INCORPORATING COLD CHAIN
FEATURE
Safety remains a key priority : " Automated systems improve workplace safety by reducing accidents and injuries . This enhancement not only protects personnel but also safeguards assets and equipment within the warehouse environment .”
RACKING AND SHELVING SOLUTIONS FOR REFRIGERATED WAREHOUSES
James Cunningham , managing director of Barpro Storage SA , emphasises that the type of racking selected hinges on the warehouse environment — whether it ’ s a freezer , chiller , or ambient space . Freezers and chillers involve significant construction costs and specific operational needs . " Considerations like fire regulations and the feasibility of in-rack sprinklers are vital ," he notes . The characteristics of the products being stored also play a crucial role . Questions such as the number of stock keeping units ( SKUs ), the necessity for strict stock rotation , whether products are palletised , and the need for case picking before dispatch must all be addressed . Cunningham recalls his experiences as a cold store manager , where he had to organise containers of frozen fish in reverse order of manufacture — oldest stock nearest to the doors — an arduous task without specialised racking like mobile systems .
In ambient warehouses , fixed selective racking , or APR , is typically preferred , while freezers often necessitate more complex solutions , combining mobile systems with mezzanine picking floors to maximise space and maintain product temperatures .
Cunningham warns that decisions regarding racking should not be an afterthought during warehouse construction . He has witnessed scenarios where a mere increase in ceiling height by 500mm could enhance storage capacity by 20 %. " Storage capacity and related requirements should dictate warehouse design ," he advises .
RETROFITTING RACKING SYSTEMS
Some racking systems are more amenable to retrofitting than others . Cunningham notes that while mobile racking can be retrofitted successfully , it usually requires replacing the existing floor or installing rails . Depending on the scale , retrofitting can take as little as five weeks .
He typically advises clients to keep spare parts on-site to mitigate long lead times , which can arise due to low volume orders . While Barpro assists with maintenance and spare parts , Cunningham cautions against clients attempting repairs themselves . " Many clients underestimate the importance of maintenance . There is a general lack of education regarding racking safety among warehouse staff ," he states . To address this , Barpro conducts training courses to raise awareness of racking safety .
Damage to racking , especially in freezers , can go unnoticed for extended periods , potentially leading to severe accidents . " Currently , the understanding of racking maintenance is inadequate . Barpro is committed to promoting safety inspections ," he explains . A SEMAapproved racking inspector is available to assist customers with racking assessments .
© Cold Link Africa
James Cunningham , managing director of Barpro Storage SA , speaking at the 2024 Cold Chain Refrigeration , Logistics and Technology Summit earlier this year .
" In South Africa , it ’ s estimated that 80 to 90 % of warehouses neglect regular inspections and lack the knowledge to identify problems ," he says .
As storage demands increase , the heights of cold storage facilities have risen , making rack safety even more critical . Cunningham highlights the risks associated with pallet construction , noting that flimsy designs can pose significant dangers , especially when stored at greater heights . The trend toward smaller pallets to optimise container space can compromise safety , as they may not fit securely in traditional racking systems .
Automated storage systems , initially popularised in labour-scarce regions like Japan , have since spread to various parts of the world , although their high costs and specialised maintenance requirements can be barriers . " In South Africa , the trend towards full automation has slowed , but semi-automated solutions like mobile racking provide a balance ," he explains .
Selecting the appropriate racking system depends largely on the scale of operations . A warehouse with a modest height may not benefit from mobile racking , while taller facilities with greater storage needs might find it invaluable . Cunningham recounts instances where mobile systems have effectively doubled storage capacity .
Reflecting on advancements in the industry , he recalls how initial racking installations significantly boosted productivity in the past . Today , replacing fixed racking with mobile systems can similarly enhance capacity . The financial return on investment for mobile racking varies based on specific circumstances ; for instance , a poultry company discovered they could achieve the same storage increase with a retrofit rather than constructing a new facility .
Cunningham advises clients planning cold storage facilities to incorporate mobile rails during initial construction , even if static racking is installed initially . Retrofitting rails later poses considerable challenges as storage needs evolve .
VERTICAL LIFTING INSTALLATION
The first South African Gonvarri Tornado 9th generation Vertical Lifting Module ( VLM ) was recently designed and installed at ACDC Dynamics ’ ( ACDC ) Edenvale , Gauteng , warehouse from Logistics Systems Engineering ( LSE ). It is an ultra-fast , virtually
Image supplied by LSE Image supplied by Acrow noiseless , computer-controlled storage and transfer lift . Using minimal floor space , this innovative storage system automatically optimises loaded goods on trays , substantially increasing picking rates while offering security on high-risk items .
“ Only once it was installed and operational did we realise the machine ’ s speed and versatility , a definitive advantage compared to conventional VLMs , enabling us to serve our customers better . The capacity from LSE ’ s VLM allows us to increase productivity in storing and picking ,” says ACDC CEO , Mario Maio . The Tornado VLM , which is 12.1m high , carries the same quantity as four competitor VLMs currently in our warehouse – and is close to three times faster . The technology and features incorporated into the Gonvarri Tornado VLM are beyond any other solution we have experienced or reviewed ,” he adds . CLA
As storage demands increase , the heights of cold storage facilities have risen , making rack safety even more critical .
Image supplied by LSE
LSE ’ s VLM has the functionality of six personnel and saves up to 87 % of the space required for conventional racking and shelving .
The official VLM handover from LSE to ACDC . From left : Pierre Fourie ( Solutions Engineer , LSE ), Fred Albrecht ( CEO , LSE ), Mario Maio ( CEO , ACDC ), Quinton van der Westhuizen ( Installation Manager , LSE ), and Frederick Albrecht ( Commercial Executive , LSE ).
Another example of Acrow racking installaiton .
COLD LINK AFRICA • November / December 2024 www . coldlinkafrica . co . za 21