INCORPORATING COLD CHAIN
ASSOCIATIONS
Sheldon Uys , general manager of SSI Schaefer .
The client ' s vision extended beyond automation to provide a one-stop solution , offering end-to-end services across the country . Emphasising the need for infrastructure and integration , the case study underscored the significance of a unified Warehouse Management System ( WMS ) that seamlessly operates from pickup to distribution .
The project was a pioneering initiative in establishing one of the largest national organised cold chain plants in the Philippines and the country ’ s first smart warehouse . Automation and technology played a pivotal role in achieving this , ensuring the efficient management of the cold chain and positioning the Philippines as a leader in the field . The facility ’ s frozen storage has a capacity of nearly 20 000 pallet locations and covers approximately one hectare in footprint .
Operating in a seismic zone and experiencing close to 20 typhoons each year in the Philippines , the ORCA 45m-high facility was built with a rack clad designed to prevent destruction from wind or seismic activities .
Future developments may potentially include the incorporation of electric vehicles , aligning with the global push towards sustainability . Underscoring the significance of exploring cost-effective
options is the example of ESB , a company outside Africa , which has already embraced electric vehicles to enhance sustainability .
LONGEVITY AND ROI : A 15 – 20 YEAR VISION
ROI is a common concern in automated solutions , and this project ' s Return on Investment ( ROI ) was estimated to be achieved within three to five years . However , what sets this apart is its longevity , with expectations that the infrastructure and technology implemented would endure for 15 to 20 years . This long-term perspective aligns with the commitment to sustainability and future-proofing the cold chain operation .
The project ' s objective was to provide superior customer service , optimising costs and enhancing efficiency through automation . The key focus was on reducing human intervention in cold rooms , minimising errors caused by
fatigue , and ultimately saving costs while ensuring the integrity of stored goods .
The team invested significant effort in material flow optimisation . Simulations and analyses were conducted to determine the most efficient material for constructing the facility , taking into account freezing water requirements and the overall demand and grid considerations .
The facility incorporated three different temperature zones :
• -18 ° C .
• 20 ° C and -25 ° C to prevent the formation of moisture and guaranteeing the freshness of the food products .
• Ambient temperatures each with zero to minimal human intervention .
This strategic temperature zoning is vital to preserve various products adequately to prevent degradation and energy loss .
The transferring area is kept at a controlled temperature of -18 ° C , from manual processing to a fully automated process , the pallets are transported via a 282m-long conveying system with weighted sensors and profile checks . Moving at a steady speed of 0.3m / sec , the pallets are automatically assigned to the respective zones without the use of pallet trucks and vehicles . With zero human intervention , it minimises error and prevents contamination .
AUTOMATED STORAGE AND RETRIEVAL SYSTEM ( ASRS ): A TECHNOLOGICAL MARVEL
The ORCA facility has four SSI Exyz automated storage retrieval machines that run vertically on tracks , operating simultaneously to provide seamless access to the stored pallets unhindered by the sub-zero temperatures . The ASRS operates with precision , optimising space utilisation and ensuring efficient retrieval and storage processes .
The facility leverages QR code technology for inventory management . Automated scanners read QR codes , feeding data into the system for automatic checking and verification . It is run from the interconnectivity station , a hub where fixed personnel monitor and manage the flow of goods , creating an efficient and interconnected system .
The ASRS system was designed with flexibility in mind , accommodating both new constructions and extensions to existing systems . This adaptability allows for the implementation of automated solutions in various settings , supporting buildings of different heights and enabling modular growth .
This case study reinforces why businesses need to embrace automation strategically . Schaefer ' s success in the Philippines serves as a blueprint for other companies seeking to optimise their cold chain logistics . By adopting a phased approach , understanding unique business needs and fostering collaboration ,
organisations can pave the way for a more efficient and sustainable future in cold storage automation .
CLA
COLD LINK AFRICA • June 2024 www . coldlinkafrica . co . za 7