For the longest time, Ocean Spray floor-stacked pallets of its juice products. And even though corrugated was used extensively to protect pallet loads from damage, that didn't solve the problem. Quite simply, the damage was caused just by the weight of the pallet loads on each other, and the difficulty of moving the loads with lift trucks.

When the company found a new packaging technique that could save it millions, the days of floor stacking were over. Instead, Ocean Spray installed high-density push-back racks. In addition to eliminating load damage from stacking, the new racks delivered several other advantages.

To begin, they increased storage capacity in the warehouse. The racks allow the facility to store more than one third more product, eliminating the need for expansion or leasing of additional space. Furthermore, the boltless racks are flexible and offer immediate access to every load stored.

Other advantages include greater flexibility to access specific loads in the warehouse. This provides a new found ability to select loads with specific manufacturing lot numbers for whatever reason.

By contracting analysis, engineering, planning, design and layout through a single project management company, Ocean Spray began installation of its new systems within three months. It had projected taking six to nine months to start installation.