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Tag: AS/RS

Project to Expand Distribution Operations Completed

Posted on by David Priestman

A state-of-the-art shuttle system, automated processes for incoming goods, 130,000 storage bins, and new picking workstations: Erwin Müller has significantly expanded its warehouse capacity at the Buttenwiesen / Germany site. FORTNA was commissioned with the concept design and implementation of the new future-oriented distribution operations, where they were a driving force and key partner throughout the project up to the go-live in December 2023.

Founded in 1951 as a textile wholesaler, Erwin Müller Versandhaus GmbH continues to grow. The company has gradually developed into a multi-channel specialist for home and household textiles and has proven it has the knack for understanding consumer needs when it opened an online shop in 1997.

“Since opening our online shop 27 years ago, we have always focused on being one step ahead of market requirements, and our current project is no exception: greater capacity, more flexible fulfillment and customer service that sets new standards,” explains Tobias Eder, Managing Director at Erwin Müller. “After so many years of being able to count on FORTNA’s technical expertise and implementation skills, we once again entrusted project manager Andreas Beermann and his team with the concept design and upgrade to our distribution operations.”

The data collected was used to design the upgrade, which consists of a new building with a main incoming goods centre and a shuttle and dispatch system connected to the existing building via a bridge. FORTNA devised a solution that took place in stages during ongoing operations. The new building will operate as a central warehouse for all items that can be ordered via the catalogue and online shops. The official opening ceremony for the new building took place in May 2021, while steel construction and other installation work for the automated logistics systems were completed in 2023. The shuttle warehouse, with 16 aisles, now provides an additional 11,000 m² of usable space. “We have combined new systems and inventory fulfillment in a multi-site strategy designed to consolidate orders and ensure high-performance processing,” explains Andreas Beermann, Sr. Manager Solution Design at FORTNA. “In the new incoming goods center, automation will significantly increase profitability and efficiency.”

Incoming articles are registered in the new building extension, transferred to containers as required, and scanned into the system using new barcode scanners. One hundred fifty-two shuttle (152) vehicles are used to transport and distribute the items automatically to the appropriate storage locations. The shuttle vehicles can be in either the shuttle warehouse for storage or directly to the eight (8) new ergonomic pick and pack workstations. Once there, they are manually picked to order and packed in up to 180 shipping cartons per hour for international dispatch. This close interaction between manual and automated processes increases productivity, saves time and reduces the error rate.

As Tobias Eder states, “With the support of FORTNA, we have put in place a future-proof solution at Erwin Müller’s central operations in Buttenwiesen that organizes the flow of goods to the best possible extent, is able to react flexibly to changing customer and industry requirements, and also offers sufficient capacity for future growth.”

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Fortna and Geek+ Partner for Order Fulfilment

 

Food Sector Fears over Warehouse Automation

Posted on by David Priestman

Past mistakes should inform, but not inhibit, the adoption of new technologies within the food supply chain. Dan Migliozzi, Sales & Marketing Director, at independent systems integrator, Invar Group, explains why the sector needs to rediscover its appetite for risk.

The food and grocery market in the UK is one of the most competitive and fast-moving retail sectors, arguably, in the world. The pressures are immense, with disruptors to existing business models ranging from the rise of the discounters and the explosion in home delivery to the impact on supply chains of everything from weather to war. In addition, there is the constant cycle of new products and trends, such as vegan/meat free, which may or may not become established.

And all this is set against the challenges of ever more costly and increasingly unavailable labour, uncertain but generally increasing transport costs, and a consumer base that despite, or because of, the ‘cost of living crisis’, demands convenience and availability at the lowest price and exhibits diminishing levels of loyalty to retailers and brands.

To meet these challenges, one might think that investment in automation in the fulfilment chain – warehouses and distribution centres – would be a no-brainer. Higher throughputs, managed, picked and delivered more accurately, improving service levels with less inventory (and waste), better transport utilisation, all with lower levels of labour and a more flexible and agile response to changing market conditions, whether there be one-off events or longer-term trends.

Past mistakes

Yet, there is a clear reluctance amongst supermarkets and other food businesses to go all-in on automation. This is perhaps unsurprising – there are few of the well-known names that haven’t experienced some sort of technology-driven crisis over the past decade or two. Not infrequently these have left the business section for the front page, leading not just to missed sales and unhappy consumers, but to panicked shareholders, questions in Parliament, and ‘thoughtful’ op-ed pieces in the media. More often than not, the ‘solution’ has been to side-line the tech and flood the warehouse with people.

As a fully independent automation and systems vendor and integrator, however, we observe that it is only rarely that there have been fundamental issues with the hardware and software. Rather, the issues lie around timescales, complexity and over-ambition, and a lack of forward vision. Major investment decisions appear to have been driven by a combination of FOMO – fear of missing out on what the competition is thought to be doing, and the understandable desire of owners, whether public shareholders or private finance, to ‘sweat the assets’. Neither of these are sound foundations for the serious investment in advanced technologies that the sector undoubtedly needs.

Paradoxically for such a fast-moving environment, our first piece of advice would be to slow down a bit. Take the time to think ahead. However fast the implementation of technology, it may well not outpace transformations in the industry: think how quickly home delivery moved from being a niche ‘inside the M25’ offer to being core business in the Highlands and Islands!

A measured approach

Implementation doesn’t have to be simultaneous and company-wide, across half a dozen DCs. Starting with a large-scale pilot across a single DC, a particular class or skus and/or a particular channel will allow you to find out, not just if the chosen automation is really appropriate, but more fundamentally, whether you have truly captured the reality of how your business works, or should work, in practice.

This may mean that some of the potential efficiencies and savings are not immediately captured, but these are by definition long term projects. If this scale of investment is really the answer to today’s problems, there are probably deeper issues at play. The business needs to look out as far as it can, with the best forecasts (or range of forecasts) available. This automation is supposed to make the company more successful – so what does ‘success’ look like, not next quarter but in five years’ time?

Change is the only certainty – how flexible, adaptable, scalable is the solution you are proposing? Do you need a higher level of ‘robotics’, broadly defined, to meet a largely unknown future, or is it appropriate (as it may be), simply to opt for significantly over-specified fixed automation? But while any level of investment must meet a business case, it is a false, and potentially disastrous, economy to allow this apparently unnecessary surplus capability to be stripped out of the proposal. Could it, in fact, be unnecessary? Has anyone mentioned promotions?

Examine flexible options

There is a lot of detailed ‘what if?’ thinking to be done – what if, for example, demands for less packaging lead to more loose goods being handled? That might steer the project towards a greater use of robotics for item-level manipulation, rather than fixed automation at a carton or pallet level. There are also assumptions to be challenged – it may be that the automation plan expects suppliers to deliver in a certain manner. Actually, they don’t but that’s alright because the workforce knows the work round. The automation probably doesn’t. The automation has to be designed around the supply realities, but equally the suppliers have to be aligned with the automation.

And although we stress the need for the longest-term planning, it does have to be accepted by the business owners that it may be desirable to replace at least some elements of the automation years before its theoretical end of life. Fixed automation, or AS/RS (automated storage and retrieval systems) may be a valuable interim solution to be augmented or replaced a few years down the line by AMRs (autonomous mobile robots), ‘cobots’ working alongside staff, or whatever else technical progress brings forward. AMRs, incidentally, are a great way of achieving great scalability for low CapEx, as units can be taken on or off lease as requirements vary – easier and cheaper than hiring a hundred extra bodies.

An appetite for risk

The food chain is always under huge pressure – consumers, media, shareholders, suppliers, and often with an added political element. To meet these pressures, the food distribution chain needs to rediscover its appetite for risk. But don’t panic – by working with an independent and experienced systems integrator such as Invar, those risks can be well-controlled.

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80% say Brexit is biggest disruption

 

Flexible Warehouse Automation Prepares for Unexpected

Posted on by David Priestman

In his latest byline, Simon Jones (pictured), UK Sales Executive at Exotec, a global warehouse robotics provider, outlines how automated systems help mitigate against inefficient warehouse processes and shortfalls in times of fluctuating demand.

Consumer demand for products remained unpredictable throughout last year, plaguing the market with uncertainty. October 2023, for example, saw high streets slump to a 2.7% drop in sales volumes year on year, with Black Friday also quieter than in 2022. This defied some predictions, which suggested Black Friday 2023 could be the busiest ever.

Navigating the unknown in 2023 has left unanswered questions surrounding how to manage workforces, warehouse space and demand, making planning for 2024 and beyond a considerable headache for many companies. Logistics will play a key role in ensuring organisations are prepared for every outcome, with automated warehouse systems presenting an opportunity to establish greater resilience through their flexibility and consistent performance.

The limits of traditional automation

Automation in the warehouse has existed for decades, with the first automated storage and retrieval system (ASRS) being deployed by German firm Demag in 1962. Since then, ASRS technology has undergone continuous development with the latest systems using robots to achieve high levels of flexibility, scalability and productivity, unfeasible for traditional fixed systems.

For example, the throughput capacity of traditional automation, such as shuttles and mini-loads must be fixed at the maximum forecast requirement when the system is installed. This means that for 90% of the year and for the first few years at least, the system will be operating at well below capacity. Many retailers have realised that more flexible systems allow them to install only what they need for the foreseeable future, because they can add temporary or permanent increases in capacity as and when needed in the future. This is a far more efficient use of capital expenditure and de-risks the investment significantly.

Since much of traditional automation was originally designed for store replenishment, shortfalls in its ability to meet omnichannel delivery requirements have become apparent. The growth of e-commerce has led to requirements such as same-day, even same hour, picking and shipping, creating a need for speed which did not exist in the days of purely in-store retail when the order to delivery cycle was a minimum of three days. With companies now operating e-commerce and in-store channels at the same time, expecting automation systems to deliver in both areas simultaneously is something only the most flexible systems can deliver. However, the benefits of both operations residing in a single system are huge in terms of space saving, inventory reduction and elimination of duplication.

How warehouse technology is evolving

The good news is that as needs evolve and pressure mounts for rapid order fulfilment, automation in the warehouse is increasing in sophistication. The advanced software in modern systems, for example, minimises order cycle times and ensures orders are ready for packing in a matter of minutes. These systems can safely scale racking up to 12 metres in height, meaning organisations can increase the storage density of their warehouses and address the problem of lack of space. The throughput capacity can also be increased rapidly with the addition of rental robots during peaks in demand so organisations can deal with uncertainty in a cost-effective manner.

Modern systems can also operate with no single point of failure: if one robot fails, the rest can dynamically adjust their workload, ensuring consistently seamless operations all year. The end result is better efficiency, accuracy and throughput capacity, both inside and outside peak periods.

Supporting humans, not usurping them

There remains scepticism that robots will take jobs from humans in the warehouse. However, their presence actually presents more advantages than disadvantages for human staff. ASRS robots, for example, help automate repetitive tasks, can handle heavy goods, and reduce the distance that staff need to walk around a warehouse during a shift. This creates a less strenuous, more rewarding work environment for staff and makes the role accessible to a wider demographic. As a result, human staff can focus on more technical and higher-value tasks in a safer environment.

On a larger scale, the presence of robotics benefits organisations from a recruitment perspective. When a peak period hits – whether expected or unexpected – pressure mounts on organisations to hire staff en masse, which can raise concerns surrounding labour procurement. The implementation of robotics balances much of this uncertainty. Businesses can forecast with greater confidence as they know they can scale their capabilities up or down at short notice, reducing the pressure to mass hire temporary staff in a tight labour market.

Demystifying demand

The year ahead holds many unknowns for warehouse operators, but the means to deal with surges and dips in demand are very much there. Businesses should evaluate where they are in terms of warehouse automation and consider how advanced robotics can make them a slicker and more adaptable organisation. If companies implement flexible warehouse automation now, they will be in a better position to serve the needs of both their customers and their employees in the long term.

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Industry View: The Tech That’s Changing Warehousing

 

Automated Storage System for Cable Drums

Posted on by David Priestman

Lödige Industries, a global supplier of logistics systems, has recently completed the installation of an automated storage and retrieval system at The Hongkong Electric Co., Ltd. (HK Electric)’s Electric Tower in Ap Lei Chau, Hong Kong Island. The system incorporates an elevating transfer vehicle (ETV) to efficiently handle heavy cable drums and transformers. This innovative solution not only maximises warehouse space utilisation and enhances safety, but it also improves material handling efficiency and streamlines inventory management processes. With the ability to control, retrieve, and monitor cable drum storage, the system provides a solid foundation for future expansion and evolution of the company.

Lighting up homes and businesses of Hong Kong since 1890, HK Electric has a long record of providing a safe and highly reliable electricity supply at a reasonable price to customers on Hong Kong and Lamma islands. Remarkably, the electricity supply rating of HK Electric has been maintained at higher than 99.999% since 1997, a record that excels many top cities in the world. This outstanding accomplishment places the company among the world’s leading performers in this regard. To consistently deliver such stable and dependable services, the implementation of modern storage systems that align with the ever-evolving demands of the industry is imperative.

As the available storage area of 800 m² is not extendable, a multi-storey solution was required to meet the growing demand. At the same time, the cable drums, weighing in at 5.3 tons each are susceptible to damage if stored incorrectly. Retrieval and stock tracking posed an additional challenge. The new fully automated 4-level system serviced by an ETV enables the customer to store significantly more stock on the same footprint in a safe and damage-free manner. Up to 293 storage positions can now be managed in the warehouse.

The customised system is comprised of high-quality hardware components such as powered decks and conveyors, as well as intelligent control software. With the introduction of automated processes, physically difficult manual labour for transporting and storing drums is significantly reduced. In conjunction, these provide HK Electric with real-time visibility and control over inventory, while improving work routines for staff.

Alan So, Head of Commercial Services at HK Electric, comments: “Health and Safety is always among HK Electric’s top priorities. We have been promoting automation and innovation as tools to improve productivity and safety in our business activities. Our cable drum inventory management has become more efficient thanks to our cooperation with Lödige Industries. The new automated ETV system helps optimise storage density and safety”, he continues. “Lödige Industries provided support at every step, from planning, permits, construction, testing to training. The system now gives us control over drum storage, retrieval, and visibility, optimizing our storage space. It also provides a foundation to build upon for future growth and changing needs.”

Joman Chong, General Manager of the BPS Global Group that was involved in the project, also confirms: “By working hand-in-hand with Lödige, we presented HK Electric with an all-encompassing solution that revolutionizes their approach to inventory management and storage optimization. We eagerly anticipate further strengthening our collaboration with Lödige as we jointly develop our businesses.”

Lödige Industries is a leading global supplier of logistics systems, with a focus on moving heavy goods. “The energy sector is a new industry in which we have now been able to demonstrate our expertise in solving complex material handling requirements for the first time”, says Nicholas Tripptree, Managing Director for Asia-Pacific, for Lödige Industries. “The project for HK Electric has shown that our in-depth and wide-ranging knowledge of transporting heavy goods is transferable to the challenges in other industries so that we can successfully design and implement projects with similar requirements for customers in a variety of sectors,” he adds.

New Patent for Warehouse Storage Optimization

Posted on by David Priestman

Fabric, a technology company for retail fulfillment, today announced it has secured a new patent for its innovative multi-tote size automated storage and retrieval system (ASRS). This first-of-its-kind technology enables the storage of multiple varying tote sizes within the same shelving unit, optimizing warehouse efficiency.

Fabric’s ASRS is the only automated warehouse system capable of handling multiple tote sizes in one shelving unit. This flexibility allows companies to optimize their use of space, especially in micro-fulfillment centers (MFCs) in smaller local areas or within the confines of their retail stores. By storing large and small products in the same location, businesses can accommodate a broader range of SKUs, avoid wasted capacity and minimize their storage footprint.

“The growth in e-commerce is fueling pressure on retailers to expand inventory selection while keeping logistics costs low,” said Ori Avraham, Fabric’s VP Product and co-founder. “Fabric is the only automated fulfillment solution offering the technology that accommodates different tote dimensions in a single storage system so businesses can maximize inventory density, reduce operational expenses and scale to meet growing demand.”

A key element in warehouse management is the ability to utilize vertical space effectively, maximizing storage capacity. In an automated system, each tote can hold either one SKU or a few, but each SKU must be stored in a separate bin within a tote to ensure precise tracking of product locations and quantities.

When dealing with diverse SKU sizes ranging from large toilet paper to small mascara, being limited to a single tote size results in wasted storage space, effectively holding nothing but air. With the ability to use different tote sizes, which can be stored freely in multiple locations, the multi tote size ASRS opens a huge opportunity for ‘smart stock management’ algorithms and ultimately denser storage. This allows companies to streamline their operations, stock a wider range of products and adapt to changing customer demands without costly and space-consuming modifications.

Fabric‘s latest patent builds upon the company’s previous patent portfolio of unique topology and robotic technologies that equip retailers with tools to stay ahead in the rapidly evolving e-commerce market. The new multi-tote size ASRS is available to customers today.

Earlier this year, Fabric also announced a collaboration with Maersk, which now uses a 38,000-square-foot automated fulfillment center in Dallas powered by Fabric’s advanced robotic and software technology.

Pallet Shuttle System is Better, Bigger, Easier

Posted on by David Priestman

A Movu Robotics atlas pallet shuttle system gives leading logistics service provider Kris De Leeneer (KDL) approximately 45,000 storage locations and the capacity to manage a potential throughput of up to 11,000 pallet movements a week. Importantly, this automated storage and retrieval system (AS/RS) fulfils KDL’s need for flexibility by allowing pallet throughput to be increased simply by adding more shuttles, while the modular rack can be extended to increase capacity to help futureproof the facility.

This project represents the first Movu atlas system for the third party logistics (3pl) market. The solution meets the issues of 3pl industry by providing flexible in product handling and throughput. In this sector it can be hard to foresee accurately future business levels, types of customers, the resulting throughput and number of pallets required, so flexible intralogistics is a must.

Better, bigger and easier

Founded in 2001, KDL is geared to helping its clients boost their supply chain management and move their businesses forward. The Movu atlas shuttle system plays a vital role in fulfilling these aims, sits at the heart of KDL’s new state-of-the-art 10,000 square metre Distribution Centre (DC). Opened at the end of 2022, the DC is located in Lokeren, Belgium. Being next to the highway, where land is more expensive, KDL wanted to go with height for storage to minimise the building’s footprint.

For its customers in the Chocolate Industry, stock may include ingredients and primary goods for chocolate making through to bars and boxes of chocolates, numbering as many as 1000 SKUs depending on the stock profile.

The new DC is designed to assist KDL in further improving its service for customers and to provide room for expansion of its own business. It not only centralises all logistical services on to a CO2-neutral site, but also reflects the company’s vision of the future: ‘better, bigger and easier’.

Realising the vision
Helping to realise this vision, the Movu atlas shuttle system was installed in summer 2022 to provide a high density, multi-pallet position AS/RS. Without the need for lift truck aisles, the atlas system maximises storage capacity on a given footprint, while also removing manual handling, helping to reduce both personnel risk and picking errors.

Movu designed a system comprising a 28 metre high atlas rack comprising ten levels, with a footprint of 60 x 100 metres to accommodate the 45,000 locations. Pallets are moved and organised within the rack on a fleet of 20 Movu atlas pallet shuttles. These self-powered robotic carriers transport pallets on the rails of the rack’s storage lanes, where the pallets are housed, and on the rails of the main lane that runs across the storage lanes. Movu WES software manages the shuttle traffic within the rack, issuing orders from KDL’s Warehouse Management System (WMS). Movu has also provided an app that allows authorised operators to control the system from their smart phones.

Next to the atlas installation is the DC’s dispatch area and three mezzanine levels, each having an area of approximately 2,000 metres square, which are served by elevators and used for processing the goods. Movu collaborated with Ceratec to provide integrated in/outbound zones, advanced conveyers and turntables. Together, these systems offer a seamless flow of goods from storage to the dispatch area, where there are ten loading docks.

The operation

Trucks bring in and pick up goods 24-hours a day via the facility’s covered loading docks. After inspection and identification, pallets are placed on the internal transport system. The Movu atlas shuttles deposit and remove pallets via three lifts. KDL’s extensive Warehouse Management System controls the orders for put-away, pallet picking and replenishment.

The atlas shuttles transport a range of different types of goods that KDL manages for its clients. Pallets – which can include a mix of standard industry, Euro and plastic pallets – are weighed before entering the atlas system so that KDL knows what it is storing. Pallets with a loading of up to 1000 kg are stored on first two levels, with units up to 850 kg housed on the levels above.

On the mezzanines, teams perform value added services such as packaging, labelling and assembling. All pallets, including those for piece picking, are brought in or picked up by the shuttles. The system has 150 pallets per hour going in and the same figure going out. When goods are ready to go they are temporarily put into storage or taken immediately to the shipping zone.

Abundant flexibility

The inherent flexibility of the Movu atlas system was a key advantage for KDL over a stacker crane-based AS/RS. With a stacker system, if one crane is out of action, the pallets in that aisle cannot be reached. It is also hard to reconfigure to meet changing requirements and is less environmentally efficient – a heavy crane takes more power than the lightweight shuttle to transport each pallet.

With Movu atlas, however, shuttles can easily be added or removed as demand requires. A swap facility allows the shuttles to change levels automatically so if, for example, there is a large number of pallets on one level, a shuttle can be brought in from a less busy level to improve its throughput.

The rack is currently 40% occupied, giving plenty of space for new customers but the Movu system also contributes the facility’s futureproofed design. A rear wall in the DC can be removed, if required, to allow an extension to the modular rack and the addition of more shuttles. The site has room to potentially double the capacity to 90,000 pallets in the future.

Stefan Pieters, CEO of Movu Robotics, says: “This project is a great demonstration of bringing easier automation to all warehouses. The atlas shuttle system offers a flexible, scaleable, modular approach to automation. It is quick to install, simple to integrate and easy to reconfigure or expand with minimal impact on ongoing operations.”

Kris De Leeneer, CEO of KDL said: “Having made the decision to introduce automation into our new DC, and after looking at other solutions, we were attracted to the flexibility offered by Movu’s atlas system. It allowed us to optimise floor space as well as to handle more pallets than we ever could manually. Furthermore, atlas is an efficient and scaleable automated warehousing solution that can adapt to our requirements due to its modularity and the ability to add shuttles as required.”

He added: “Movu Robotics is a neighbour in Lokeren, and we talk the same language. Having been a long-term customer of its parent company stow Group, we have a trust relationship – it really understands our requirements. That is why we decided that Movu was the company to design, install and maintain an automated storage and retrieval system that would meet our needs into the future.”

Shuttles or Stackers?

Posted on by David Priestman

When considering automated warehousing, stacker cranes have often been the default storage and retrieval choice for pallets and bins. Shuttles, however, are increasingly being seen as the more efficient, flexible and sustainable alternative, as Stefan Pieters, CEO of Movu Robotics, explains.

Most firms that have to move quantities of palletised goods moving in, out or through a warehouse are familiar with that old stalwart – the stacker crane. Indeed it is no exaggeration to say that in many cases the warehouse is designed and built around the craneage. That, though, is far from ideal, whether viewed in terms of operational efficiency or through the increasingly important prism of sustainability.

Stacker cranes are undeniably chunky. They consume a lot of material in their construction, and a lot of energy moving all that mass around. Partly as a result they require significant upfront capital investment, which is a particular challenge for smaller businesses with budget constraints.

They are also very wasteful of available, expensive, floor area. They require generous aisle space to work in which reduces the overall storage density within the warehouse. They are not well suited to more space-efficient deep storage. They require the site to be all on one level, which for a warehouse of any magnitude often means building on a flood plain. They may demand floors to have a greater load-bearing capacity and place other demands on the building’s structure and services that are difficult to meet in older facilities. Also, a stacker crane layout cannot make effective use of the irregularly-shaped pockets of the site that are common in older developments or in urban areas. On some warehousing sites well over 50% of potential storage space is reckoned to be wasted.

Being complex systems, stacker cranes are demanding of meticulous planned maintenance, which has to be carried out in situ, and whilst that is in progress that aisle is essentially out of action. Similarly, any breakdown or malfunction will disrupt operations – they constitute a ‘single point of failure’ – just one apparently minor problem can render an entire aisle’s inventory inaccessible.

Perhaps most fundamentally, warehouse systems built around a stacker crane concept are fundamentally inflexible. The specific configuration of locations, aisles and cranes places a fixed limit on the maximum throughput of the facility: increasing throughput is likely to require a fairly large scale and expensive redesign and rebuild.

Shuttles and space

Stacker cranes still have their place – particularly for heavy goods, and where maximising the use of the vertical space is an imperative, although as we will see that is less of a differentiator nowadays. But for many palletised warehouse operations there is an increasingly attractive and viable alternative in the form of shuttle systems, such as those manufactured by Movu in alliance with our group partner stow Racking.

Pallet shuttles are small vehicles with a low height, and with a footprint essentially that of the pallet they are moving. They move on rails within the storage lanes of the racking system to bring pallets to and from a loading/unloading end aisle which can also be used to transfer pallets between storage lanes. Shuttles operate in two dimensions in each ‘layer’ of the racking system, but can be transferred vertically as well as between lanes. The latter is carried out automatically, through the management system and, unlike some earlier systems, without the use of a forklift truck to effect the transfer. Movu Atlas shuttles, for example, can carry pallets of 1 m x 1 m, or 1 m x 1.2 m, weighing up to 1,500 kg.

Besides greatly reducing the amount of ‘wasted’ aisle space required, this approach has a number of advantages. There is no particular limit to vertical height – 18 metres is commonplace, and we have one client whose racking extends to an eye-popping 46 metres. Odd-shaped pockets of the site, whether this is in the plans or because of uneven ground, can be brought into use economically simply by using some shorter lanes. And because shuttles, unlike stacker cranes, in no sense fixed, it is relatively straightforward and economical to reconfigure the racking if needs be – the racking itself is of modular design.

Being battery-powered and mobile, shuttles can be moved out of the way of operations for battery charging, routine maintenance, or in the case of breakdown, so not impairing the operation of the warehouse. At times of peak activity the number of shuttles in use can be increased – either across the warehouse or by transferring shuttles between lanes or levels, to meet increased demand in a particular section of the warehouse. Shuttle systems can thus be fully scalable and flexible.

Sustainability advantage

In terms of sustainability, as well as making better use of scarce real estate, shuttle systems employ much less material both in their construction and in terms of building modifications. And the saving in energy consumption simply from not having to move massive cranes around is substantial – a shuttle weighs 300 kilograms; a crane may weigh up to 15 tonnes, and so a shuttle system can be up to five times more energy efficient than craneage.

The shuttle concept can also be applied to transporting bins of material in goods-to-person picking operations. Carrying a lighter loading (up to 50 kg) enables a significant difference from pallet shuttles. Movu’s escala shuttles, for example, can work in full 3D, moving up and down ramps to access different storage layers – a bit like a multi-storey car park.

Integrating with Autonomous Mobile Robots (AMRs), picking arm robots or with other forms of automation permits a high degree of automation that can yield further sustainability benefits. These can support areas of a warehouse that does not have to support regular human labour so can be run ‘lights out’ or with reduced heating. Cold store operations, meanwhile, can be made more energy efficient – Movu equipment, for example stands out as capable of working in temperatures down to -25° C.

Bringing easier automation to warehouses

Shuttles offer a flexible, scalable, modular approach to automation. Systems are quick to install, even in existing buildings and on awkward sites, simple to integrate, and easy to reconfigure or expand with minimal impact on ongoing operations. An operator can start small – shuttle systems can be viable for sites with as few as 5000 pallet locations – and expand as finances or business allows: we have users with as many as 80,000 pallet locations.

Consumer requirements, especially for e-commerce, combined with rising pressure on resources from land and labour to energy, mean that warehouse automation is an imperative. But in these uncertain times, heavy upfront investment in solutions that are in their nature limited and inflexible may not be the best option, either now or on your business growth path. Modular shuttle systems, such as those provided by Movu Robotics, offer an economically and environmentally more sustainable alternative.

ASRS and Software Enhance Milk Delivery

Posted on by David Priestman

Swisslog, a leading provider of best-in-class intralogistics warehouse automation and software, has announced that Walmart will install a Swisslog automation solution within its Valdosta, Georgia, USA facility to enable seamless material flow and increase uptime. Walmart is planning to break ground on the milk processing facility later this year and the project is scheduled to be completed in 2025.

According to Walmart, the automated storage and retrieval solution (ASRS) will bolster the company’s capacity to meet consumer demand for milk. It continues the company’s commitment to building a more resilient and transparent supply chain to deliver high-quality products. This is Walmart’s second milk processing facility. The company worked with Swisslog to open its first milk processing facility in Fort Wayne, Indiana, USA in 2018.

Designed by Swisslog’s automation experts, the ASRS brings together five Vectura pallet stacker cranes with KUKA palletizing and de-palletizing robots, a ProMove pallet conveyor system, as well as a conveyor system for small loads. The automation solution operates on synchronized intelligence from Swisslog’s SynQ software, which provides warehouse management, material flow and automation control system functionality in a single, modular platform.

“We are excited to partner with Walmart once again to open its second milk processing facility. From the initial discussion through design completion, it has been a very hands-on, collaborative and proactive approach,” said Sean Wallingford, president, and CEO of Swisslog Americas. “Our automation experts worked closely with Walmart’s group to incorporate lessons learned and best practices from the first processing facility, as well as improvement concepts designed to enable Walmart and its farmers to bring fresh, transparently sourced dairy to market.”

The project also includes Swisslog’s IT Managed Services, which puts in place experts to proactively manage the IT systems and software required to keep the equipment running at peak performance. The higher-level 24/7 support allows Walmart to free up internal resources from routine IT system administration, while also enabling data-driven proactive maintenance that helps reduce unplanned downtime.

SynQ management software not only optimizes the flow of the equipment to increase efficiency and accuracy of the operation, it also orchestrates the operation of multiple sub-systems. It equips warehouse automation and IT systems with synchronized intelligence of people, processes and machines to boost the efficiency and productivity of warehouse processes and adapt to changing market requirements. SynQ provides sophisticated inventory management and material flow capabilities that enable real-time inventory tracking and management of items to ensure freshness, quality and transparency of the food supply chain.

DHL Supply Chain and AutoStore Partner

Posted on by David Priestman

DHL Supply Chain, global leader in contract logistics, and AutoStore™, a pioneering robotic technology company specializing in automated storage and retrieval systems, are expanding their partnership in a move set to further automated warehouse operations on global scale.

DHL Supply Chain, already involved in nine operational AutoStore warehouse projects with four more in the planning stage, is poised to become one of AutoStore’s largest 3PL clients, reinforcing their commitment to digitalization and automation. The nine existing Systems effectively operate 800,000 bins, with the forthcoming four Systems elevating the total number of bins to a remarkable 1.2 million. In the future, DHL also intends to construct five further facilities in addition to those already in operation or planning.

This innovative automated storage and retrieval system (AS/RS) technology has been developed to efficiently manage and optimize inventory using vastly reduced space within warehouses. Its highly modular and scalable design makes it a preferred solution for e-commerce and businesses handling smaller products such as fashion and tech items. The strategic aim of DHL and AutoStore through this partnership is to accelerate the implementation of this ground-breaking technology that enhances abilities to meet diverse client needs.

Fleet of more than 1,000 robots will enhance operational efficiency and throughput

Markus Voss, COO and CIO at DHL Supply Chain, emphasizes the importance of this collaboration: “We are pleased to expand our existing relationship with AutoStore as we continue to implement our digitalization and automation strategy in a growing number of warehouses, allowing us to better and faster serve our customers. AutoStore’s standardized and modular technology perfectly aligns with our aim to make our operations more efficient, enabling swift scalability and adaptability across various use cases and end-markets – a crucial factor for us as a third-party logistics provider. Through a standardized approach and dedicated stock availability we will be able to significantly drive down implementation times. Additionally, AutoStore’s network of partners is invaluable in supporting our growth strategy across multiple geographies.”

Since 2012, DHL Supply Chain and AutoStore have partnered to implement cutting-edge solutions across sites in Singapore, Poland, Germany, Australia, and the US. The ongoing collaboration has already led to expansions at all operational sites, resulting in a fleet of more than 1,000 Robots worldwide that significantly increasing operational efficiency and throughput.

Mats Hovland Vikse, CEO of AutoStore, expressed excitement about the expansion: “Our longstanding collaboration with DHL Supply Chain has showcased the strength, reliability, and efficiency of AutoStore’s technology. We are thrilled to further expand this valued partnership, supporting DHL Supply Chain’s global deployment of automated warehouse solutions. We are excited about the significant growth opportunity that this represents for AutoStore, as we continue to drive innovation in the world of logistics.”

This expanded partnership between DHL Supply Chain and AutoStore promises to redefine the future of warehousing, offering scalable, adaptable, and efficient solutions that cater to the ever-evolving needs of customers worldwide.

Irish Private Business of the Year Award

Posted on by Keith McKinley

At the distinguished Irish Exporters Association Awards 2023 in the Convention Centre, Dublin, Moffett Automated Storage shone as a symbol of outstanding achievement, securing the esteemed honour of being named Irish Private Business of the Year. This not only acknowledges their remarkable impact in the realm of automated storage solutions but also highlights their crucial position in Ireland’s flourishing export industry.

A Testament to Innovation and Excellence

Moffett Automated Storage, headquartered in County Monaghan, has recently been at the forefront of revolutionizing the logistics and storage industry. Established in 2017, the company has consistently pushed boundaries and set new standards for quality, efficiency, and reliability in the sector. The award is a testament to the tireless dedication and innovative spirit that the team at Moffett Automated Storage brings to their work every day.

Moffett Automated Storage has been a pioneer in the development and implementation of automated storage systems. Their state-of-the-art technology has empowered businesses across industries to optimize their operations, reduce costs, and increase productivity and sustainability.

Their solutions encompass a wide range of products and services, including automated storage and retrieval systems (AS/RS), conveyors, picking systems, and warehouse control software. By integrating these technologies seamlessly in a black box solution, Moffett has enabled businesses to achieve levels of efficiency that were previously unimaginable.

Catalysing Ireland’s Export Growth

The recognition as Irish Private Business of the Year serves as a testament to their vital role in shaping Ireland’s export landscape, particularly in an era where efficient logistics and warehousing are more crucial than ever.

Moffett Automated Storage also stands out for its commitment to sustainability and corporate responsibility. They have made substantial efforts to reduce their environmental footprint by implementing energy-efficient technologies and promoting sustainable practices in their operations.
Moreover, they have actively engaged in community endeavours, supporting local businesses and charitable causes. This approach to business not only reflects their values but also sets an example for others in the industry.

A Vision for the Future

With this award, Moffett Automated Storage claims to have affirmed its status as a trailblazer in the field of automated storage solutions. Their dedication to excellence, innovation, and corporate responsibility positions them as a beacon for the industry as a whole. Looking ahead, Moffett’s vision extends beyond national borders. They aim to continue their expansion into global markets, sharing their expertise and technology with businesses worldwide.

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