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New storage concept bids to maximise pallet density

10 December 2015

Flexi Warehouse Systems – the projects and systems division of Narrow Aisle – has introduced the Flexi StorMAX space saving storage concept.

Based around established double deep pallet racking, Flexi VNA truck and warehouse management systems technology, StorMAX allows 50% more pallet locations to be achieved when designing a storage system in a warehouse with the same dimensions as a system served by conventional reach trucks, claims the company.

Flexi claims StorMAX allows users to handle two pallets from the same side of each very narrow aisle - which effectively doubles the capacity of each run of racking.

The pallets are put-away and retrieved by Flexi StorMAX with hydraulic forks that reach twice as deep within the racking as those on a conventional truck.

The Flexi’s design which, being ‘counterbalanced,’ provides an exceptionally stable lifting base, also features a patented Stability Control System (SCS) which controls costly pallet weight derations when lifting at height.

One of the major drawbacks associated with two deep pallet storage systems in the past has been the poor residual capacity of converted reach type trucks at high lift heights.

Key Points

• Throughput claimed to be better than shuttle-based systems.
• Allows users to handle two pallets from the same side of each very narrow aisle.
• Claims double deep storage issues - ‘zoning’ and ‘honeycombing’ - have been overcome.

Now, the Flexi’s ability to handle standard supply chain loads at top beam level means that the problem of product weight control by location, sometimes known as ‘zoning,’ which has been associated with double-deep storage systems in the past has been overcome.

The StorMAX uses WMS software that can track and locate every pallet of product in a modern warehouse, but the software has been adapted to ensure that ‘honeycombing’ is also eliminated.

‘Honeycombing’ is the effect on the storage cube when the back pallet locations towards the top of the storage system are under-utilised because of problems encountered by the materials handling equipment – usually reach trucks – when products are put away into the rack storage system in the wrong order, ie, not obeying important date (first-in, first-out) data or customer order data before allocating rack locations.

The StoreMAX's WMS ensures that pallets are put away in the order from which they will be picked. In other words, the WMS places incoming pallets that will be kept in storage for a shorter time, in front of products that will normally be in stock longer to allow fast access from the aisle for the faster moving stock units.

To further enhance safety and efficiency when picking at height, the Flexi trucks that operate within the StorMAX system are fitted with a hi-definition operator CCTV system.

Early adopters of StorMAX technology have experienced impressive results. For example, one user – a well-known food manufacturer - is storing 40,000 pallets in a StorMAX system that is served by five Flexi trucks.

The company chose to invest in StorMAX technology in an effort to improve its costs per pallet stored and lower its handling expenses after an automated shuttle-based system in operation at another of its European sites had proved less than efficient. The shuttle’s relatively low pallet throughput - which was due to extended internal pallet transfer speeds and, therefore, long waiting times - meant that up to 50 per cent more reach trucks were required to operate at the installation than originally forecast.