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Whittan celebrates 70 years

Posted on by David Priestman

Whittan is celebrating its 70th anniversary as a trusted supplier of storage products and solutions.

Whittan’s story – capturing 70 years of British design, manufacture and installation of pallet racking, shelving and lockers by one company – remains unique today. It was in 1951 that father and son James and Peter Kinnear established The Handy Angle Company at Brierley Hill in the heart of England’s industrial ‘Black Country’. They set up a small workshop with an original staff of six. From there, they started manufacturing a range of practical slotted steel angles.

The region was already considered influential in shaping trends and consumer tastes, and the company was well placed to tap into that growth. They developed a tensioning plate design which provided a stable and highly configurable storage system. Building on this innovation, the business grew to meet the increasing demand for improved, purpose-built storage equipment. In 1966, it changed its name to Link51, combining the year of incorporation and the word Link which described the various types of storage equipment and techniques grouped within one company. It has never looked back.

Throughout the seven decades, Whittan tracked the changing needs for storage while innovating and setting trends. Today it is the UK’s largest manufacturer and supplier of steel storage systems, recognised for their extensive range of solutions that expand capabilities with storage.

The backbone for many of the UK’s leading and household brands and organisations, Whittan’s solutions continue to meet the demand for rigorous and effective storage management for all types of industries and specifications. They are present in warehouses, retail, stores, offices and organisations across industries and sectors – from creating the space to store defence equipment on board a Royal Navy submarine; housing 13.5 million litres of Macallan single malt; protecting Stella McCartney’s couture archives; to providing secure storage lockers for offices, schools and gyms, or storing decades of film reel for the BFI.

Jon Templeman, Whittan CEO, commented on the achievement: “Not many businesses have the durability to last 70 years. Whittan and its predecessor businesses, Link51 and Apex, have demonstrated their resilience and ability to adapt to a changing market over the years.”

As the largest UK manufacturer, Whittan has been at the forefront of changes in the industry. It has also been influential in the development of industry standards, at SEMA in the UK and in Europe, where it has become an increasingly important player since its acquisition of the Permar (now Polypal) business in Spain.

Templeman added: “Our use of technology, and the knowledge and experience of our experts has enabled us to respond to the growing demand for inventive, automated solutions. We have also changed our customer service approach from being product-based to focusing on solutions for customer challenges. However, it has been the commitment and innovation of generations of Link51-Apex-Whittan staff that has enabled the business to thrive. I am confident that this dedication and success will continue.”

As Whittan celebrates seven decades of expanding storage capabilities and maximising opportunities with Link51, it brings an outstanding range of trusted storage brands. These include Link51 and Apex, providing design, manufacture and installation of racking and shelving products; HiStore, for mezzanine floors; market-leading display and storage solutions for retail sectors from Polypal UK and an extensive range of lockers and workplace products from Probe and Link Lockers.

Whittan products are part of the UK legacy showcasing quality in manufacturing. The company is committed to sustainability and is moving towards net-zero. All Whittan products are manufactured locally, keeping them close to installation sites. This cuts down on carbon emissions, delays, cancellations to orders and disruptions to timelines. It also maps against an extensive UK-wide network with experts to help with queries and handle simple to full turnkey environmentally-efficient installations.

In the tradition established in 1951 by James and Peter Kinnear, Whittan continues to bring the power of storage to help businesses large and small, across sectors, with a huge array of storage needs. Throughout, it makes space work harder by providing the most innovative, flexible and future-proof storage solution possible.

Randex launches vertical storage-robotics integrator

Posted on by David Priestman

Vertical storage lift company Randex is launching Compact 24/7, a solution that integrates the company’s Compact family of automated vertical storage systems with robotics technology to allow continuous, 24/7 warehouse picking with, it says, up to 50% fewer warehouse workers.

Compact 24/7 allows automated vertical storage to be integrated with a wide range of robotic types including autonomous mobile robots (AMRs), collaborative robots (cobots) and automated guided vehicles (AGVs).

“Automated vertical storage already delivers proven benefits for warehousing and logistics users,” said Randex director James Roberts. “Randex user feedback shows that robotics doubles its impact.”

Compact vertical storage lifts already save up to 90% of floor space compared to standard shelving and pallet racking. They can manage loads of up to 100 tonnes and already enable warehouse operatives to complete up to four times more picks than in a traditional warehouse, with goods automatically presented to the picker. When the same goods are presented to a robot using Compact 24/7, picking performance improves by a further 100% according to Randex users.

Randex Ltd is the sole UK distributor for Compact Vertical Storage Lifts, manufactured in Sweden by Weland Solutions, a member of the privately owned, global group Weland AB. Randex customers include Bombardier, DHL, Fujifilm, Howdens, Hutchison Ports, Jaguar Land Rover, Ministry of Defence, P&G, Pfizer, Rolls Royce and Specsavers.

Waitrose expands warehouse with AR Racking

Posted on by Keith McKinley

The renowned supermarket chain brand Waitrose & Partners has increased its storage capacity with the extension of its facilities in Magna Park (Milton Keynes, UK) to consolidate its position as a leader in its sector in the British market. To do so, it has relied on AR Racking, a European benchmark in storage systems.

The new extension consists of an intralogistics solution with AR Racking’s adjustable pallet racking that achieved an added storage capacity for 13,604 UK pallets. It is a storage system that will provide the warehouse with great agility in loading and unloading operations, with direct and immediate access to the goods. A solution perfectly adapted to the increase in demand for consumer goods and the demand on delivery times.

Waitrose is owned by the John Lewis Partnership retail group, the largest example of an employee-owned business in the UK with over 80,000 members. “Our aim is for Waitrose to remain the supermarket chain most valued by the British people and to do that we need a logistics infrastructure that allows us to hold more stock of products that can be delivered in less time,” explained Lawrence Ireson, Project Manager of the John Lewis Partnership. “We knew that AR Racking would meet their promises on this strategic extension.”

“This is a project that is tailored to the client’s needs and characteristics,” said Mike Smyth, UK Key Account Manager at AR Racking. “The racks have a paint finish in Waitrose’s corporate green colour.”

“We have strictly adhered to the delivery and installation schedules agreed with Waitrose, whose standards are exacting,” added Jim Albans, AR Racking’s UK Project Manager.

AR Racking, based in Maidenhead, has a well-established presence in the UK thanks to a service tailored to customers’ needs and the ability to deliver large projects to tight deadlines.

Peterhans benefits from micro fulfilment centre

Posted on by David Priestman

As part of a holistic realignment of its intralogistics, Peterhans Handwerkercenter AG, located at Würenlos near Zurich in the Swiss canton of Aargau, has remodelled and automated the logistics processes of its central warehouse and store for faster order processing and more storage capacity.

After comparing various AKL technologies and solution approaches, the family-owned company, founded in 1952, opted for an AutoStore solution from Element Logic.

“With around 500,000 articles, our multichannel strategy and our continuous growth, we wanted to invest in a system offers close to zero picking errors and maximum flexibility for future system expansions,” said Dieter Egloff, deputy managing director of Peterhans Handwerkercenter AG, explaining the main reasons for the decision. “Therefore, we examined various logistics facilities in practical operation and visited reference facilities with AutoStore solutions. When we weighed up all the factors, it quickly became clear: AutoStore technology was on our wish list. The simplicity of the technology, the flexibility of the storage concept and the output convinced us right from the start.”

Peterhans Handwerkercenter AG distributes building materials, tools, machines, fittings, fasteners and personal protective equipment directly to tradesmen and companies in the construction industry, making it one of the leading companies in this segment in Switzerland. Continuous growth, the servicing of different distribution channels promoted the decision to automate intralogistics.

“We are continuously strengthening our business through future-oriented investments in digitalisation and logistics,” Egloff said. “The automation solution allows us to handle volume increases with the same number of employees.”

The contract for system planning and implementation was awarded to system integrator Element Logic, the first official AutoStore integrator and the world’s most successful AutoStore distributor in 2020. With nearly 200 implemented AutoStore solutions, the company has extensive experience and a competitive edge in the planning, implementation and support of maximally efficient storage and picking systems for container-ready products. Based on this broad foundation, the system integrator is continuously developing further optimisation options in the field of AutoStore technology.

Integration of tailored system

For Peterhans, Element Logic installed an AutoStore system with a footprint of just 400 sq m for around 25,000 storage locations during ongoing operations in a two-stage project.

“The system includes 11,650 totes that are subdivided up to eight high,” said Egloff, illustrating the storage capacity. The 220mm-high bins used allow a load of up to 30kg with internal dimensions of 603 x 403mm.

“The main objectives of the automation project were to improve in-house logistic processes and maximise storage capacity in the existing building by increasing storage density,” said Joachim Kieninger, Director Strategic Business Development Element Logic Germany. “For an optimal layout of the facility, we analysed the very different sales channels and took them into account with regard to layout and processes.”

Peterhans supplies the shelves in the retail store from the central warehouse, orders via the online store, deliveries with its own vehicles to fitters and tradesmen, as well as output for direct pick-ups or orders in the store.”

For these goals, Peterhans and Element Logic already worked closely together in the planning phase. “The result is the perfect integration of an auto store system tailored exactly to our requirements into our existing building,” explained Egloff.

With the AutoStore automated storage and picking solution, the family business opted for an innovative storage concept in which the containers for small parts storage are stacked on top of each other in shafts and stored and retrieved by small robots. The system impresses with its efficiency and flexibility as well as minimal space requirements and comparatively low investment and operating costs.

The container stacks are stored in a standardised aluminium grid up to 5.4m high. The robots work on the surface of this grid. Depending on the container height, up to 16 or 24 bins are stacked on top of each other in a grid. The compact overall system with integrated workstations, the so-called ports, offers 60 to 70% better space utilisation than conventional miniload solutions.

The system layout can be adapted precisely to any structural conditions and is easily scalable with additional robots, ports or shafts to meet growing performance or capacity requirements. Consequently, AutoStore systems achieve the highest storage density among the available miniload solutions. The same applies to energy efficiency: with an average energy consumption of 100W per robot per hour, AutoStore systems have by far the lowest need for energy of all available miniload solutions.

In the system built for Peterhans, 20 bins are stacked on top of each other, adapted to the height of the hall. Ten robots move along the top of the grid. They lift the totes with the desired goods, transfer them to the workstations and stack the totes back into the system after picking.

Special feature: The system was realised in two construction stages due to the fact that it was implemented during ongoing operation. One of the advantages of the modular AutoStore concept, its high flexibility, came to the fore: first, one half of the grid could be conveniently erected, put into full operation and filled with goods. The empty shelving units were then dismantled and the AutoStore system was expanded to include the second half. This solidified the idea of connecting three of the six installed workstations directly to the sales floor.

“Customers are amazed and impressed to see an automated logistics system and transparent processes tied directly to the store,” Egloff said proudly. “This makes us very advanced – and allows us to offer customers something in additional, a unique shopping experience.”

The same applies to energy efficiency: with an average energy requirement of 100W per robot per hour, AutoStore systems have by far the lowest energy consumption of all available miniload solutions. With these attributes, AutoStore solutions form a proven basis for automated processes and fast order processing in modern micro-fulfilment centres, for example in online retailing.

97% fill rate

The workstation modules used in the AutoStore system are so-called carousel ports for higher warehouse throughputs and conveyor ports for lower throughputs. The carousel ports serve both as picking and repacking stations for loading the system totes.

Of the six ports at Peterhans, the three conveyor ports on the sales floor are used to retrieve goods for store customers. The three ports that are not visible in the store are used for retrieval of dispatching orders from the online store and for external deliveries to companies and fitters in the field, for example.

“In less than two minutes, a customer’s order is at the sales counter,” Egloff pointed out. “The system control of the AutoStore system knows which bin is in which place, calculates the routes and then distributes the driving orders to the robots via radio link.”

The robots work in a coordinated manner, quickly rearranging the totes, quickly releasing the required bins and filling them into the shafts for the integrated workstation modules. Thereby  the system automatically ensures that the bins are positioned according to ABC criteria: Less frequently requested containers slide successively further down, while fast-moving items remain continuously in quick access on the upper levels.

“Compact, high-density storage and fast, virtually error-free picking,” summarised Egloff. “With a system filling level of 97%, an average of 15,000 picks are made with the system per month – between 700 and 800 accesses per day.”

Immediately after installation, Element Logic’s AutoStore solution enabled the company to meet customer expectations for same-day delivery and shorter waiting times at in-store pickup counters. And the AutoStore system is also a great benefit for employees: “Our new, fully automated AutoStore system simplifies important loading processes and significantly supports our employees in their daily work. They no longer have to cover long distances or lift heavy goods. Overall, the picking processes are less labour-intensive for them than before.”

Element Logic ensures high system availability through its service team with preventive maintenance on site, as well as qualified telephone and online support.

According to Peterhans’ calculations, the investment in the AutoStore system will be paid off in five years. The flexibility of the storage system supported the two-stage project creation during ongoing operations as well as future growth.

“Without the AutoStore system, we would have had higher staffing requirements in logistics,” said Egloff. “With the AutoStore facility, we were able to meet the steady growth and even the rapid increase in online orders, because the retail store remained closed during the pandemic, without additional resources. An investment in the future from the very beginning. We can now count on a high-performance, automated small parts warehouse and our partner to meet our customers’ expectations for fast order fulfilment.

“And the system is still standing so well because we had such a good implementation partner in Element Logic. We are completely satisfied with the project handling, the cooperation and the results.”

The project details at a glance:

  • 400 sq m AutoStore plant footprint
  • 11,650 bins with around 25,000 storage locations
  • 10 robots
  • 6 ports
  • Simplified and ergonomic warehouse processes
  • Increased efficiency through automation
  • Important component of the digital transformation
  • Nearly zero defect picking
  • Same-day order processing and delivery
  • 80% Space savings offer future expansion potential
  • Highly reliable plant technology
  • Reduced burden on employees

CLICK HERE to watch a video of the project

AR increases capacity by 40% for AZA Logistics

Posted on by Keith McKinley

The AZA Group, which has been strengthening the logistics strategy of its subsidiary AZA Logistics, has opened an ambitious logistics warehouse in Sagunto (Valencia) with a capacity for 45,000 pallets thanks to AR Racking’s industrial storage solutions.

The 25,000 sq m warehouse will be fully optimised with VNA racking designed, manufactured and installed by AR Racking. This type of racking is a high-density storage solution that can increase warehouse capacity without having to increase the space. Greater compaction is mainly created by narrowing the work aisles, which can reduce the width by up to 1.85m and save up to 40% in space. The industrial racking installed is 19m high.

During a second phase which will be completed in the coming months, another storage area will be installed with a capacity for a further 6,000 pallets. An area of the warehouse that will be adapted to maintain a controlled temperature from 10°C to 25°C in Phase 1 and from 5°C to 10°C in Phase 2 for the planned storage of pharmaceutical and food sector products.

The new logistics platform confirms the group’s firm commitment to its comprehensive logistics operator AZA Logistics. “Undoubtedly this warehouse represents a major milestone in AZA Logistics’ history,” commented Juan Zamorano, CEO of the AZA Group. “We are very satisfied with the quality of the installation and strict completion of deadlines provided by AR Racking.”

In addition to AR Racking’s storage solutions, the warehouse includes the latest technology for the preparation of pallets and other unit loads, positioning AZA Logistics as a leading 4PL logistics operator.

Vicente Marin, AR Racking’s Sales Representative in the Levante region, added: “After initial conversations with the AZA team, we immediately identified that we needed an agile warehouse. VNA racking allows a loading and unloading operation with direct and immediate access to the goods, minimising times.”

This type of racking which is also operated by turret trucks (Combi) makes great use of the available height in the warehouse, optimising the storage space to the full.

The project was executed with a perfect coordination in the delivery of materials and assembly of the structure, strictly meeting the deadlines.

CLICK HERE to watch the video.

 

Storage Direct launches new website   

Posted on by David Priestman

Storage Direct, the online retail destination for UK-manufactured storage products and solutions for home, warehouse, industrial, office and retail environments, has launched a newly designed and rebranded website.

The new website, with over 2,000 products available to buy online, is more than just a refresh. Based on ongoing research and direct user feedback, it has been rebuilt with the customer in mind. The site features a new brand identity, a modern design and improved functionality, with direct and easy access to help and support for customers engaging online.

Storage Direct has a wealth of experience in serving business customers and consumers. The ecommerce site showcases an extensive range of storage solutions, warehousing equipment, industrial shelving, storage bins, lockers and much more. This online one-stop-shop provides customers with a quick efficient way to order regular requirements like pick bins, plastic boxes, step ladders, warehouse steps, metal lockers, plastic lockers, metal shelving, pallet racking or industrial racking.

With this rebrand and rebuild, Storage Direct has introduced a new generation of technology and ecommerce that underpins a streamlined online customer experience. It is easier to use and navigate, with clear product information, increased online payment facilities and an improved help and support service, complete with online chat available during office hours and new enquiry forms.

The new Storage Direct website reflects insights and in-depth analysis of the ways customers engaged with the online shop over the years. A key requirement was an upgrade of the search function for ease-of-use while on the website. A new filter system directs customers to find exactly what they’re looking for, quickly and easily. There is also immediate help available from expert sales support: customers can use the new reinvigorated online chat platform or engage using traditional methods of contact such as digital enquiry forms or telephone.

Logged-in customers have better visibility of their orders, with the ability to track the order status from their redesigned profile. While logged in, they can also update contact details and edit their basket with a few clicks. Other new features include a “recently viewed” slider for customers to go back to products that they had discovered previously. Best sellers and popular items are clearly visible across the site for easy access, and customers will see the latest deals, offers and competitions as soon as they visit the website.

Storage Direct says its new website is faster, easier to use and much more efficient for customers. It reinforces Storage Direct’s position as a leader in online high-quality storage solutions, showcasing an extensive range of storage products manufactured here in the UK and their approach to supporting clients. It also brings the power of storage through Whittan to support a wider variety of projects. Storage Direct is offering a free bespoke site survey service for customers with larger requirements.

Whittan’s Product Marketing Manager, Tom Campbell, said: “Customers using the new Storage Direct website will immediately see and feel the benefits of the new site. The technical architecture is next generation, providing an enhanced user experience with improved features for better online shopping. At Storage Direct, we want to ensure that all our customers, regardless of their fluency with ecommerce, are provided with the best and most intuitive and efficient service that we can provide.

“As a leading online one-stop-shop we are also increasing our general online presence and engagement to provide the best offers for the highest quality product on the market. We are present on social media, where you can find all our latest deals, offers, information and competitions!”

The new Storage Direct website is accessible online across all laptops and devices, bringing the direct power of storage to customers. Customers can browse through favourites – such as the Linbins range, garage shelving and personal effect lockers – as well as new storage products and offers across shelving, lockers, racking, Linbins, cabinets and cupboards, workbenches and workstations.

The new site reflects the rebranded Storage Direct which forms part of the Whittan Group. Whittan launched a group-wide rebrand with a new look and website earlier this year consolidating storage brands, products and solutions within one unified approach to provide extended capabilities in storage.

Vertical storage lift planning tool launched

Posted on by David Priestman

Vertical storage lift company Randex is claiming an industry first for its rollout of a free online service that organisations can use to generate CAD drawings and specifications for their automated handling using vertical storage.

“By sharing our vertical storage technology freely with organisations and the supply chain community in this way we are helping to democratise business planning,” says Randex director James Roberts.

Manufacturing, logistics and other supply chain users of the ‘Compact Configurator’ service tool enter key data including their building height, storage and picking needs. The tool then generates a customised CAD drawing and specification showing their vertical storage lift height and footprint, optimum storage capacity and other information. An additional, warehouse optimisation questionnaire can also be accessed HERE.

Compact Vertical Storage Lifts save up to 90% of floor space compared to standard shelving and pallet racking, says Randex, minimising the floor area while maximising storage volume, and can manage loads of up to 100 tonnes. Their load tray system enables warehouse operatives to complete up to four times more picks than in a traditional warehouse, with greater accuracy and without the need to search for goods, which are automatically presented to the picker.

The ‘Compact Twin’ also doubles any picking rate by utilising two load trays simultaneously – thought to be unique in the industry. Compact Vertical Storage Lifts can be integrated with all leading WMS and other business systems and typically pay for themselves within a year, based on Randex user feedback.

Randex is the sole UK distributor for Compact Vertical Storage Lifts, manufactured in Sweden by Weland Solutions, a member of the privately-owned, global group Weland AB.

The new vertical storage lift planning tool is available HERE.

Warehouse Partners stages Pallite storage open days

Posted on by David Priestman

Warehouse Partners, a leading supplier of labelling and warehouse solutions to the suppliers of storage and material handling equipment, is staging a series of open days to showcase its versatile Pallite Pix storage solution.

Pallite Pix is a range of flexible, lightweight and durable storage systems, specially designed to consolidate pick locations. By utilising the between-pallet space the system enables operators to maximise the available space they have in their warehouse, helping them store more product and improve their pick efficiency.

The system incorporates easy-to-fit interchangeable dividers that can be designed around a specific product. Pick positions are available in 12-, 16- or 32-compartment configurations, helping to reduce pick times and walk sequences, and accompanied by suitable identification labels, the system enables operators to easily locate product.

The durable honeycomb construction walls and reinforced edges help to protect stock from damage and pickers from injury, while each Pallite Pix storage unit can hold up to 500kg of product. Despite the lightweight nature of the product, it is strong enough to be moved by a forklift, even when full.

To support the sustainability requirements of the modern warehouse, the Pallite Pix product is also 100% recyclable and made from responsibly sourced materials.

Chris Hopkirk, Sales Director, Warehouse Partners, said: “We made Pallite Pix the subject of one of our product webinars earlier this year and the feedback we received was very positive. Many people said they would like to see a live demonstration of the product, so we have responded their requests by organising these open days.

“I’ll be joined by David Rose of Pallite, who co-presented the webinar with me, and we’ll be showcasing the system and answering any questions people may have. Anyone who has customers planning a major warehouse project or looking to improve their fulfilment operations should not miss this opportunity to see this game changing system.”

Suppliers specifying the Pallite Pix system to their customers have reported very positive results, with several placing repeat orders based on the strong performance of the product.

Eurocell, a leading manufacturer, distributor and recycler of uPVC windows, doors, conservatories and roofline products, installed the system at its new national distribution centre earlier this year. Quickline was the Warehouse Partners distributor working with Eurocell on the DC installation.

Tim Robins, Contract Project Manager at Eurocell, said: “We were delighted with Warehouse Partners’ recommendation of Pallite Pix. The system has helped to overhaul our picking operation and improve the productivity of our new warehouse no end.”

The first Open Day takes place at Warehouse Partners’ national headquarters, Unit 3, Easter Court, Warrington, WA5 7ZB between 10am and 3pm on Wednesday 10th November. This will be followed on Tuesday 16th November, with the second Open Day. This event is being staged at the headquarters of First Class Safety, Swift House, Cosford Lane, Swift Valley Industrial Estate, Rugby CV21 1QN.

“We have staged one event in the North West and one in a central location to offer people the broadest choice of venue. Hopefully, this will help people decide which event best suits them,” added Hopkirk.

Each day will be split between morning and afternoon demonstrations, while there will be product samples available to take away, along with data sheets describing the Pallite Pix system in more detail.

CLICK HERE to register for one of the Open Days.

Geodis implements highest-throughput AutoStore

Posted on by David Priestman

Global leading transport and logistics provider Geodis has formed a partnership with Bastian Solutions to implement an AutoStore system into a new fulfilment site for a leading clothing retailer. The US$48 material handling equipment deal will deliver the highest throughput documented of an AutoStore system globally to support the retailer’s omnichannel capabilities, including e-commerce and its more than 1,000 stores across the United States.

AutoStore is a pioneering goods-to-person automated storage and retrieval system that is the market leader in storage density. AutoStore Bins are stacked vertically in a grid and retrieved by robots that travel on the top layer of the system, allowing the grid to be placed around columns and on mezzanines and multiple levels. This design allows bins of products to be stacked on top of each other in a condensed grid-style system, increasing storage capacity up to four times in the same footprint and performance up to 10 times without added workers.

“Geodis’ strategic partnership with Bastian Solutions and AutoStore will provide us even greater efficiencies and added capacity as we continue to navigate ongoing industry challenges on behalf of our clients, such as swiftly changing consumer buying patterns and labour shortages,” said Rob Thyen, Senior Vice President of Engineering and Facilities at Geodis in Americas. “By investing in technology such as the AutoStore system, we can ensure we are supporting our clients’ future growth and exceeding their expectations.”

Geodis is estimated to move up to 270,000 order lines per day in service of both retail store and direct-to-consumer channels, making this the AutoStore system with the highest throughput in the world. Geodis will use the AutoStore system to facilitate fulfilment for its customer’s retail and e-commerce channels to deliver a truly omnichannel solution.

Geodis will also utilise the AutoStore technology to expedite e-commerce returns, which continues to be an industry priority due to recent increases in online purchases. In addition to featuring the innovative AutoStore storage and fulfilment technology, the 400,000 sq ft (c.37,000 sq m) facility will include robotic piece picking with five robotic arms, automated packing and carton closing, and more. Construction for the site is expected to begin in January 2022 and wrap in November 2022.

“It has been a pleasure working with the Geodis team,” said Marvin Logan, Vice President of Solution Delivery at Bastian Solutions. “We pride ourselves on providing our clients with the necessary advantage to remain competitive – especially as the retail and e-commerce markets continue to change drastically. With this system, Geodis will be well-equipped to meet demand, thanks to the advanced automation in this new omnichannel facility.”

Bastian Solutions is one of the leading partners in AutoStore installations. This project marks the second AutoStore system that Bastian Solutions has implemented on behalf of Geodis. Construction is currently underway for an AutoStore system at a highly automated fulfilment site on behalf of a top pet product retailer, which is expected to be completed in November 2021.

“It is an exciting time for retailers, especially given the substantial increase in e-commerce orders that we have seen over the past 18 months,” said Paul Roy, North American General Manager for AutoStore. “We’ve always aimed to provide an autonomous robotic solution that empowers our customers to fully leverage their warehouse operations to ensure an efficient, reliable and sustainable supply chain. Now, in partnership with Geodis and Bastian Solutions, we’re proud to continue empowering retailers with a system that delivers the highest throughput globally.”

Successful storage: “the difference is in the detail”

Posted on by David Priestman

Innovative design details often make the difference for successful storage and order picking, says Edward Hutchison, Managing Director of BITO Storage Systems.

Constantly developing logistics and supply chain techniques have generated a diverse array of intralogistics solutions tailored to meet the precise needs of individual operations. Order volumes, SKU numbers and sizes, order lead times, the temperature of the goods being stored and available space are just some of the variables that can pose specific challenges on a project. Often it will be the small, innovative design details that make the critical difference for designing a truly successful storage and order picking solution.

While new warehouses offer easy to use space, many operations have to make the best of the compromises inherent in older buildings, with their typically inconveniently located obstructions as well as irregular footprints and ceiling heights. Squeezing sufficient storage into these areas can be a real test of ingenuity. Even newer warehouses can come with obstructions – a cold store, for example, may have fans at the top of a wall where the company may want to put racking.

Faced with the challenge of fitting a required number of locations in a given volume, while also successfully negotiating obstacles, needs careful calculations to devise the right combination of beams and uprights. It may entail profiling the ceiling areas above top level bays to plot where full or half pallet positions will fit. Sometimes the maths refuses to add up as desired – and that’s when innovation is required.

The performance of racking and shelving in any storage and order picking application will very much depend upon the quality of the components and their manufacture. However, the performance of the solution will depend on the experience and the expertise of the supplier to produce a bespoke system that will overcome any compromises and ultimately lead to an improvement in productivity and operational costs.

Holistics storage system

Pallet racking may be at the core of a project, yet having the capability to engineer solutions for other key aspects such as shelving, picking carts and packing tables will allow a more holistic system. On one occasion, supplying bespoke racking led to BITO also designing special order picking carts equipped with detachable steps. The pallet racking was configured with a single pallet bay level, with shelving above to provide locations for unpalletised ‘returned to stock’ items. Operatives pick orders into the carts and the steps allow staff to reach the shelves above the pallet bay. The carts can be picked up and moved by an AGV (Automated Guided Vehicle) as if it were a pallet.

Ecommerce operations often require a large number of pick spaces to hold a broad range of SKUs. The perennial challenge is fitting all the locations in the limited amount of space that can be allocated to storage.  One novel solution devised by BITO was a shelving system that would work in a similar way to a sliding wardrobe. Using boltless shelving formed the basis of the ‘Smart Slide’ system, which combines fixed shelving at the rear and a slideable shelving system at the front, giving pickers access to the full width of each bay at the rear.

Companies know their business best and often have their own great ideas for solutions to their particular issues – so sometimes it is a case of turning a client’s ideas into reality. Such was the case when a major online retailer wanted a shelving product of certain dimensions, which didn’t actually exist, and wanted dividers to be spaced to suit a robotic picking system. BITO manufactured a bespoke design to suit these specific requirements. The client was able to bring its own staff to test it and adjust it, to make sure it worked exactly as required and that its investment was maximised.

Try it out and get it right

With any bespoke design there will not, of course, be previous examples to refer to. It is important therefore to test out such a solution and fine-tune it to gain confidence in the end result. It is particularly beneficial to test carton and pallet live systems to see how they work, paying particular attention to ergonomics that allow the best system for staff to use throughout their shift. A client can bring their own items and containers to try out in a test facility or a sample system can be set up in a client’s own warehouse. This allows time to be spent, for example, finding the right height for flow lanes and to select the right container to match its products. Having the opportunity to look at other products will further contribute to zeroing in on the most successful outcome. For instance, this may come through trying out a variety of containers to examine the pick efficiency and bay configurations required to get the optimum quantity needed on the given footprint. Testing will ultimately lead to a layout that saves an incredible amount of picking time.

A supplier that can contribute expertise and experience to the solution and offers a complete range of storage equipment, which can be seen in a showroom and tried out in a test facility, will help to contribute to a seamlessly integrated system. It also helps to have a single point of contact from the design and manufacture through to the installation and support. The passion and involvement at design stage should be continued through to project planning and then execution to deliver a truly successful storage and order picking project.

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