Twice as many pallets

The double deep racking configuration allows one pallet to be placed behind another. Twice as many pallets are stored for a given number of aisles with similar space utilization to Narrow Aisle. At Kellogg's, the twenty-four double entry and two single entry racking runs stretch to nearly 120 metres in length. The warehouse stores full pallets, which either replenish a forward picking area or are despatched as complete units. Throughout the scheme, storage is on four levels, with the top beam at 10.8 metres. Sacrificial legs are fitted throughout and an automatic sprinkler system is built into the racking.

Picking bays

An interesting feature of this installation is the layout of the picking bays. The ground level bays are fitted with horizontally mounted push back rails. Two pallets sit one behind the other. The rear pallet is pushed back when the front pallet is in position. The bays house case picked products. When the front pallet is removed the operator pulls on a pulley rope and the rear pallet glides forward to the front of the bay. "This give us significant safety and ergonomic benefits." Adds Mark.

Push back

The second level pick face consists of inclined push back bays for products shipped by the pallet. The rear pallet sits on a trolley mounted at a small gradient. It rolls gently forward, when the forklift truck has lifted the front pallet out. Three bays have been left empty to house a computer terminal, printer and scanning equipment. Once an order is complete, the operator comes to the closest printer station to create a despatch label for the load.

Mezzanine floor

A mezzanine floor, measuring 570 square metres, provides additional floor space for an inspection and re-work area. Any pallets requiring inspection can be lifted directly onto the Redifloor mezzanine. Counter balanced pallet gates are located at each end of the floor, providing access for pallet movements and a safe barrier for anybody working in the area.

Redirack performed extremely well

"Redirack performed extremely well." Mark concludes. "On a project of this scale, flexibility and cooperation are key ingredients. They were able to adapt their installation schedule to accommodate changes to the overall build programme and liaise closely with other suppliers to ensure that deadlines were achieved."

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