Workwear Specialist Chooses Daifuku Miniload System

Portwest, a fast-growing online workwear company, has appointed global materials handling specialist Daifuku to design and install an automated storage system (AS/RS) at its distribution centre in Barnsley UK.

Due to go live by summer 2024, the warehouse automation system is expected to more than double handling capacity, thereby enabling Portwest to meet anticipated demand for its products, which include high viz jackets, PPE kit and safety gloves.

Based on proven technology adopted by brands such as Coca-Cola, Nike, Netto, UNIQLO and Honda, Daifuku’s planned AS/RS solution will facilitate the fulfilment of full carton orders and also replenish the linked goods-to-person system, which is also being introduced at the Barnsley location.

Currently in development, the AS/RS system comprises four high bay aisles serviced by four automated twin-fork mini-load cranes. High density racking will create more than 76,000 unique locations within the upgraded facility, significantly improving the efficiency of the 15,000 sqm warehouse.

Harry Hughes, CEO of Portwest explained why they selected Daifuku as their automation partner: “The introduction of this mini-load system is a major step forward for our UK operation, which is faced with a huge opportunity to increase sales throughput without moving to new warehouse premises. This will be achieved by embracing tried and tested automation technology, which will further improve service levels, enabling us to support our online customers in even more ways.”

Russell Hutchinson, UK sales manager at Daifuku, added: “This is a key project for us as it demonstrates our ongoing commitment to the e-commerce sector in the UK and its adoption of leading-edge automation to remain competitive.

“We are also pleased to have secured this project despite tough competition from other warehouse automation suppliers. We pride ourselves on the highest quality machinery and technology, which is matched by our open, honest and transparent approach to our customers.”

Portwest employs approximately 5,500 people across 130 countries. Headquartered in Ireland, the company was established in 1904 and remains a family-owned business which is currently managed by the third generation of the Hughes family. A global company, Portwest has already introduced Daifuku automation technology into one of its warehouse operations in Spain.

Software to Manage Delivery of All Goods

Workwear Uniform Group Ltd (WWUGL) recently awarded Dematic an extensive goods-to-person automation project that features the largest AutoStore system in the UK that Dematic has provided to date, for the delivery of all goods.

Sam Sohal, WWUGL CEO, says, “We selected Dematic because they listened to what we were looking to achieve and, as a specialist in their field, gave us a solution that has the potential to surpass in performance our initial expectations and future proof our business with a Warehouse Management System (WMS) to fully manage our logistics.”

In 2021 Direct Corporate Clothing acquired InCorporateWear to form WWUGL, the largest independent workwear, uniform and personal protective equipment business in the UK. Previously, the two businesses occupied three logistics sites totalling 180,000 square feet of space. As WWUGL, the company began searching for a new location where they could relocate and convert into a super hub and consolidate space.

However, after exploring numerous options, the Birmingham-based company decided on a solution that would allow them to utilise an existing 76,000-square-foot facility. WWUGL was in touch with several leading automation companies before deciding to select Dematic to install a solution that featured an AutoStore system. Dematic Software will manage all the storage, transport, and picking processes within the entire facility.

A phased commissioning has been planned for the AutoStore system, and the first phase is scheduled to be completed by February 2024. It covers a 4,500-square-metre space (nearly 48,000 square feet) and consists of a 40 x 95 metre grid that can store 129,654 bins using 60 R5 robots, nine picking stations, and three inbound ports. The project’s second phase, which includes software functionality and connecting conveyor, is set to be completed in the second quarter of 2024.

According to Sohal, the project benefits to his company go well beyond creating and consolidating WWUGL’s three locations. “Not only does the solution help us as market leaders by providing our customers with the best possible delivery of goods, but it also allows us to get the maximum use of space and still have room to double our business with a new system that is more efficient and accurate in our overall stock management.

“In addition, it will reduce our CO2 footprint and energy consumption to help meet our goal of being carbon neutral by 2025. We are seeing a trend in the UK where customers are steadily wanting more than just the right solution; it is now critical for them to find the right company to partner with for the long-term,” explains Neal Rowe, sales project manager at Dematic.

“Initially, our discussions were around the AutoStore system, but as WWUGL began to see that Dematic could provide technology beyond the initial project scope, they asked us to design an even larger solution where our software is expected to run most of the processes within the four walls of their facility.”

Rowe says Dematic committed a dedicated team to meet customer expectations for the entire AutoStore portfolio, which provides smaller and mid-sized companies with access to the first steps to logistics automation. “After going live, Dematic customers can rely on continuous support for the entire lifecycle of the solution.”

Adds Simon Barnwell, vice president and market leader for UK and Ireland at Dematic, “Dematic recently reached a global milestone with its 100th commissioning of an AutoStore system. I believe it has brought substantial benefits to our customers by boosting productivity, realising faster ROI’s and providing agile project delivery without interruption. Dematic brings a depth of expertise in this technology, which, I think, is matchless in our industry.”

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