Like any good warehouse equipment, a pallet rack system must accommodate growth. Unfortunately for Boar's Head Provisions, provider of deli meats and cheeses, theirs fell short. Replacing it with a new pick module and flow storage system helped create more pallet positions and increase productivity.

Their 50,000-square-foot DC in Holland, Mich., handles 186 SKUs and services 370 distributors on a next-day delivery basis. But soon after opening, it had growing pains.

“We grew faster than the warehouse—five years of growth in just over a year,” says DC manager Dan Crook.

The storage rack system and the employees were overwhelmed. People were constantly looking for product and working around double- and triple-stacked pallets, which led to $2,000 a week in overtime. Plus, pallets were sticking and wheels were falling off.

Boar's Head ordered a 17-bay-long pick module flow storage system. It has a well-constructed rack with an excellent roller and brake system. The new system has added 260 new pallet positions.

On the floor, through the center of the system, is a lit tunnel from which orders are picked. Overhead is the flow storage, which is two levels high by five pallets deep. As product is depleted on the floor, it's replenished by lift truck from the upper levels.

The system meets rugged specs. The verticals are double-column structural steel channels. All components are galvanized, creating an impervious corrosion-resistant surface necessary to meet sanitary requirements.

“Corporate can't believe the numbers we're putting out of this little place,” boasts Crook. “They're looking at expanding our New York and Virginia plants into the same pick module style.”

Steel King 800-826-0203 www.steelking.com