INCORPORATING COLD CHAIN
PROJECT
Barpro introduces SA to high-density multitier case picking mezzanines at Eskort
Robert Kershaw , Barpro sales and marketing manager : Johannesburg , says that one of the biggest challenges in managing and running a modern-day cold store facility like Eskort is how to pick individual cases as opposed to full pallets . “ Now case picking from multitiered mezzanines strategically placed inside cold and freezer stores has great potential in maximising volume utilisation .”
Barpro ' s involvement stemmed from an existing partnership with Eskort pig abattoir , having previously installed their freezer infrastructure . “ The primary challenge lay in the augmentation of storage facilities to accommodate the increased throughput . Initially equipped with mobile racking capable of holding 800 to 900 pallets , the existing freezer was no longer sufficient to meet the heightened demand . Eskort also possessed a chiller with similar pallet requirements , albeit with a different racking system in place ,” says Kershaw .
Barpro is on a drive to promote mezzanine structures – and Eskort proved the ideal ice-breaker for South Africa . This is because case picking constituted approximately 70 % of pallets — and the team were able to devise a solution tailored to enhance efficiency in this aspect . The introduction of a multitier mezzanine concept facilitated box picking , optimising the retrieval process within the facility . “ The upgrade encompassed the installation of approximately 1 500 pallet positions on mobile racking in both the freezer and chiller , ensuring high density while granting access to each pallet location . By transitioning from static to mobile racking systems , Eskort not only augmented its storage capacity but also streamlined retrieval processes , thereby enhancing overall operational agility ,” says Kershaw .
The transition from conventional static racking to mobile configurations marked an important shift in Eskort ' s operational landscape and played a crucial role in augmenting storage capacity .
“ One of the primary hurdles faced by Eskort was the inefficiency of the existing pushback system in accommodating certain packaging configurations . Recognising this bottleneck , Barpro proposed the implementation of multitier mezzanines in the chiller area . This innovative approach optimised storage capacity and also facilitated easier access to products , thereby streamlining the picking process .
“ By introducing mobile racking systems , Eskort was able to maximise space utilisation while ensuring easy access to products . This strategic enhancement not only addressed immediate capacity needs
but also laid the groundwork for future scalability ,” says Kershaw .
“ With a comprehensive analysis of SKU requirements and operational workflows , Barpro devised solutions that optimised picking efficiency while minimising time and resource wastage . The introduction of multitier mezzanines in both the chiller and freezer areas considerably enhanced the picking process , enabling operators to access a wide range of SKUs with ease .”
However , the journey towards operational excellence was not without its challenges . The transition to multitier mezzanines represented a paradigm shift from traditional methods , necessitating a change in mindset and operational practices . The process began with an initial trip overseas , where the CEO of Eskort and key executives visited Reed Bordeaux in the UK . Witnessing firsthand the implementation and efficacy of multitier systems at Reed Bordeaux , Eskort ' s leadership was immediately convinced of its potential to improve their own operations , notwithstanding a higher initial capex .
While the initial focus was on the implementation of mezzanines , Eskort ' s journey towards operational excellence didn ' t stop there . Recognising the importance of safety and efficiency , Eskort embraced a holistic approach to its operational redesign . The adoption of mobile storage systems , coupled with multitier mezzanines , both optimised storage capacity and ensured a safer working environment by segregating pickers and material handling equipment .
“ The dispatch area witnessed a significant enhancement with the integration of a gravity feed roller system supplied by Barpro .”
Kershaw explains the space saving characteristics as being that mezzanines are located at the side or corner of a cold room . Only one fixed aisle is required for a reach truck to feed it . Reducing the number of aisles required increases income generating storage capacity . CLA
The transition to multitier mezzanines represented a paradigm shift from traditional methods , necessitating a change in mindset and operational practices .
COLD LINK AFRICA • July / August 2024 www . coldlinkafrica . co . za 25