W alk into any bar across America and there ’ s bound to be a bottle or two of bourbon , rye or vodka produced by Buffalo Trace Distillery . Today , Buffalo Trace Distillery is a fully operational distillery , as well as a National Historic Landmark . However , when it came to the distribution of its fine whiskies , Buffalo Trace Distillery found that its historic buildings were simply not built to handle modern materials handling processes .
CHALLENGE
Buffalo Trace Distillery was using approximately 240,000 square feet of conventional warehouse storage , which mostly consisted of bulk storage with limited pallet racking . This included 50,000 square feet of off-site contractor space , and seven floors of space for bourbon barrel storage aging . The distribution center was replenished from seven on-site locations and an off-site contractor location . Yet , the replenishment process included more than nine movements of the same pallet from the production line to loading the customer outbound trailer . Pallet movement was by trailer and often consisted of moving pallets from second floor storage via floor openings to the loading dock . This was not efficient in terms of time , cost and risk associated with inventory damage during movement .
In need of improving its storage capacity and streamlining its materials handling processes , Buffalo Trace Distillery sought to build a new , conventional warehouse with a traditional rack system . However , when it found that available space was limited , the distillery looked to an automated warehouse with an automated storage and retrieval system ( AS / RS ).
SOLUTION
Buffalo Trace Distillery selected Westfalia Technologies , Inc ., to spearhead the construction of a new 83,000 square-foot facility . Westfalia first thoroughly analyzed Buffalo Trace Distillery ’ s current business and warehousing operations , and then developed an automated warehousing system with the right balance of throughput and storage to support the company ’ s projected growth needs .
Simulation software played a key role in developing the overall solution , allowing efficient use of automation technology and the ability to prove the capability of Westfalia ’ s design to meet sustained system throughput rates .
RESULTS
Within the new distribution center , Westfalia ’ s AS / RS occupies 46,574 square feet and contains three storage and retrieval machines ( S / RMs ), or cranes , which operate in three aisles , serving storage lanes five deep , and storing pallets six levels high . Each crane can induct / output 55 pallets of finished goods per hour with a total of 165 pallets moving within the system . The AS / RS contains 20 pallet-staging lanes which can hold 180 total pallets . The AS / RS is integrated with Westfalia ’ s Savanna . NET ® warehouse execution system ( WES ), which directs , controls and optimizes internal material flow , order picking and inventory management . The technology is linked with Buffalo Trace ’ s enterprise resource planning ( ERP ) system , providing real-time inventory accuracy and streamlining order processing .
One of the first spirits suppliers to use an AS / RS , Buffalo Trace Distillery is now more efficiently and effectively managing , moving , storing and retrieving pallets of finished goods . It is able to verify that the right products are retrieved at the right time to satisfy outbound orders . Plus , Westfalia ’ s systems ’ design ensures the secure storage of products . All pallets are triple-supported within the rack structure , eliminating pallet deflection / breakage and product loss .
In addition , Westfalia ’ s solution is built with the flexibility to expand , supporting Buffalo Trace Distillery ’ s future growth and warehousing distribution needs , ensuring sustainable , long-term growth .
FEATURES :
Size
• 83,000 square foot facility
• AS / RS occupies 46,574 square feet
• Stores pallet loads 6 levels high , 5 pallets deep
• 4-aisle solution based on the flexibility of expanding to accommodate future growth
• 10,621 pallet rack positions
• 18 truck staging lanes
Capacity :
• 3 S / RMs operating in three aisles
• 20 pallet-staging lanes , holding 180 total pallets
• 55 pallets per hour per S / RM , with 165 pallets moving within the system
Technology :
• High-density AS / RS
• Savanna . NET ® Warehouse Execution System
• S / RM using Satellite ® technology
www . WestfaliaUSA . com The Satellite Review 33