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Case Studies
 Featured Case StudyMCG Paardeneiland completes their warehouse upgrade In 2007, The Metal Closures group, situated in Carlisle Street, Paarden Eiland, found that their finished goods warehouse could not hold sufficient stock. The warehouse was 9 metres to the rafters and had fixed racking for 569 pallets. Production capacity also needed to be increased, and the warehouse was the only area available for expansion. The problem of increasing storage capacity while at the same time reducing the storage volume was given to site engineer Andrew Cousins and logistics manager Alfie Danster. Their solution was to raise the roof on one portion of the building and create a storage area. A mezzanine floor was installed over part of the existing warehouse and the ground floor was used to accommodate the new machinery. Storax Mobile Racking, supplied by local company Barpro Storage, was installed in the remainder of the warehouse volume. The storage capacity of the mobiles is 855 pallets compared to the 569 pallets that could be stored previously. This represents a 50% increase in a warehouse where the volume had been reduced by just under 40%. Capacity could have been further increased if the roof of the existing warehouse had been raised. However, it was agreed that this additional capacity was not required. Raising the roof was not a simple matter, and the poor winter weather didn't help. Keeping the storage and production processes operating while the building work was taking place required a huge amount of patience and management skill. The project was completed in February 2008 and warehouse foreman Ivan Fredericks is delighted with the results. "I am over the moon with the mobile racking ", he says. "It is easy to use, I have sufficient additional capacity and can access any pallet quickly by moving the mobiles." "Stock control has greatly improved," he continues. "I have labelled the pallet slots and all stock must be put away as nothing can be left in the open aisle." I have also been able to consolidate all my stock in one place." Previously I was using 3 offsite warehouses". More Case Studies Client had a space constraint in his normal ambient warehousing and only limited additional space. A warehouse was erected to take 5 pallets in the height but it had a cable servitude running beneath a portion of the floor. The Storax mobiles were designed so that the weight bearing rails did not encroach on the servitude. In order to increase capacity, cantilever racking was installed over the servitude itself.
Maximum capacity was required in the new cold store. By increasing the width of the cold store by 300mms an extra 100 pallet positions were created at minimal additional cost.
Client needed to pick the pallets up on the 1200mms side with the pallet going 1000mms into the mobile rack. At three pallets per bay, the bay pitch was approximately 4000mms meaning that the normal 155mm deep load beams could not carry the weight. A heaver box beam was designed and tested for use in this application. The bay pitch could have been reduced to carry two pallets per bay, but this would have been a relatively expensive solution in this particular instance.
From a fire safety aspect, there had to be sufficient escape routes from the cold store. To achieve this, a rear cantilever was used which minimised the storage capacity lost. This client needed to store 280litre drums on pallets. While a 1200mm by 1000mm pallet can hold 3 drums it is more cost effective to use a 1200 by 1200mm pallet which can store 4 drums. This system was designed to store two 1200 x 1200mm pallets per pair of beams allowing 7 pallet levels in the height.
This store was originally designed for 4 mobile bases each 6 bays long. However, to begin with only 2 mobiles were installed each 5 bays long. An additional rail was laid in the floor and sufficient cabling inserted in the 2 bases to allow for future extension in the cold.
I&J had five cold store warehouses in the Cape Town area. Management decided to install Storax Mobile Racking in the biggest, Auckland cold store, and were then able to close two of the others. One was sold, while the second, situated next to I&J's Woodstock factory, was converted into production space. Subsequently a third store, situated in Diep River, was also closed. While other factors played a role in this rationalization, it could not have been achieved without the use of Storax mobiles. The capacity at Auckland cold store was almost doubled while at the same time each pallet position was made immediately accessible. Consolidating I&J's warehousing function onto one site provided major savings in electricity, inter-store transport, personnel and other running costs, not to mention the possibility of using some of the surplus space for productive activities. |
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