Adding value through smart solutions

Business, and indeed industry itself, is constantly reacting and evolving, driving the race to discover new ways to gain a competitive advantage. While the focus is often on the ‘what’ — the physical products that come to market — Big Box Group Director Iain Gillard says the way technology is integrated is equally as vital in helping businesses achieve a more profitable future.

Automation has seen strong growth over the last 18 months and its advantages are obvious. Picking, moving and sorting with robotics can help improve efficiencies and, ultimately, the bottom line. But there’s more to it than that, says Iain.

“Businesses face challenges every single day. Often, they want quick, cost-effective solutions to solve it. Depending on what the challenge is, racking, handling equipment, a robot or even an entire building can plug that gap. However, we pride ourselves on delivering smarter solutions — making sure they are fit for purpose but also designed to improve the situation beyond what’s in front of the client.”

Big Box Group has been providing innovative solutions to a variety of businesses, from SMEs to blue chip companies, since its formation over twenty years ago. Its ability to solve complex issues is driven by an analytical and technological approach that is both proactive and creative.

With a wide range of cutting-edge and high-performing products to hand, Big Box Group can integrate exactly what’s needed, allowing any type of business — from manufacturing and warehousing to online fulfilment — maximise their return on investment.

Iain says: “We see the challenge, which we can solve, but we also see the opportunity by looking at the bigger picture. The opportunity to help our clients achieve a better return on investment can often be found in analysing the way they do things, how they use their space and the technology they already have.

“We can deliver market-leading technology. We can give our clients the solution they’re looking for. But the real difference is felt in how it’s all integrated. We look at the bigger picture, and look deeper at the operation, which means we strip things back and examine the challenge from different angles. That’s often when we discover areas where a client can make further gains.”

When a client came to Big Box Group requesting more racking, Iain and his team analysed the existing racking within the warehouse and proposed they reconfigure the space by making their aisles narrower to create a more streamlined and efficient operation, which maximised the footprint of the entire building.

“Sometimes, the solution isn’t as complex or as expensive as the client believes,” says Iain. “It just needs a bit of smart thinking. We’ll take the time to listen, to really understand the issue at hand. That’s how we can deliver an effective solution while also creating opportunities the client never knew they had.”

This approach allows Big Box Group to provide a unique take on a challenging situation. Everything they do is to add value and offer an advantage — all the while making their clients lives easier and simpler.

Iain says: “The tech and the products are one thing, but the creative approach and the integration to know they’re exactly what’s required is the thing that really drives efficiencies and long-term profit. Ultimately, it’s all about getting the right fit and, through our trusted partnerships and innovative approach, we’re perfectly placed to create smart and efficient integrated solutions.”

Animal feed producer gets high-density storage solution

Skretting, a leader in the production and supply of animal feed, has commissioned AR Racking to fully optimise the floor space of its new 2,400 sq m warehouse in Cojóbar (Burgos, Spain) with high-density storage. The new warehouse is located next to the plant dedicated to the production of feed for aquaculture and attached to the one for the production of pet food.

AR Racking installed two different storage solutions for the Dutch multinational, both designed for high-density compact storage.

On the one hand, the warehouse has the shuttle system with capacity to store 2,953 europallets of finished product. It is a semi-automated solution that uses motorised pallet shuttles to transport the load autonomously inside the racking.

On the other, drive-in compact pallet racking systems are designed to store 594 europallets of auxiliary material.

“Our logistics capacity has been greatly increased with this new installation, which will help consolidate our position as leaders in the sector. We are very happy to have a warehouse equipped to operate in a very agile way and that takes advantage of every square metre,” said Skretting’s management.

Mikel Bilbao, Northern Region Sales Executive at AR Racking, added: “The semi-automated shuttle solution is ideal for a continuous flow of goods required by Skretting with its finished product. Rotation of auxiliary materials was not a primary factor, so we opted for a solution that would make the most of the space dedicated to those goods with Drive In compact pallet racking systems.”

Skretting belongs to the multinational Nutreco, a global leader in animal feed. Skretting is present in 18 other countries on all continents. Founded in 1899 and with its HQ in Stavanger, Norway, its aquaculture feed production capacity reached 2.4 million tonnes in 2020. Skretting España manufactures and supplies innovative and sustainable nutritional solutions for the aquaculture and pet industry.

WATCH A VIDEO OF THE PROJECT HERE

 

AR Racking sets up research programme

AR Racking and the University of the Basque Country (UPV) have signed an agreement to collaborate in a research programme that will take shape through the launch of the AR Racking Research Centre: Storage Solutions at the School of Engineering of Bilbao of the University in this city.

The agreement between both bodies was ratified on 15th July at the School of Engineering of Bilbao by Eric Arana (pictured on the left), Chairman of the Arania Group (the organisation to which AR Racking belongs), and by the principal of the School, Charles Pinto (pictured on the right). The inauguration was also attended on AR Racking’s behalf by Iñaki Arriola (Managing Director), Pablo Montes (Technical Director), Javier Ruiz (Product Manager) and Lorena López (Marketing and Communications Manager). Jesús Cuadrado (professor at the UPV and technical director of the research centre) also attended the agreement event. The centre will begin its activity in September, coinciding with the start of the next academic year.

It will be dedicated to analytical studies of structures made up of thin-walled profiles. In the short term, and as a matter of priority, the bases for carrying out the studies and research on fatigue in these types of profiles are being established. Other objectives include promoting studies on seismic analysis, the characterisation of components and spacers, and analyses of structural collapse mechanisms in case of fire.

Another of the main ongoing objectives of the AR Racking Research Centre: Storage Solutions is that it should serve as a career development space for member engineers, who will be able to join AR Racking’s structure to support the growth of the company, both in terms of actual projects in execution and in the product and solutions development area.

AR Racking, a company of the Arania Group with headquarters in Zamudio (Bizkaia), is specialised in the design, manufacture, calculation and installation of industrial storage systems for all types of loads. With an export rate of over 85%, AR Racking has a commercial presence in more than 60 countries. A trajectory marked by internationalisation and a clear and firm commitment to R&D&I. This is the second research centre provided by AR Racking and connected to the University after the collaboration agreement signed in 2019 with the University of Mondragón, where the AR Lab research facility and test bench is located.

The creation of research centres/labs is a valuable and effective instrument both for academic institutions and for companies for their contribution to technological development, the training of engineers and the generation of expertise in the industrial fabric. A goal shared by such an important institution as the UPV and by AR Racking, whose sound track record is clearly associated with a pioneering spirit of continuous improvement.

Jaylo’s logistics platform now at full capacity

After a commissioning period, the specialist transport and logistics services company Jaylo is now operating its new 17,000 sq m logistics platform in Tudela (Navarra, Spain) at full capacity. AR Racking has equipped the innovative logistics centre with its storage systems.

The installation integrates Jaylo’s facilities with those of its customer SKF, a company specialised in the design and manufacture of bearings for the automotive sector. Its first intralogistics division project, Jaylo did not hesitate to count on AR Racking as its trusted partner to optimise the space of the logistics platform, which is now at full capacity.

AR Racking installed, on the one hand, adjustable pallet racking, providing 2,700 new positions for pallets and 2,200 new positions for half pallets. And, on the other, FIFO live pallet racking, resulting in 2,160 new positions for half pallets. In total, a storage capacity of 7,060 new positions for pallet loads, occupying 4,250 sq m of the total area of the warehouse. Thanks to these storage solutions, Jaylo can supply and collect the finished product at the request of its customer SKF 24 hours a day.

“It is a strategic project for us because we can directly and immediately improve the competitiveness of one of our most important customers,” explained David García Osta, Jaylo Director. He added: “AR Racking knew how to put all its experience and know-how at our service during the design, planning and installation phase. The deadlines were also strictly met, which was an advantage in a project that involved the participation of both companies and teams.”

The combination of both storage systems has given Jaylo a logistics platform that fully optimises the space as well as enable time and resource savings in handling goods.

The adjustable pallet racking area provides direct and immediate access to products, while the FIFO live pallet racking facilitates perfect stock rotation and fast movement of the unit loads. To guarantee the correct positioning of the half pallets of the live pallet racking systems, the structure has been fitted with lateral guide wheels, ensuring a maximum lateral movement of 15 mm in the descent of the loads down the conveyor. This means that the driverless AGV forklifts can satisfactorily collect all the unit loads.

“It was clear to us that Jaylo needed a logistics proposal with both plenty of storage capacity and fast handling. We are fully confident that, with the solutions installed, the performance of the platform will be immediate”, said Xabier Rica, AR Racking Sales Representative.

Click here to watch the video

 

Frozen veg group gets clad-rack warehouse

AR Racking and Swisslog have started the installation of a new clad-rack warehouse in Funes (Navarra, Spain) for Virto Group, a leader and reference in the production and distribution of frozen vegetables for retail, food service and industry.

The new clad-rack warehouse, which covers 11,020 sq m and will be 38m high, will have a storage capacity for 56,166 europallets, which will allow Virto Group to have a stock of between 50 and 70 million kilograms of frozen products.

AR Racking’s 100% galvanised racking, apart from supporting the external exposures and external forces of the warehouse, will be designed to integrate a Swisslog compact storage system with 31 transfer cars for pallet handling. An ideal solution for high-density storage and maintaining maximum operational speed, with flows of 350 pallets per hour.

“We fully trust AR Racking’s expertise in industrial racking systems, having worked with them on previous occasions to fulfil our storage needs in other frozen product facilities that we have in Segovia, Badajoz and La Rioja,” explained José Antonio Baldero, Technical Director of Virto Group.

“Clad-rack warehouses provide great low density resulting in significant savings due to lower investment. Our racking also adapts perfectly to warehouses that require cold work such as that of Virto Group, which will be at a temperature of -24°C,” added Roberto Arriaran, Director for Integration Business Unit at AR Racking.

 

 

Clad-rack warehouse system for Spanish dairy company

García Baquero, a well-known Spanish company with an international presence in more than 60 countries dedicated to the production and distribution of dairy products, has improved its intralogistics with a clad-rack warehouse for pallets installed by AR Racking in Ciudad Real, Spain.

The new warehouse has 36m-high racking which, apart from storing the load, is part of the structure of the building supporting the external enclosures. The main characteristic of clad-rack warehouses is that the racking is part of the building structure, thus fully exploiting the space. García Baquero’s new warehouse, covering 1,080 sq m, is equipped with a stacker crane to handle the goods.

AR Racking, a company that specialises in industrial storage systems, worked on this project with a European engineering company to integrate automated elements in the racking structure. The new centre is also designed to store refrigerated products so “the structure has AR Racking 100% galvanised racking that offers ideal corrosion resistance for this type of environmental conditions”, explained Juan Francisco Contreras, AR Racking Project Manager.

According to Diego Medina, Technical Manager at García Baquero, “this new automated warehouse will help us to improve our daily operating performance and our logistics efficiency. We are delighted to have a structure perfectly suited to the characteristics of our product and this large load capacity.”

“The clad-rack warehouse is the most suitable solution for high-bay storage. We worked painstakingly on the planning of the installation phases and carried out an exhaustive follow-up to ensure the project would be completed as planned and strictly meet the customer’s storage needs,” explained Bernardo Sopeña, AR Racking Sales Engineer.

Bullet Express equipped to go the extra miles

Bullet Express, the Glasgow-based international logistics, transport and storage company, has installed 3.5 miles of pallet racking in its new 30,000 sq ft storage logistics facility in the city. Laid end to end, the racking is long enough to stretch from the storage facility at 2129 London Road, Glasgow, to George Square in the heart of Scotland’s largest city.

The new racking, manufactured by Spanish specialist AR Racking and installed by local installation experts, Rackit Ltd, means that the facility is now fully operational only two months after Bullet Express received the keys to the building.

The new storage facility:

Represents a seven-figure investment from Bullet Express
Can hold 5,000 pallets
Increases Bullet Express’s capacity by 25% to 26,000 pallets
Has 20 rows of high-capacity racking, creating 364 storage bays stacked seven layers high
Operates 10 aisles
Has a narrow aisle configuration to accommodate Aisle Master forklift trucks

Bullet Express’s creation of the new storage facility reflects a surge in demand from both existing and new customers for storage services. This is in response to tighter consumer delivery demand following a 40% rise in online shopping due to Covid-19 lockdowns. The new facility will result in the creation of up to 10 new jobs initially.

David McCutcheon, co-founder and Chief Executive Officer at Bullet Express, said: “Demand from existing and new customers for storage space close to their customers is at unprecedented levels and investing in this high-capacity racking means that we can accommodate their needs, offering an end-to-end service. So much so that the facility is already close to reaching its capacity with new business wins from blue-chip customers in the retail grocery sector.

“I’m full of admiration for the service we’ve received from AR Racking, Rackit and Douglas Gillespie Plant, whose high-lift plant was used throughout the installation. I’m proud, too, of Bullet Express’s own team who have moved heaven and earth to get this installation completed in record time.”

The Rack Group acquired by IWS 

IWS Group, The Industrial Workspace Specialists, has acquired The Rack Group, a leading provider of pallet racking safety, inspection, repair and maintenance solutions.

The move will see The Rack Group become part of a growing family of specialist, market-leading businesses that currently includes impact protection solutions provider, Brandsafe, and visual communication solutions supplier, Beaverswood.

IWS Group provides essential services and supplies to the logistics, warehousing and material handling sectors in the UK, across Europe and beyond. The acquisition will further strengthen its position in core markets, extend the scope of the existing offering and open up opportunities to provide customers with additional product solutions and services.

Established for over 40 years and based in Barnsley, The Rack Group supplies its innovative racking protection products, such as Rack Armour, and its racking inspection, repair and maintenance services to some of the largest brands in retail, warehousing, logistics and material handling.

Management of both businesses believe that there is a uniquely complementary fit between the companies in terms of product ranges, services, people and expertise. Under the terms of the deal, The Rack Group will continue to trade as usual under its existing brand.

Jeroen van den Berge, CEO of IWS Group, said: “We are excited to welcome The Rack Group to the IWS family. We have known The Rack Group for some time and, as a business that has built a market-leading reputation for quality and expertise in racking safety, with a long-standing, multi-site customer base, it represents a strong and natural strategic fit for IWS Group.

“The warehousing, logistics and materials handling sectors have seen unprecedented growth due to new shopping behaviours and IWS Group is bringing together businesses built on specialist expertise and customer centricity to serve these sectors with essential products and services. The addition of The Rack Group provides further opportunity to broaden the scope of services and solutions each of the IWS Group companies can offer their customers. We look forward to a bright, prosperous and successful future together.”

Jenny Charlton, director at The Rack Group, said: “This is an extremely positive development for both organisations, bringing new opportunities to add greater value to customers in terms of product solutions, technical capabilities and enhanced customer service.

“Our market presence will remain as strong as it has always been. Indeed, an attraction of linking up with IWS Group means that we can benefit from the additional resources, infrastructure, and product offering that it brings, without loss of brand identity or the core values that have contributed to our success over four decades.”

Pallet storage and pick solution improves efficiency

SEC Storage has designed and installed a highly efficient pick and pallet racking storage solution at Midlands-based Nero Pipeline Connections, ensuring improved pick operations through swift replenishment of stock held in the additional pallet locations.

Nero Pipeline Connections is a market-leading distributor of stainless pipeline products and has been specialising in the supply of high-quality pipe fittings and valves for over 30 years, with a broad portfolio of products suitable for commercial and industrial environments.

Its warehouse facility had some existing racking in place which it had steadily expanded as the company grew. However, this offered Nero mainly pick locations and only limited pallet storage capacity. The racking was also only 4m high and, with the building offering 9m of height capacity, it was only utilising 50% of the available storage space.

Nero needed to increase both its pick areas and pallet locations, which would act as replenishment stock for tote locations. The increase to 630 pallet locations designed and installed by SEC Storage comprising adjustable pallet racking with timber decking and anti-collapse mesh, now allows Nero to hold considerably more bulk stock, ready to replenish the 6000+ tote locations for picking, which are situated directly below the pallet racking, as and when required.

The operation benefits from the use of a reach truck for all pallet movements, and the manual pick process has been improved considerably as all stock is front-facing, providing quicker replenishment as well as 100% selectivity with pick options from either side.

The project further benefited from a finance scheme via Systems Finance, which was able to source a favourable, tax-friendly payment option via CBILS (Coronavirus Business Interruption Loan Scheme), a Government scheme provided as a result of the COVID-19 pandemic. This offered attractive terms for Nero, with a strong ROI and one that turned a significant CAPEX project into a manageable, fixed monthly payment scheme.

Darryl Spencer-Hicks, Operations Director at Nero, commented: “Due to the significant ongoing growth of the business, we needed a quick solution to ensure the flow of stock remained unhindered. With this in mind, we contacted SEC to design and project manage the re-racking of the warehouse with the minimalist disruption to Nero. As with any large project, things change and it is how they are dealt with. SEC went to great lengths to rectify any delays and this meant our customers saw no impact on their orders.

“SEC worked alongside Toyota Material Handling to design the racking system to maximise the use of the warehouse space and worked with Systems Finance to deliver a cost-effective finance package with us.”

 

 

New Pallet Racking Solution

Logistics service provider Great Bear has selected AR Storage Solutions as its trusted partner to add new pallet racking and reconfigure its 20,000m2 warehouse in Nottingham, England. Part of Culina Group, Great Bear offers nationwide warehousing and distribution solutions for leading international customers.

“The Great Bear warehouse in Nottingham required a brand-new racking solution accompanied by some layout modifications to transform it into a more flexible operating facility” explained Andrew Collinson, Capital Projects Director, Culina Group. “We are delighted to have entrusted AR Racking and to now have a warehouse with capacity fully optimised.”

The project included the dismantling and disposal of old non AR pallet racking and the installation of new AR adjustable pallet racking resulting in a storage capacity for 17,400 pallets. “We had to deal with the added complication of Great Bear requiring to keep the warehouse fully operational while we dismantled the old pallet racking and replaced it with new AR pallet racking equipment”, commented Mike Smyth, AR Racking UK Key Account Manager.

The installation of adjustable pallet racking also has a number of dedicated mesh deck panels and individual adjustable mesh dividers to create a quantity of low-level pick locations for Great Bear. Adjustable pallet racking systems come with a wide variety of accessories for the storage of any type of products, making this type of racking highly versatile. It is also a storage solution that allows maximum use of space, due to the ease and speed in adjusting the load levels to adapt them to specific volumes. In this case the top beam level is 8.75 m high.

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