Collaboration Creates Efficient Storage Picking Solution

The client, Next plc had a requirement for a manual storage solution for boxes that enabled them to locate, store, empty and fill the racking in the most ergonomic, efficient and effective way possible.

Space for this project was allocated on an existing level of an Avanta mezzanine floor with an existing conveyor layout and column grid to integrate into the designed solution.

Working closely with the client, Next tasked AVANTA with supplying a FILO (First In Last Out) flow racking system (Also known as carton live storage)that could store up to 12,000 BDC1 Boxes. In the early design stages, the client supplied AVANTA with the size of the boxes and the details of our conveyor layouts in order for a proposal to be put together.

Avanta engaged with 2x prominent manufacturing partners on this project:

AR Racking – A leading European manufacturer of racking systems.

Interroll Group – A world leading provider of material handling solutions and in this instance – Roller beds.

Avanta UK designed, supplied and installed 151 bays of carton live storage with 3x levels giving 453 roller beds measuring circa 2700mm length x 2500mm depth.

The client commented:

“The solution supplied does exactly what we need, we are now able to use the flow racks to load and unload boxes with ease, the roller system allows us to stand in one spot and load boxes without overreaching or twisting and allows us to be close up to the conveyor system as we do it, saving time and keeping our operators safe.

The installation of the flow racks could not have been better, the modular style of the racking system allowed the installers to put them together quickly and allowed them to create a production line of installation. All nuances to the install were consulted with by ourselves, such as column clashes, walkway gaps and flow rack heights, this ensured speed and certainty of correct installation.”

Avanta commented:

“Next plc and Avanta UK collaborated effectively yet again to create a highly efficient and ergonomic storage solution. The use of a FILO flow racking system, along with the integration of AR Racking and Interroll Group’s roller beds, seems to have met all their needs perfectly.

The modular design and the attention to detail during the project, such as addressing column clashes and walkway gaps, contributed to the project’s success. It’s great to hear the feedback from Next that the system allows operators to work safely and efficiently.”

Carton Live Storage Systems – The Detail

For stock that needs to be hand picked and loaded, carton live storage is the ideal warehouse storage and picking system.

Carton Live Storage includes inclined trays of roller tracks, set at levels within storage bays, to allow goods to roll under gravity down dedicated lanes within the trays, from the loading to the picking face.

Order picking times are reduced and errors minimised, as not only are items presented precisely at the picking face, but also effective management of the throughput and stock levels of goods can be easily maintained.

To read more about Carton Live Storage, please click the link