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Reassessing storage due to exceptional growth

11 January 2016

Exceptional sales growth and recent contract award from a leading home furniture retailer has seen the RGE Group need to increase its storage capacity. A pallet live racking solution from SEC Storage has enabled RGE Group to re-assess its logistics operation, bringing efficiencies and cost savings.

The contract award for the production of household storage boxes has seen the RGE Group invest heavily in its Whittlesey factory, including dedicated production lines and warehouse for the storage of the finished products. Due to the cost effective, lean manufacturing process, RGE had the desire to not only maximise its production and storage capacity in the new warehouse, but operational efficiencies in order to maintain its high level of customer satisfaction.

An initial appraisal from SEC Storage found that the non-perishable, low SKU profile of the plastic containers would be suited to a dense storage system. Understanding RGE Group’s production process meant that SEC Storage knew the storage system would have to work seamlessly with the despatch process and as a result, a pallet live racking system was specified.

The final solution is a pallet racking system configured on a First In First Out basis with the ability to store over 300 EUR pallets. The system, by its nature, provides the highest storage density in the new warehouse and delivers pallets to the despatch area. Further product analysis enabled SEC Storage to develop a unified bay size to accommodate the two different pallet sizes further maximising capacity and operational flexibility.

A challenge of the installation was to maximise capacity and as a result the system is over 24 metres deep, a length not common in pallet live installations. Each pallet racking bay stands at over 6 metres high and the 4 degrees slope delivers pallets to despatch on zinc coated rollers complete with speed controllers and a safety separator at the end of the run.

Installed as Phase One to meet initial storage needs of 300 pallets, the warehouse has the ability to accommodate over 2,100 pallets across 114 lanes of pallet live storage, allowing RGE to meet their future growth and capacity needs.

“This was the first stage of our desire to automate our production and storage process” says Neil Simons, logistics manager. “It is our intention to complete the pallet live installation and couple this with a cross facility conveyor system from production to the warehouse, which will increase our operational efficiencies in Whittlesey. We anticipate the pallet live system will be fed by the conveyor delivering pallets direct from the production facility.

“SEC Storage worked closely with us and helped to conceptualise a solution which means the new Whittlesey warehouse can facilitate our growth and form the foundations of our automation plans, ultimately helping us to deliver efficiencies for our customers”