Subscribe to our free, weekly email newsletter!


Casebook 2011: Retrofitted AS/RS expands capacity 150% for Fage

Provider revisits older model to increase storage density in same footprint.
By Josh Bond, Associate Editor
January 07, 2011

Based in Athens, Greece, Fage produces a popular yogurt. After much success in Europe, the company expanded into the U.S. market and the additional growth necessitated an expansion into a new building for both the manufacturing and storage capacity.

Back in early 2008, Fage USA opened a new manufacturing plant and distribution center with a single-aisle automated storage and retrieval system (AS/RS; Westfalia Technologies, 800-673-2522, http://www.westfaliausa.com)) designed to store 1,600 refrigerated pallets. The rapidly growing company soon realized the need for additional storage and expanded its high-density storage system to accommodate 4,100 pallet positions—a 150% growth.

The new storage/retrieval machine (SRM) handles both the existing and expanded distribution center with an extended aisle. The 150% growth was made possible by extending the crane aisle for more storage lanes and increasing the depth of those storage lanes.

New rack entry vehicles are capable of storing pallets up to 12 deep in a single lane, which allows for the company’s expansion without the need for an additional SRM. Without this capability, the company would have needed a building 25% larger to accommodate the additional storage.

At only 33 feet high, the facility’s height is typical of conventional warehouses, but with the high-density AS/RS technology, its dense four-level cubic storage requires a smaller building footprint, thereby having less impact on the environment around the facility.

Designing for growth was only one of the company’s objectives. Others included buffering the product from manufacturing, full pallet movement, case picking, and buffered pre-picked material back into the AS/RS for future truck loading. The system handles individual orders, distribution center orders, and combinations of both, in advance and just in time.

 

About the Author

image
Josh Bond
Associate Editor

Josh Bond is an associate editor to Modern. Josh was formerly Modern’s lift truck columnist and contributing editor, has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce.


Subscribe to Modern Materials Handling magazine

Subscribe today. It's FREE!
Find out what the world’s most innovative companies are doing to improve productivity in their plants and distribution centers.
Start your FREE subscription today!

Recent Entries

Transportation & Logistics companies are winning customers and improving profitability by taking a fresh look at their operations. Don't miss this brand new ebook from Barcoding, Inc. and Honeywell, "Automating Transportation and Logistics: How automation and assessment programs are helping T&L companies cut costs, increase cash, and improve customer experience."

After 53 years in Jonesboro, Ark., the company will add new manufacturing capabilities and 75 permanent jobs.

Loscam, Asia Pacific’s leading pallet pooling service provider, recently opened a new depot in Kota Kinabalu, capital city of the state of Sabah Malaysia, further extending its services to East Malaysia.

The PMI, the ISM’s index to measure growth inched up 0.7 percent to 53.5 over May’s 52.8 (a PMI of 50 or greater represents growth). This reading marks sequential growth for the third month in a row.

More than 30 leading suppliers of reusable products and services will be available in the Reusable Packaging Pavilion. The exhibitors include manufacturers, material suppliers, providers of washing and other specialty equipment, and service providers of reusable packaging systems and solutions.



© Copyright 2015 Peerless Media LLC, a division of EH Publishing, Inc • 111 Speen Street, Ste 200, Framingham, MA 01701 USA