’s leading drinks manufacturers has transformed the capacity and efficiency of its finished goods warehouse thanks to a shuttle racking solution which can store pallets in blocks up to 15 deep and 6 high.
The client had originally enquired about installing a mezzanine floor to create additional capacity to their current position of 800 pallet positions. However after working with Thistle Systems’ special projects team to understand the client’s plans, the number of SKUs to be stored together with their current external pallet storage, there was the opportunity to consider other solutions.
With significant growth plans in place, the client was keen to Max the Cube both in terms of capacity and operational efficiencies and with a relatively low number of SKUs, Thistle proposed their Maxi Cube Shuttle Racking solution.
The finished solution achieved a total of 2736 pallet positions, a staggering 242% increase in capacity on their original capacity within the same 1300 square metre facility. The pallets were accessible via 228 picking locations which were designed to store either 12 CHEP pallets deep or 15 Euro pallets deep – with the facility to store both types of pallets in the same lane.
With 2 different heights of pallets being used, Thistle developed the solution to feature 3 blocks of shuttle racking, two of which were 4 pallets high with the remaining allowing the pallets to be stored 6 high.
Thistle Systems’ Projects Director, Stephen McCormick, explained “The original intention was to maximise capacity by using either mobile racking or push back racking, however the low number of SKUs leant itself perfectly to the shuttle racking approach.”
He continued, “The storage capacity we were able to achieve enabled the client to eliminate the need for external pallet storage which dramatically reduced their monthly expenditure whilst the shuttle is also able to tie into its Warehouse Management System, offering even greater management control.”
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