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Surecold: 3PL warehouse for fish processing and refrigeration

Sector: Fresh and frozen, 3PL

Surecold is a Canadian company specialising in the processing of fresh salmon. They specialise in particular in the processing and refrigeration of fish.

Problem

Existing facility consisted of a 22,000 sq. ft cooler, 8000 sq. ft dock area and 4800 sq. ft of additional cold room storage in a separate part of the building.

The storage cooler could handle approximately 880 pallet positions when placed in selective pallet rack and pyramid stacked on the floor.

Daily inbound ranged from 15-25 full trailers of full pallets of fresh Salmon, and that same amount was required to be received, stored, picked and shipped primarily within 24 hours.

The operational challenge was losing the 4800 sq. ft of additional cold room storage and the requirement to increase pallet density and throughput within the 22,000 sq. ft cooler.

Solution

A design layout that created both a staged/completed order area and deep lane storage and selective rack that accommodated full pallet pick and case pick.

6 LIFO lanes of 22 pallets deep (full trailer load) for pre-picked staged orders and 13 FIFO lanes of 18 pallets deep and a few rows of selective rack for SKUs of less than eight pallets and case pick operation.

8 Pallet Runner carts were required to maintain the velocity of the product, both inbound and outbound.

Advantages

Increase pallet storage density to approximately 1620 pallet positions. (Increase of over 50%).

Reduced forklift travel by over 60% as operators no longer had to retrieve completed/staged orders from other parts of the facility.

Trailer unload and put-away time decreased substantially as the Automha system was located within the cooler proximal to the receiving dock.

Eliminated the requirement for costly refrigerated trailers as temporary storage when product volume exceeded the limits of the old cooler configuration.

Considerable increase in warehouse efficiency due to the elimination of ‘extra steps’. (Reduced forklift travel, no need for extra outside trailer storage, ability to stage completed orders in the same cooler).

See past layout vs new layout schematic!!

Gallery

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