Logistics Manager
  • Logistics
    • A-E
      • 3rd Party Logistics
      • Air Cargo
      • Coronavirus
      • Express & e-delivery
      • Editor’s Blog
    • F-M
      • Health & Safety
      • International logistics
      • Latest issue
      • Logistics & Supply Chain
    • O-Z
      • Ocean Freight
      • Policy and legislation
      • Professional development
      • Rail freight
      • Road transport
      • Sustainability
      • Temperature-controlled
  • Intralogistics
    • Automation
    • Commercial Vehicles
    • Equipment
    • Infrastructure & Services
    • IT & Software
    • Materials handling
    • Packaging
    • Picking and sortation
    • Robotics and innovation
    • Storage
  • Supply Chain
    • A-L
      • Automotive
      • Construction
      • Energy
      • Fashion
      • Food & drink
      • Forecasting
      • Healthcare and Pharma
      • Hi-tech
    • M-Z
      • Manufacturing
      • Military
      • Omni-channel
      • Public Sector
      • Retail
      • SME
      • Sourcing and procurement
      • Supply Chain Analysis
      • Supply Chain Awards
      • Supply Chain Strategy
      • Supply Chain Technology
      • Supply Chain Visibility
      • Technology
  • Property
    • A-M
      • Big Sheds
      • Design & Build
      • East Midlands and East Anglia
      • M25 East
      • M25 West
      • Mid-box
    • M-Z
      • North East & Yorkshire
      • North West
      • Scotland
      • South-West & Wales
      • Speculative Development
      • Urban Warehouses
      • West Midlands
  • Corporate Insight
  • Digital Magazines
    • June 2023
    • May 2023
    • April 2023
    • March 2023
    • February 2023
    • January 2023
  • Events
    • Sustainable Supply Chain Conference
    • ESG Industrial & Logistics Conference
    • Supply Chain Excellence Awards
    • CiTTi Awards
    • IntraLogisteX
    • Robotics & Automation
  • Webinars
LinkedIn Twitter
  • Subscribe
  • Free weekly e-newsletter
  • Free daily e-newsletter
  • Advertise
  • Contact Us
LinkedIn Twitter
Logistics Manager
SUBSCRIBE >
  • Logistics
      • 3rd Party Logistics
      • Air Cargo
      • Coronavirus
      • Express & e-delivery
      • Editor’s Blog
      • Health & Safety
      • International logistics
      • Latest issue
      • Logistics & Supply Chain
      • Ocean Freight
      • Policy and legislation
      • Professional development
      • Rail freight
      • Road transport
      • Sustainability
      • Temperature-controlled
  • Intralogistics
      • Automation
      • Commercial Vehicles
      • Equipment
      • Infrastructure & Services
      • IT & Software
      • Materials handling
      • Packaging
      • Picking and sortation
      • Robotics and innovation
      • Storage
  • Supply Chain
      • Automotive
      • Construction
      • Energy
      • Fashion
      • Food & drink
      • Forecasting
      • Healthcare and Pharma
      • Hi-tech
      • Manufacturing
      • Military
      • Omni-channel
      • Public Sector
      • Retail
      • SME
      • Sourcing and procurement
      • Supply Chain Analysis
      • Supply Chain Awards
      • Supply Chain Strategy
      • Supply Chain Technology
      • Supply Chain Visibility
      • Technology
  • Property
      • Big Sheds
      • Design & Build
      • East Midlands and East Anglia
      • M25 East
      • M25 West
      • Mid-box
      • North East & Yorkshire
      • North West
      • Scotland
      • South-West & Wales
      • Speculative Development
      • Urban Warehouses
      • West Midlands
  • Corporate Insight
  • Events
    • Events News
      • Conferences
      • Exhibitions
      • Top 50
    • Sustainable Supply Chain Conference
    • Industrial & Logistics Property Conference
    • Supply Chain Excellence Awards
    • CiTTi Awards
    • IntraLogisteX
    • Robotics & Automation
  • Digital Magazines
    1. October 2023
    2. September 2023
    3. August 2023
    4. July 2023
    5. June 2023
    6. May 2023
    Featured

    Logistics Manager Magazine October 2023

    2nd October 2023By Michelle Mooney
    Recent
    2nd October 2023

    Logistics Manager Magazine October 2023

    4th September 2023

    Logistics Manager Magazine September 2023

    1st August 2023

    Logistics Manager Magazine August 2023

  • Webinars
LinkedIn Twitter
Logistics Manager
Analysis

Stacking up the challenges

Christopher WaltonBy Christopher Walton1st September 201411 Mins Read
LinkedIn Twitter Email Facebook

Storage systems are being pushed to new heights, but balancing demands of individual customer requirements is key, says Johanna Parsons.

The growth of e-retailing is pushing storage and retrieval systems to new heights, demanding ever faster and more efficient performance. But it’s not just retail that’s demanding better systems, and with sectors like automotive and manufacturing experiencing growth, investors in new technologies are coming from far and wide.

Batch picking is of course still a huge area where efficiency can drive profits, but one particular effect of the rise of e-retail in particular is the surge of smaller orders. The millions of online shoppers fuelling the growth of this market all tend to order individual items, which means millions more single picks.

Picking systems such as pick-to-light and voice picking have done well in this new environment, but it’s also given rise to new racking configurations. As well as narrow aisles and higher racks, there are also modular and retrofit systems emerging to adapt existing systems to often unpredictable online flows.

For example Nene’s Shelf Partition System which adapts racking to create smaller storage locations. Designed to fit any standard pallet racking or long span shelving, the system is suitable for use with all types of decking including wire mesh, galvanised steel, timber and chipboard.

It has two channel tracks fitted to the back panel of the system which act as runners, enabling individual dividers to be positioned according to the customer’s specific product requirements. “This flexibility maximises the volume within the Shelf Partition System thereby avoiding the wasted space that occurs with fixed divider systems,” says the firm.

Similarly Link 51 has launched a new trackless mobile shelving system. This design removes the need for fixed tracks, allowing unobstructed aisles and easy access for trolleys or steps, as well as removing trip hazards for pedestrian users.

Featuring just a single guide rail attached to the floor along the wall to keep the shelving unit aligned, this design feature means the floor can be reinstated with minimum effort if the shelving needs to be relocated.

The versatility of adjustable shelving systems is widely acknowledged throughout the retail industry as these systems offer very flexible solutions to overcoming the restrictions of limited space and the demand for lean operation.

Mike Alibone of SSI Schaefer says that he is seeing that for retailers, this is a challenge that goes beyond the warehouse, and the back of store has assumed greater importance in terms of being able to hold increasing volumes of stock for rapid access for shop floor replenishment.

“Maximising holding capacity in this area has become a prerequisite for many store managers,” he says. And that increasingly means a requirement for a flexible system.

“These systems are available in a range of sizes, including long-span, to accommodate almost all products from food items to non-perishable goods and they provide benefits in terms of simple and fast assembly and can be disassembled, rebuilt and expanded at any time.

“Add to this the mobility aspect with wheel-mounted standard shelving, or dedicated mobile shelving, then the challenges posed by back of store space restrictions become more manageable,” says Alibone.

He gives the example of one retailer, Bournemouth-based Consortium which organised and planned its own back of store layout and has recently purchased shelving from SSI Schaefer’s R3000 range, subsequently installing it as a self-assembly project.

Storage capacity right up to the roof can be achieved through multi-tier shelving where the design of the upright supports allows not only shelves to be hung from them, but also elevated walkways, which allow access to shelving at higher levels.

Edward Hutchison, managing director at BITO Storage Systems, highlights the problems at the other end of the scale, where because of online retailing, bulky goods requiring two-man delivery are now subject to end-user expectations for excellent delivery service and speed. This is putting extra pressure on storage operations, and some established working methods need revision, he says. “Despite the density that block stacking can provide, racking will lead to a greater space saving – perhaps by up to 30 per cent – because it optimises the warehouse cube more effectively.

“Giving each stillage its own location within racking allows stock to be mixed in random stock locations, which leads to much better use of the total space. With the racking taking over the load bearing (and thus height limiting) duties from block-stacked stillages, the full height of a warehouse can be used, enabling more than three levels high, provided there is sufficient roof space.”

Hutchison says that when designing racking to accommodate large storage units such as stillages, an experienced supplier can also make the most of any space by looking at the unit itself.

“This would involve calculating the possible volumes given by different heights to determine the stillage height that gives the desired number of levels and the optimum volume capacity. Making a small adjustment to the height of the stillages themselves (by shortening the legs) can contribute more space saving towards that extra level of locations,” says Hutchison.

And there are plenty of new offerings entering the market aimed at maximising storage and picking efficiency. Jungheinrich is launching two carousel-based storage and retrieval products: Jungheinrich Lift Racking and Jungheinrich Paternoster Racking.

Both the LRK and PRK systems are based on the goods-to-man principle and have been developed to offer space saving storage and efficient order picking.

Steve Richmond, director of Jungheinrich UK’s systems and projects division, says: “These new storage solutions complement our existing portfolio of intra-logistics products and services perfectly and can be integrated with equipment within our extensive intra-logistics systems range.”

And Snorkel has re-introduction its TM12 model name to mark the launch of the latest version of the popular 3.6m self-propelled telescopic mast lift, which now features an 0.5m roll-out extension deck as standard.

The Snorkel TM12 has a reverse concentric mast design to give a lift capacity of 227kg and an extremely stable work platform, even when fully elevated. Powered by dual front-mounted hydraulic motors, it also has a high amp hour rating, ensuring a long operating life between battery charges.

The roll-out deck, which has previously been available as an option, provides extra reach, which is ideal when working in retail and warehousing environments, allowing the operator to safely access areas above low level obstacles, such as shelving.

These changes brought on by new retailing models include at least one trend that’s influenced other sectors beyond retail. Automotive manufacturers are experiencing a shift towards customisation, with seemingly every car requiring bespoke elements. This of course increasingly requires automated access to a huge range of parts and components.

For example, the Volkswagen Centre in Fulda Germany showcases a range of vehicles from the VW, Skoda and Audi. With sales and after sales services for each brand kept entirely separate a brand new semi-automated parts stores was introduced last May on two levels.

Its warehouse logistics operation features SSI Schaefer’s multi-functional LogiMat storage lift. The parts are stored in modular shelving, cross-beam and mobile racking systems as well as in drawers. The LogiMat lift has 60 trays and is directly integrated with the other systems. It fulfils a range of functions: for example, it serves as a link between the levels, with one service opening at each level and it acts as an interim storage for picked items before they are retrieved. 

Waiting times

Philip Atzert, chief executive at the group’s VW Centre explains: “Because orders are pre-picked and stored in the lift for our employees, we cut waiting times at the collection point. It’s really smart.”

The idea of customisation does not just apply to the end user. Many firms are finding that customers require somewhat bespoke storage systems. For example, Dovecote Park the supplier of British beef to supermarkets required containers for use in its new automated cold store in Stapleton, North Yorkshire.

The firm selected Schoeller Allibert’s 180° Stack Nest trays, but Simon Knights of Schoeller Allibert says that while these are usually made of high density polyethylene, Dovecote Park required them to be manufactured from polypropylene for improved performance on the chilled automated conveyor systems.

The firm supplied an initial 32,000 180° Stack Nest containers to Dovecote Park, all in red PP which also featured the customer logo.

Peter Boyes, technical manager of Dovecote Park, said: “Compatibility with our new automated handling and racking systems were key when selecting containers for the cold store. The trays run well through both the automated system and the tray washing equipment we have installed.”

A decided side effect of the e-commerce boom and the rise of social media is that end users are more clued up as to what they want and what they can demand than ever before. But this increased level of expectation has been cascaded back through the supply chain, so that operators too now want individually tailored systems. Certainly the unprecedented growth of e-retail has put the focus on scalable systems and lean operations which make the right storage configurations more crucial than ever.


 

CASE STUDY: Installer training is paramount

The Storage Equipment Manufacturer’s Association’s requirement for installer training to be on-going in the storage equipment industry has been backed by the Construction Skills Certification Scheme.

Now in its 15th year, the Storage Equipment Installers’ Registration Scheme, SEIRS, is an ID card and registration system run by the industry’s lead body, SEMA.

Mike Tucker, chairman of SEIRS, says: “SEMA places health and safety at the heart of its agenda. The SEIRS scheme stands out because installers are obliged to keep up to date. That’s why we insist that all CSCS card holders installing storage equipment have current SEIRS qualifications.”


 

CASE STUDY: Fashion transition for Perry Ellis

Fashion manufacturer Perry Ellis is responsible for brands such as Farah Classic, Farah Vintage and Original Penguin. Its European business is located at Witham in Essex.

The facilities at Witham include a 56,000 sq ft distribution centre which was originally completely fitted out as a garment hanging facility, but had to be converted to take boxed products.

Distribution manager Tom Cole says the transition has been gradual. “It began with switching our incoming product from hanging to boxed ten months ago which helped to make the conversion a smooth process. Last year we changed our mezzanine floor to carton storage and recently the entire ground floor has been altered to flat pack too.”

LB Foster was chosen to install the longspan shelving system which now comprises over 80 per cent of the firm’s total storage capacity.

“The longspan shelving system they have installed maximises the available space in our facility and we can now store 820,000 units. This is an increase of more than 25 per cent on our previous capacity which brings down our overall operating costs,” says Cole.


 

CASE STUDY: Stylish storage for Sally Salon

Sally Salon Service, SBH UK & Ireland, is a distributor of professional hair and beauty products to both retail consumers and salon professionals. When it moved into a new national distribution centre to keep up with demand, it also required a full kit out, for which it turned to BITO Storage Systems.

BITO provided pallet racking and boltless shelving as well as pallet and carton live storage, integrated with a Dematic conveyor system. The firm also designed a multi-tiered mezzanine to house it.

The new live storage order picking area consists of two multi-tiered mezzanine structures that essentially mirror one another. Running down the width of the warehouse area they are linked at one end by a walkway. This structure gives SBH UK & Ireland three levels of live storage picking.

Between the two mezzanine structures are two pallet racks of bulk storage for replenishing the fastest moving stock on each run.

Each of the picking area’s three storeys features carton live picking on one side and pallet live on the other. The carton live has five levels of lanes that are 2.7m wide between uprights x 2.7m deep.

This gives 30-40 pick locations per bay, depending on the size of product. The roller tracks can be adjusted to suit the needs of capacity and stock profile.

Replenishment aisles either side of the two mezzanine runs allow man up forklifts to replenish the carton live on all three storeys, while reach trucks replenish the pallet live.

The far side of one of the mezzanine runs spreads out to provide an area for standard BITO Boltless Shelving.

Flanking both sides of the order picking mezzanine area are bulk storage areas where 13 aisles of BITO’s PRO Pallet Racking, just over 10m high, provides bulk storage in 2.7m wide x 900mm deep bays to house SBH’s mix of standard Chep and Euro pallets.

Ian Fleming, programme manager at SBH UK & Ireland, says: “This is a carbon copy of a design of the warehouses we run in the USA, although the US warehouses are typically much larger than the one at Walker Park.”

Originally printed in Logistics Manager 09/2014

 

Share. LinkedIn Twitter Facebook Email
Christopher Walton
  • Website
  • LinkedIn

Chris succeeded the legendary Malory Davies in September 2019 as Editor of Logistics Manager and host of the Supply Chain Excellence Awards. Day-to-day Chris writes about all things supply chain; materials handling and industrial property and is curator of the annual LM Top 50 Service Providers. He has worked as a business journalist since 2002 and his career as a logistics journalist started in 2008. Before joining Logistics Manager, he was Editor-in-Chief for road transport titles at DVV Media International.

Related Stories

Hai Robotics unveils new robot and picking solution

2nd October 2023

GXO deploys AI to reduce emissions in Iceland supply chain

27th September 2023

Consortium makes first paperless cross-border shipment

25th September 2023
Latest News Stories
2nd October 2023

Godwin Developments secures 54-acre Northamptonshire site

2nd October 2023

West Midlands industrial estate acquired in joint venture

2nd October 2023

Logistics Manager Magazine October 2023

Free weekly e-newsletters

Discover what’s causing a stir in the world of logistics and supply chains


Key Content
  • Digital Magazines
  • Logistics
  • Intralogistics
  • Supply Chain
  • Property
  • Corporate Insight
  • Events News
  • Opinion
Akabo Media
  • About Us
  • Advertising
  • Contact Us
  • Subscribe
  • Free Daily E-Newsletter
  • Free Weekly Top Stories E-Newsletters
  • Free Weekly Supply Chain E-Newsletter
  • Free Weekly Property E-Newsletter
  • Sign up to be notified when we publish a new digital edition
Our Events
  • Sustainable Supply Chain Conference
  • ESG Industrial & Logistics Conference
  • Supply Chain Excellence Awards
  • CiTTi Awards
  • Robotics and Automation Exhibition
  • IntraLogisteX
© 2023 Akabo Media Ltd Registered No 07766641 England | All rights reserved.
Registered Office: Akabo Media, GG.007, Metal Box Factory, 30 Great Guildford St, SE1 0HS
  • Terms & Conditions
  • Privacy Policy
  • Cookie Policy

Type above and press Enter to search. Press Esc to cancel.

We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits.
By clicking “ACCEPT ALL”, you consent to the use of ALL the cookies. However, you may visit "Cookie Settings" to provide a controlled consent.
Cookie settingsRejectACCEPT ALL
Privacy & Cookies Policy

Privacy Overview

This website uses cookies to improve your experience while you navigate through the website. Out of these cookies, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may have an effect on your browsing experience.
Necessary
Always Enabled
Necessary cookies are absolutely essential for the website to function properly. This category only includes cookies that ensures basic functionalities and security features of the website. These cookies do not store any personal information.
Functional
Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.
CookieDurationDescription
__cf_bm30 minutesCloudflare set the cookie to support Cloudflare Bot Management.
_zm_chtaid2 hoursZoom sets this cookie to facilitate video conferences via zoom from the website.
Analytics
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
CookieDurationDescription
_ga1 year 1 month 4 daysGoogle Analytics sets this cookie to calculate visitor, session and campaign data and track site usage for the site's analytics report. The cookie stores information anonymously and assigns a randomly generated number to recognise unique visitors.
_ga_*1 year 1 month 4 daysGoogle Analytics sets this cookie to store and count page views.
_gat_gtag_UA_*1 minuteGoogle Analytics sets this cookie to store a unique user ID.
_gid1 dayGoogle Analytics sets this cookie to store information on how visitors use a website while also creating an analytics report of the website's performance. Some of the collected data includes the number of visitors, their source, and the pages they visit anonymously.
CONSENT2 yearsYouTube sets this cookie via embedded YouTube videos and registers anonymous statistical data.
Advertisement
Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.
CookieDurationDescription
OAID1 yearCookie set to record whether the user has opted out of the collection of information by the AdsWizz Service Cookies.
VISITOR_INFO1_LIVE5 months 27 daysYouTube sets this cookie to measure bandwidth, determining whether the user gets the new or old player interface.
YSCsessionYoutube sets this cookie to track the views of embedded videos on Youtube pages.
yt-remote-connected-devicesneverYouTube sets this cookie to store the user's video preferences using embedded YouTube videos.
yt-remote-device-idneverYouTube sets this cookie to store the user's video preferences using embedded YouTube videos.
yt.innertube::nextIdneverYouTube sets this cookie to register a unique ID to store data on what videos from YouTube the user has seen.
yt.innertube::requestsneverYouTube sets this cookie to register a unique ID to store data on what videos from YouTube the user has seen.
Others
Other uncategorized cookies are those that are being analyzed and have not been classified into a category as yet.
CookieDurationDescription
TS018dd1basessionDescription is currently not available.
TS01f92dc5sessionDescription is currently not available.
SAVE & ACCEPT
Powered by CookieYes Logo