Modular picking solution
January 1st 2011

TGW's PerfectPick promises a high performance retail picking solution based on direct handling of SKUs without additional load carrier

TGW has introduced a fully automated modular picking solution for retail distribution centres. PerfectPick directly handles every SKU throughout the distribution centre.

Products handled in retail distribution centres range from small chewing gum packages to voluminous and heavy detergent multi packs.With many retail distribution centres based on pallet storage and manual picking activities, picking workers often manipulate up to 15 tons daily in rather non-ergonomic operations.

In contrast to competing solutions, TGW handles every SKU directly on its conveyor and storage equipment without an additional load carrier. Therefore the material flow within the distribution centre is much simpler and the solution does not need any handling of empty load carriers.Moreover the system's lean modules, based on standardised components, enable customers to choose among different levels of automation, depending on their individual processes and needs.

PerfectPick is designed to automatically configure and pack complete shop orders on pallets or roller containers. The configuration of the shipping load meets the customer's requirements, by optimising the stacking pattern to the unloading process within the individual shop's layout. The solution is applicable for the entire temperature range within the grocery retail product range, including deep freeze applications.

The process starts with the automated de-palletising of single SKU pallets coming directly from the goods receiving or a pallet warehouse. Layer by layer the de-palletising unit - SPLITEX - separates each package or carton from the pallet and delivers it to the automated conveyor system that feeds the subsequent operations.

TGW's automated mini-load storage and retrieval technology - Twister - handles these singularised SKUs in the warehouse.

Between one and four packages of the same incoming product are stored in one storage channel, depending on their size, while providing access to each individual SKU. To boost the warehouse and process performance the AS/R machines not only pick for one single customer order each but these orders are combined to batches that are delivered to a small but highly dynamic sequence buffer. In the sequence buffer two high speed TGW COMMISSIONER AS/R machines sort the incoming SKU batches into a rack and create the optimum sequence for the palletising process.

The exact product sequence is needed for performing a fully automated palletising process that ensures the stability of the loaded pallets and the right loading pattern reflecting the customers requirements. Each TGW AUTOSTAX palletising unit loads more than eight pallets per hour with an average of 90 packages each. In both palletising options the loaded goods are secured on the pallet or roller container within the process.While lowering the finished pallet to the subsequent conveyor system it is automatically shrink wrapped. Then the pallet is ready for dispatch labelling and delivery to the stores.

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