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 - MMH Editorial

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

Early indications suggest 2014 on track to avoid second-half softening.

Report highlights executives' focus on direct store delivery processes.

Supply chain visibility is the Holy Grail for warehouses and distribution centers where the fast and efficient movement of goods is the solution to satisfying customer demand. This is especially true for the 68% of companies which are not satisfied with material movement efficiency from source to destination. These companies are seeking new ways to get the right goods to the right place at the right time. They are finding that change, complexity, compliance, competition, and connectivity are leading to further confusion.

Instead of ignoring a forklift fleet and its associated costs, asking the right questions can lead to substantial savings.

This white paper outlines five ways to increase profits with automation. By implementing automated storage and retrieval equipment-such as horizontal carousels, vertical carousels and vertical lift modules, multiple areas of a manufacturing or distribution facility will benefit from savings in inventory accessibility, floor space, time, improved ergonomics and better accuracy.

Comments

Post a comment
Commenting is not available in this channel entry.


© Copyright 2013 Peerless Media LLC, a division of EH Publishing, Inc • 111 Speen Street, Ste 200, Framingham, MA 01701 USA