Interlake Mecalux News Magazine Vol:2 No. 5

VOL. 2 NO. 5

news

interlakemecalux• NEWS

El Milagro: Micro Chips, Then Macro Chips

Desert Depot: 3PL to Yuma

SanMar:

The Clothes Make the Plan

2012- VOL.2 NO.5

Alimerka: Bringing It All Back Home Amagosa: Thriving in the Desert Microlan: Thinking Outside of the Box

•FRIENDLY•EXCELLENT SERVICE•SUCCEED•EFFICIENT•LOVE•SUPPORT•GUARANTEED•QUALITY•SOLUTIONS•LOVE•EFFICIENT•TEAMWORK•QUALITY•FRIENDLY•LOVE•TEAMWORK•SAFE•SOLUTIONS•LOVE•GROW•PROGRESS•QUALITY•FRIENDLY•BUILD•VALUE• •LOVE•BUILD•TEAMWORK•INSPIRE•EXCELLENT SERVICE•LOVE•EFFICIENT•TEAMWORK•QUALITY•SOLUTIONS•LOVE•TEAMWORK•VALUE•EXCELLENT SERVICE•EFFICIENT•LOVE•EFFICIENT•TEAMWORK•QUALITY•GOOD SERVICE•EFFICIENT•INSPIRE•FRIENDLY• •TEAMWORK•QUALITY•FRIENDLY•LOVE•ENGINEERING•EFFICIENT•QUALITY•FRIENDLY•LOVE•TEAMWORK•GROW•EFFICIENT•ENGINEERING•QUALITY•SOLUTIONS•VALUE•LOVE•EXCELLENT SERVICE•QUALITY•SOLUTIONS•LOVE•EFFICIENT•TEAMWORK•DELIVER• •DELIVER•PROGRESS•EXCELLENT SERVICE•LOVE•SOLUTIONS•BUILD•EXCELLENTSERVICE•GUARANTEED•LOVE•EXCELLENT SERVICE•INSPIRE•SOLUTIONS•LOVE•EFFICIENT•TEAMWORK•EFFICIENT•SUCCEED•LOVE•QUALITY•SAFE•GUARANTEED•EXCELLENT SERVICE• •FRIENDLY•EXCELLENT SERVICE•GROW•QUALITY•ENGINEERING•LOVE•SUCCEED•DELIVER•EXCELLENTSERVICE•EFFICIENT•LOVE•EFFICIENT•TEAMWORK•SAFE•LOVE•EXCELLENT SERVICE•QUALITY•PROGRESS•ENGINEERING•EFFICIENT•LOVE•TEAMWORK•QUALITY•

INTERLAKE MECALUX • New & Used materials • Largest inventory in Southeast US Region • Selective – Drive-in – Push back Pallet Rack • Mezzanine – Flow System SERVICES: • Design of warehouse & distribution centers: optimization of space • Installation and dismantle, relocation • Buy USED

OUR CUSTOMERS: • General Electric • Carnival Cruise Lines • B/E Aerospace • DHL Global Forwarding • BrightStar Corp.

• Red Bull • Baxter

• Pepsi • Coca Cola • Bacardi • Britto • Nasa • Nestle • Red Strip

Made in America

Visit us at www.AtlanticRack.com – 5255 NW 163 ST Miami Gardens, Fl 33014 – Tel:1-866- 310-7225

Interlake Mecalux News is published by Interlake Mecalux.

Vol. 2 - No. 5 2012, Publication Number ISSN: 2159-0575 print 2159-0583 web

Editor in Chief:

Losevsky Pavel/Shutterstock

Javier Carrillo

Marching Through the Distortions

Editor at Large: Inés Arocena Managing Editor:

C

ompanies parish or profit based on what they

housing solutions, but also showcase instances in

can do for their clients. We understand that our

which we go to abstract lengths to do so. You’ll read

customers are as loyal to us as we give them reason

about new technologies that are just starting to in-

Art Director:

to be. In this sophisticated client-manufacturer part-

filtrate your business, shape your efficiencies and

Cristina Maciejczyk

nership, growth must be a two-way proposition or

change your capabilities forever. You’ll also read

the deal will inevitably sever. There can be no mixed

about technologies that won’t have such an effect

sentiments, no false promises.

for another decade. Read up, then prepare accord-

Adam Shafer adam.shafer@interlakemecalux.com

cristina.maciejczyk@interlakemecalux.com Layout: Kara Taylor

Nobody wins, unless

ingly. It isn’t complicated; that’s the profoundness

everybody wins.

tomating your storage space to properly slotting it,

This is the flag the Mecalux Group is waving into

slowly if it’s more appropriate than a fully fortified

Jesse Wu

the new year as we continue marching through

storage space.

jesse.wu@interlakemecalux.com

uncharted global economic crisis, stunning shifts in

Editorial Office

the industry’s technological capabilities, increased

This is the new whole for the Mecalux Group. There

1600 N. 25 Ave.

competition in the world’s few blossoming econo-

is not just one, but countless solutions, and we are

Melrose Park, IL 60160

mies, and the specter of change threatening to bury

interested in finding the one best suited for our cli-

companies resistant to change. The success of this

ents spaces. No matter what the size, budget or de-

march is entirely predicated on customer satisfac-

mand, we can optimize the maintenance costs and

without the express written consent of

tion. If the Mecalux Group can grow our clients

efficiency of your business by 10 percent. We can

Interlake Mecalux, Inc.

businesses, add value to their operations, optimize

out-deliver, out-package, out-price our competitor’s

The views expressed in this magazine are

their process flows and satisfy them with our ex-

rack. We know it can be done. We’ve done it. And

not necessarily those shared by Interlake

ecution, the minimizing effect those affairs have on

we know our march will continue because we’re

Mecalux, Inc.

business growth will prove toothless.

already moving.

Christine Javier Contributors: Dave Batka Marta Jimenez-Lutter Advertising/Subscriptions:

th

U.S.A. marketing@interlakemecalux.com No part of this magazine may be copied

of it. It’s all remarkably simple. From partially auwe’ll take you through economical ways to improve

In this issue, we will show you our total dedication to bringing our clients (and indeed, some of your clients) closer to their end goal and, by proxy,

Javier A. Carrillo

our goals as well. We’ll show you best practices in

President

which we not only bring our clients the best ware-

Interlake Mecalux

news

news 2012- VOL.2 NO.5

14

Business Index

record R

8

Micro Chips, Then Macro Chips Alchemy Models Inc. - pg. 56

Family-owned tortilla company, El Milagro, attempts a used system retrofitting only to discover they were

Alimerka S.A. - pg. 34

on the wrong side of the racks.

Amagosa Distribution and Logistics - pg. 40

14

Amazon.com - pg. 62 Apple - pg. 89

The Clothes Make the Plan

Boeing - pg. 55

How new construction of a distribution center in Dallas, Texas, for garment provider SanMar, relied on old friends.

Chivas Regal - pg. 43 Coca-Cola - pg. 29

22

Codefrut S.A. - pg. 35 Cognex - pg. 99

3PL To Yuma

Crown Equipment Corporation - pg. 47

Third-party logistics company Desert Depot sees alternatives and growth in agriculture.

CVS - pg. 85

Microlan: Thinking Outside the Box

DuPont - pg. 77

A corrugated box manufacturer automates its warehouse and

El Milagro - pg. 8

doubles its storage capacity.

ESS Group - pg. 10 eWON - pg. 67

GENCO ATC - pg. 52

46

74

Fueling Sales of Fuel Cells Fuel cells have flown past most other forms of alternative energy on the wings of their value to the auto industry.

54

The Dueling Promise of 3-D Printing Additive manufacturing is quietly looking to break into the material handling industry, leaving those inside it to decide what to do next.

28 62

Desert Depot - pg. 22

FedEx Kinko’s - pg. 47

F forefront

34

Bringing It All Back Home

An Alimerka expansion resulted in a brief profit dip and the need to reshuffle company operations.

Google - pg. 62

40

Gowan Company - pg. 22

Complex Flexibility

Grocery Manufacturers Association - pg. 10

Logistics distribution company Amagosa expanded its warehouse

Hawthorne Lift Systems - pg. 26

operations without expanding its floor space.

The Clouds Roll In Despite the debate among warehouse owners about the merits of third-party software management, cloud computing remains poised to take the industry by storm.

70

Smarter Warehouses Save Energy and Money Energy savings strategies used in automated storage mean lower electric bills.

28

Hayat Group, The pg. 72 Heineken - pg. 40

40

Home Depot - pg. 85 Honeywell - pg. 60 IBM - pg. 66 Inland / Hobbs Material Handling - pg. 26

62

8

74

In order to make you smile, Novo Mundo always goes farther

Novo Mundo’s history began 55 years ago in a store barely 861 square feet. Now, there are over 160 stores and more that five thousand employees making more the five million clients smile across north and central Brazil. Nevertheless, Novo Mundo’s network does not stop there. In the next months, you will see more people, from more places, smiling with Novo Mundo.

96 industry I

74

Index continued...

Fire Works

Matching the right storage facility with the right fire prevention Insight Group, The - pg. 106

system can make the difference between scorch or soot.

80

Leche Pascual Group - pg. 29 Loughborough University - pg. 61

Taking the Dents out of Bolted Rack

Mahou San Miguel Group - pg. 29

Why bolted rack is making slow, begrudging, overdue inroads

Mallard Manufacturing Corp. - pg. 11

in the North American welded market.

MapQuest - pg. 62

86

Masas Congeladas De Panaderia S.L. - pg. 35

Inside the Margin of Success

Microlan S.A. - pg. 28

Your company’s logistical operations may be the last part

Microsoft - pg. 64

of your supply chain, but far too few companies

Naumann Hobbs Material Handling - pg. 24

make it their first priority.

Netflix - pg. 67 Nissan - pg. 50 Panasonic - pg. 88

90

Semi-Automatic Solutions As companies’ need to expand wrestles with their need to save,

Peerless Industries - pg. 88

the three stages of partial automation have quickly

Pernod Ricard - pg. 29

merged from the middle.

Rack Space - pg. 63 Reuters - pg. 89 RH Brown Company - pg. 15

86

Sysco - pg. 47 Target - pg. 85 University of Southern California - pg. 56 University of the UK - pg. 61 US. Foods - pg. 50 Wal-Mart - pg. 47

The increasing capabilities of image-based ID readers are capturing more than just the attention of the material handling industry.

100

A Turning Point Named Crisis Interlake Mecalux takes the challenges of the market crisis and turns them into an opportunity for growth.

104

The Well-Slotted Warehouse How a highly organized storage facility can save money and time in a difficult economy.

108

Product Spotlight: Cantilevers From architecture to aviation, cantilevers are ideal for

80

SICK Group - pg. 97

Sony - pg. 88

96

Readers Between the Lines

warehouse applications.

SanMar - pg. 14

Siemens - pg. 55

108

100

record R El Milagro

Micro Chips, Then Macro Chips

Family-owned tortilla company, El Milagro, attempts a used system retrofitting only to discover they were on the wrong side of the racks.

By Adam Shafer

8 •interlakemecalux• NEWS

M

ore than 65 years ago, Raul Lo-

linois Central Railroad. “El Torero,” as

pez Sr., a Mexico City native with

many would later come to call Lopez,

childhood dreams of being a bullfight-

spent his mornings inspecting and

er, moved north to the U.S. during the

installing railroad tracks throughout

Second World War The economic situ-

the Chicagoland area and his nights

ation of the young orphan who had

applying the first trade he learned

lived with his uncle since he was 11,

through his flour mill owner uncle:

compelled him to take a job offered

making flavorful tortillas. Soon, Lo-

by a U.S. recruiter to work for the Il-

pez’s days were jammed not only

El Milagro R

record

[Top} The exterior of El Milagro’s production facility, which also has a small store attached in which customers may directly purchase pre-packaged products (right).

“El Milagro bought a system that they

with rail work, but also with selling

son Jesse, daughter Paz and five

had to fit into their

his tortillas to his fellow trackmen.

other children and a smattering of

By 1950, Lopez ditched the rail work

grandkids, expanded El Milagro into

to open a restaurant in a Chicago

Texas in 1997, about the same time

neighborhood central to the railroad

Lopez Sr. passed away. “Expanding

they have the ability

personnel. He called it El Milagro, or

to Texas is something our dad con-

“the Miracle.” And while Lopez per-

sidered,” said Paz Ramirez, Lopez

to create something

haps viewed his business’ existence

Sr.’s daughter and GM of the com-

as miraculous, its continued success

pany’s Texas division. “He wanted

today certainly isn’t.

to retire in a warmer atmosphere.”

operations, Now

brand new.

”

~Jeff Ross, ESS

The opportunity to expand to Texas After slow conservative growth in

came when local tortilleria, El Lago,

Chicago, Lopez’s family, led by his

offered up its business for sale.

www.interlakemecalux.com•

9

record R El Milagro within the plant, but El Milagro was Early in the process, adjustments to the racking height were necessary, as there were low-hanging ceiling

hesitant to spend additional money for

Technical Details

a new system to replace the pre-owned system it had just purchased.

pipes that were not originally accounted for.

Upright Height:

18 ft.

Flow rail lines:

50

Jeff Ross, president of ESS Group, got involved in the El Milagro installation two years ago. He said that by the time

Total pallet storage capacity: 1,188 lb.

Top level pallet capacity:

he visited the site to evaluate the efficiency of the used pallet flow, the

700 lb.

booming tortilla company had already

Bottom 2 level pallet capacity: 2,200 lb.

realized adjustments were necessary.

Total bays:

Hector Ramirez, one of the company’s

“It was a grab-bag kind of a deal,”

25

managers, reflects today. “It was a Pallet depth:

6-10

mish-mash system that didn’t match up correctly.” “They had no flow lanes and only two flow rails, neither of which had brakes,” Ross says. “A pallet flow system has to be in a straight line, but if you looked down this one, it looked as if it were inclining up a hill and then

The plant, located in Austin, was

to retrofit the facility with a used pallet

used primarily to manufacture tor-

flow rack that fit the company’s GMA

tillas, more or less picking up right

Grocery Manufacturers of America pal-

Adding to these issues were some miss-

where El Lago had left off. It didn’t

let specifications. Using the contacts El

ing rollers and a few makeshift beam

take long for El Milagro to find suc-

Milagro had spent years building in Chi-

connectors. ESS wasn’t fully convinced

cess in Austin and in 2009, the busi-

cago, Jesse and Hector Lopez found and

the rack sitting in the San Marcos ware-

ness branched out further, purchas-

purchased an inexpensive, pre-owned

house was usable, much less salvage-

ing a modest manufacturing plant in

pallet flow system he believed would fit

able. Finally, El Milagro’s staff found

the nearby city of San Marcos. The

in their San Marcos facility. Soon after

something they weren’t completely ad-

facility was renovated and fortified

the racking materials were shipped to

ept at doing. “ESS was brought in only

with a corn silo allowing El Milagro

Texas and installed, El Milagro turned

after there was a problem,” Ross said.

to produce pre-cut corn tortilla chips,

to local distributor ESS. It was immedi-

“My first action, really, was education;

flour tortillas and other similar prod-

ately apparent that the system wasn’t

to show them how a proper pallet flow

ucts. The result was a sudden influx

going to being smoothly operating

system should function.”

back down.”

of new business and, of course, new challenges.

Fixing the Mix ‘n’ Match Knowing that the new facility in San Marcos would be storing, not only finished products, but also raw materials – and lots of it – Jesse and Lopez Sr.’s grandson Hector hoped 10 •interlakemecalux• NEWS

“There were things that we were able to optimize that we couldn’t have with the existing system.

”

~Hector Ramirez, El Milagro

El Milagro R

record

Ebbing Tide

would have taken a dismantling it

Molding Clay

El Milagro’s most pressing problem

and then piece-by-piece reconstruc-

ESS, working closely with both

at the outset was the lack of brakes

tion.” For El Milagro to have replaced

Mallard conveyors and El Milagro,

on much of the pallet flow system.

the dysfunctional flow rails with new

revised the design concept a half-

With nearly 200 pallets of chips cir-

ones would have cost them about 70

dozen times during the summer of

culating each day, it is vital to have a

percent of what it would cost to re-

2010. Generally, every specification

solid braking system so the high vol-

place the whole system. “If you want

was taken into account, leaving the

ume of pallets don’t go careening off

to do it,” Ross advised the tortilla

only blip a small oversight on the

the rack. Immediately, ESS identified

manufacturer, “do it right and make

clearance height of the facility’s

the importance of determining the

sure it’s an engineered system.” The

ceiling. Quickly altering the area

flow rail’s efficiency, so the distribu-

message, essentially, was that every-

needed for clearance in addition to

tor brought in flow rail manufacturer

thing about El Milagro’s car needed

taking into account the manufac-

Mallard to determine if El Milagro’s

replacing except its steering wheel.

turer’s combination storage of both

necessary pallet specifications would

It was a sentiment El Milagro had

raw and finished materials, ESS de-

work with the system installed in

feared, but fought against fervently.

signed an efficient plan and called

the space.

“We were shopping around to see

on the Interlake Mecalux pallet

if there was anything salvageable

flow system to replace the unstable,

ESS and Mallard ordered a sample

about the system,” Paz Ramirez la-

hodgepodge initially installed. “The

flow lane, but were unable to get it

mented,“ because it was going to

Mecalux rack appealed to us – the

operating. Even if they’d gotten one

be a complete loss if there wasn’t.

wheels especially,” Hector Ramirez

flow lane functioning, there was still

El Milagro agreed that the best thing

explains, “because they were guar-

the issue of knowing if the system was

to do was reset and install new rack

anteed to work. We were in a posi-

even engineered to hold the loads of

components engineered to hold the

tion [with the used system] where

what they were going to be storing.

load. “Eventually we had to bite

we were getting red flags every step

“All the components for the rack were

the bullet and get something new,”

of the way. When we heard the rack

a potpourri of things,” Ross said. “It

Ramirez said.

was guaranteed to work, we were

If you want to do it,do it right and make sure it’s an engineered system.

~Jeff Ross, ESS

Corn Substitute To simulate the weight El Milagro’s

a period of weeks to ensure

newest products would heap

the system can withstand the

onto the pallet flow system,

demands of the product without

they gathered over three dozen

risking a malfunction. At the time

2,000 lb. oil containers on the

of publication, the system was

lower racks. The idea is to keep

flowing properly and everything

the oil situated on the rack for

remains on schedule.

www.interlakemecalux.com•

11

record R El Milagro good.” Even now, months after the seven-foot-high pallet flow systems have been put in place, El Milagro remains cautious. Leading right up to the new year, the tortilla manufacturer was heavily testing its rack by loading it up with 2,000-lb. drums of oil representing the weight being placed on each pallet. In 2012, El Milagro plans to begin production on a new product, (not yet announced at the time of this printing) and wanted to ensure beyond a doubt that the pallet flow racking can withstand the weight and frequency of Taught, Then Bought Texas distributor ESS proves that most of the work necessary for a turnkey solutions provider must be done before the materials are even ordered.

use. “We’re not just hoping it’s going to work,” Paz Ramirez said, “it’s definitely going to work.”

The depth of flow lanes, aisle width, load and unload placement and direc-

ESS Group’s quick study and control of situations similar to the one presented in the El Milagro

tion of flow were all priorities when

case study is neither new nor unusual. For the last decade, the material handling and storage

designing the new system. El Milagro’s

supplier, servicing much of the state of Texas, has made it a point not only to install warehousing

main concern was the sheer volume

solutions into their client spaces, but to also make sure they are getting the biggest ROI possible.

Located 70 miles northwest of Houston in Brenham, Texas, the ESS Group specializes not just in

of product necessary for storage. The installation began in June 2011 and completed two weeks later. ”It actually works,” Hector Ramirez says today

servicing installations, but in designing solutions around the end desires of each customer. More

with a laugh. “We put on a pallet and

than half of ESS’ client work happens before a single storage system is delivered. Sometimes,

it flows just how we want it – all the

these services manifest simply as maximizing a client’s space, or articulating why a customer’s

way to the end. It’s easy to get out,

current process flow isn’t working (as was the case with El Milagro). In other instances, ESS will educate clients on how the systems operate and how to achieve maximized efficiency.

easy to get in. It works perfectly.” “El Milagro bought a system that they had to fit into their operations,” Ross says today. “Now they have the ability to

In addition to installation and repair services, ESS has earned a reputation in East

create something brand new. They’ve

Texas as having one of the best and most comprehensive product lines on the

got a piece of clay and they’re molding

market, including the full roster of Interlake Mecalux storage solutions. Ultimately however, it is ESS’ technical services that provide it with an extra advantage.

it in the shape they want.” ESS chose Mecalux pallet flow for the same reason it pushed El Milagro to ditch the retrofitting and install a new system:

Company president Jeff Ross views the job for which ESS is best suited as not only a solutions

both would allow the customer the

provider, but as an education source, striving to work with employees and clients alike in

most highly efficient, flexible system,

order to “ensure the concepts are understood and followed” throughout every project.

something the distributor felt just couldn’t be accomplished with any other solution.

12 •interlakemecalux• NEWS

LOGISTICS

INC.

B EN SEN V I L L E,

I L

OV E R t h e ROA D a n d L O C A L T R A N S P O RTAT I O N

Cabrera Logistics Inc. was founded in 1997 by Martin Cabrera.

He began as an owner operator under his own authority and after years of hard work, dedication, and support of his family he was given more contracts, which gave him the opportunity to buy more units and hire dedicated drivers to take Cabrera Logistics Inc. from just a couple of trucks, to a large fleet, his own warehouse, mechanic shop, and his own road side assistance for all the units. Now in 2010, Cabrera Logistics Inc. continues to grow thanks to a good team of dedicated drivers, mechanics, dispatchers and most importantly thanks to all the customers who place their trust and freight in the good hands of Cabrera Logistics Inc. Tel: 708 343 4715 | Fax: (708) 356-1312 | Melrose Park, IL 60160

record R SanMar

The Clothes Make the Plan How the new construction of a distribution center in Dallas, Texas, for garment provider SanMar, relied on old friends.

By Adam Shafer

14 •interlakemecalux• NEWS

I

t is noon in Texas, and many ware-

tion center. However, at SanMar, the

house employees throughout the

company’s regional distribution cen-

state are preparing for lunch. For

ters do not dictate operating hours:

SanMar, however, the day is just

the home office does. So while most

beginning. The wholesale garment

of Texas awaits 11:30 shifting into

distributor, based out of Seattle,

noon, it is functionally only half-past

recently expanded eastward into a

nine in SanMar’s 700,000-square

newly constructed Dallas distribu-

foot facility.

SanMar R

record

Ultimately, the company values effi-

of RH Brown, the rack distributor

Also worth noting is the wholesale

ciency and punctuality over all other

and installer who collaborated with

distributor’s

qualities of a successful business,

SanMar on the Dallas project, views

which not only expanded outside

which is exactly why the company’s

SanMar’s national synchronization

the Washington area into Texas,

busiest time is later in the afternoon

as a boon to customer service. “It’s

but has veined into Florida as well.

when the day’s orders are in and the

awesome,” Larsen says. “Whenever

Nourishing that growth is the in-

personnel stays as late as necessary

a company does something a little

creasing footprint of clubs and cor-

to see that each shipment makes it

off the norm and they make it work

porations demanding high-volume

out the door. Scott Larsen, president

successfully, it’s worth noting.”

garments such as embroidered t-

pattern

of

growth,

Nourishing that growth is the increasing footprint of clubs and corporations demanding high-volume garments such as embroidered t-shirts and polo shirts designed for large groups.

Technical Details Previous facility size:

300,000 sq. ft.

New facility size:

700,000 sq. ft.

Type of rack installed:

High-capacity, high-height Selective pallet rack

Upright height:

38 ft.

Truckloads of rack installed: 45 Storage type(s):

full pallet, partial pallet, 24-inch span single-case

Pallet depth:

1-2 deep

Bay bracing:

z-beam

www.interlakemecalux.com•

15

record R SanMar

Friendly Competition Competitors are finding an

based RH Brown, says. “That

increasing number of reasons

doesn’t work. When we go to plac-

to rely on each other for logisti-

es like Florida, we have peers – and

cal help as gasoline prices and

I guess on some level, you can say

carbon emissions remain high.

competitors – we can call upon to help us get our projects integrated.”

Known as both collaborative logistics or “horizontal collaboration,”

Optimizing transportation costs

an increasing number of partner-

and reaching a geographically

ships are forming between industry

wider customer base by sharing

competitors in order to optimize

truck capacities and orchestrating

transportation operations, usually

client deliveries with each other’s

because one company has a geo-

fleets, has not only increased

graphical advantage over another.

profitability and customer service, but also opened the door to

“You can’t just fly your people all

an innovative way of remaining

over the country all of the time,”

competitive in the market place:

Scott Larsen, president of Seattle-

by temporarily not competing.

shirts and polo shirts designed for

location. Red shirts, for example, go

pallet racking according to whether

large groups.

with red shirts; black sweatshirts go

or not they are high-turnover or low-

with black sweatshirts and so on. As

turnover items. The Dallas facility

With business expanding nationally,

the product comes off the contain-

has a primary pick area, which ne-

SanMar recognized the necessity to

ers into storage locations, the com-

cessitated the bulk storage or full

expand its warehouse space, too.

pany then re-palletizes the product

case picks. Part of the 38-foot high-

Under the current product flow, San-

according to SKU. The products are

height racking is full pallet, part of

Mar receives product by the truck-

then stored on Interlake Mecalux

it is partial pallet and some of it is

load that is then divided by storage

high-height, narrow-aisle, selective

single-case.

The company’s desired turnaround speed

Whether the item in question is a size XXXL neon-green polo shirt or

dictated that each distribution center inventory

a medium-sized plain white tee, the

enough stored product to facilitate getting

dictated that each distribution cen-

anything out the door with minimal lag time.

to facilitate getting anything out the

16 •interlakemecalux• NEWS

company’s desired turnaround speed ter inventory enough stored product

SanMar R

record

door with minimal lag time, most of the time with less than a day’s turnaround. To do that, a lot of product must be on the premises; and to do that, SanMar needed to build out and up.

Pattern of Growth Few organizations understand SanMar’s growth as much as RH Brown, which has worked with the wholesale garment company since its first 2005 retrofit collaboration in Seattle. RH Brown, the systems integrator specializing in turnkey conveyor and storage packages, also calls Seattle home and synchronized with SanMar’s patterns of growth enough that after the garment company identified the need to expand into larger facilities in Dallas and Jacksonville, Florida, RH Brown had the goods to expand right along with them. “[SanMar] was looking to build bigger facilities and they needed a partner they could turn to to handle both facilities,” Larsen said referring to both the Texas and Florida warehouses,

www.interlakemecalux.com•

17

record R SanMar

Interlake Mecalux takes the U.S.

ranges, number and volume of SKUs and cube space. Also of notable importance, was the manner in which SanMar wanted to organize the project.

The garment wholesaler wanted this

Sunburst, MT

installation project organized around its materials and wanted their distri• Melrose Park, IL • Pontiac, IL

bution center managers to be able to continue working unabated throughout the installation. “It was important

• Sumter, SC

• San Diego, CA • Dallas, TX

to SanMar that they had a partner able to insulate the existing operations from having to get involved, while also involving hundreds of other on the contract,” Larsen said.

With the design in place, RH Brown worked closely with the contractors in

• Distribution Center

charge of the building’s construction

The circles show IKMX’s expansive reach throughout the U.S., a fact that RH Brown said

in order to ensure the product would

made the company most attractive to doing business in both TX and FL. IKMX can even

come in on time and had a place to

deliver to Sunburst, MT. the farthest geographical point between distribution centers in the

go once it arrived. “We actually inter-

continental United States.

faced quite a bit with the contractor,” Larsen said. “A big part of it was the coordination facilitation of the on-site schedule for shipping and receiving product.”

“and had the capacity to manage and

at the seams to handle its product

The difficulties of working around an

install both facilities as well as turnkey

flow, SanMar relocated to a new con-

unfinished building proved myriad:

projects from their entirety.”

struction more than twice the size of

construction of the warehouse went on

the old building that allowed a more

for weeks with neither an asphalt path

Saddled with a 300,000-square-foot

even flow and efficient operation. The

(which made deliveries from truck to

building in Dallas that was straining

trick, in this instance, was going to be

dock quite difficult) nor a roof (which

creating a design and completing the

made safely storing materials risky). In

installation before the building was

a pinch, RH Brown safely blanketed the

fully erected. It was no small trick.

rack in tarp outside the facility until it

The trick, in this instance, was creating a design and completing the installation before the building was fully erected.

18 •interlakemecalux• NEWS

could be relocated indoors. “You can Operating Room

imagine we were taking in about six

RH Brown identified SanMar’s business

to eight deliveries a week for a couple

objectives and enacted a design plan

months because we didn’t have room

that would encompass those goals. The

on-site to store a lot of materials,”

plan aggregated a number of factors

Larsen says, reflecting on his biggest

including product capacity, shipping

challenge of the installation.

SanMar R

record

Inside Out

put it, the company had a wealth of

Almost immediately, SanMar saw

Once the product made it inside

regional distribution centers from

its efficiency rise and its daily

the facility, the installation went

which to ensure the product could

turnover capacity skyrocket. Today,

smoothly and SanMar was pleased

be manufactured and “the logistics

the garment wholesaler turns over

with RH Brown’s decision to use In-

to deliver the volume of product.” As

more than four time the orders it

terlake Mecalux shelves. “One of the

Larsen went on to explain, the origi-

did in the original Dallas facility, a

reasons we turned to Interlake Me-

nal plan was to complete the SanMar

feat only partially explained by the

calux for the racking solution,” Lars-

installation in Dallas first and then

increase in storage space. It isn’t

en said. “We needed a solution for

immediately complete a similar instal-

just the space, but the optimal lay-

the high-bay shelving. A lot of this

lation in Jacksonville, Florida. After

out, the durability of the rack and

rack is 38 feet tall with beams every

several schedule changes related to

the company’s increased storage

two feet. It isn’t high capacity.” The

weather or other unforeseeable mat-

capacity.

solution, in this case, came in the

ters pushed the Dallas installation

form of z-beams at the ends of the

back and forced both installations to

As the clock creeps ever closer

bays. SanMar had been using pallet

coincide with one another, Interlake

to noon in the garment distribu-

rack beams to store its products in

Mecalux proved to be the right choice

tor’s new facility, there’s a chance

the previous facility, which was not

again. “These two projects combined

that despite working as if they are

as reliable.

for the biggest job we’ve done [with

running on Pacific Standard Time,

SanMar],” Larsen said. “Mecalux had

these SanMar employees will clock

More than the rack bracing, Interlake

the capacity to get that material out.

out at Central Standard Time, as

Mecalux proved to be the best choice

I’m sure there are people out there

they’ve become just too efficient to

for the installation because, as Larsen

that wouldn’t.”

necessitate staying any later.

www.interlakemecalux.com•

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a turnkey provider of not only services, but of finding hidden value. “We get to know what our customer’s objectives are,” Larsen said, “and really get to know their business so that we can really help the client decipher what their options are for material handling systems and how they may benefit their business.”

Founded in 1911, RH Brown began manufacturing industrial wheels, wheelchairs, bicycles and the like – a division still present within the company. As time passed and industries became increasingly segmented, the company branched out from simple wheel production to create conveyor systems for industrial use starting in the ‘60s. By the 1990s, RH Brown absorbed industrial steel rack distribution into its business. In the last 10 years, the systems integrator adopted more systems to integrate by not only distributing industrial shelving, but installing it as well. “That’s been a huge asset to our business,” Larsen says about that particular expansion. “Bringing those services in-house gave us control over the projects and job sites. So if the project is not so large that it’s just a full-time management posi-

A Rolling Century

tion, we can actually return some value to the customer by leading and helping with the installations.”

What started as a small wheel manufacturer has evolved, 100 years later, into a full-scale systems integrator with a few new

About 2/3 of RH Brown’s clientele hail from the Wash-

tricks up its sleeve.

ington/Oregon area, but the company’s recent expansion eastward is proof positive that its dedication to

Scott Larsen is a fourth-generation owner of RH

adding value has been successful; as company’s expand,

Brown, a racking distributor celebrating its 100th

they bring RH Brown along to help them. Indeed, some

anniversary. Actually, Larsen would almost certainly

clients cannot remember a time they were without RH

take issue with the term “racking distributor,” as the

Brown’s services. “One our suppliers,” Larsen says,

Seattle-based company has worked tirelessly to be-

“they’ve been a supplier of ours for, I think, 97 years.

come better known as a systems integrator; essentially

It’s pretty crazy that we’re both even still around.”

20 •interlakemecalux• NEWS

Holding things together since 1976.

Tel: 815-637-9002 Fax: 815-637-7575 www.fieldfastener.com

record R Desert Depot

3PL To Yuma Third-party logistics company Desert Depot sees alternatives and growth in agriculture.

By Dave Batka

22 •interlakemecalux• NEWS

U

ntil the Industrial Revolution, ag-

since 1996. Residence within a FTZ

riculture was the primary trade

allows customers to store imported,

for much of the world’s population.

raw, active goods and gradually import

Even today, there are roughly 5 mil-

them in order to produce the finished

lion acres of US land and 2 million

product. Desert Depot stores an array

employees devoted to some facet of

of products during its transformation

farming. Desert Depot, a subsidiary of

from both active and inert ingredients,

the Gowan Company, is a key player

down to the packaging and merging

in the agricultural chemicals market.

them together. The company’s storage

The provider of custodial warehousing

needs are not common to the typical

for clients’ products, Desert Depot has

warehouse, given the drastic range

been a third-party logistical enterprise

in both the product container’s size

in Arizona’s foreign trade zone (FTZ)

and shape.

Desert Depot R

record

Technical Details Type of system:

Push-back

Pallet Dimensions: 40 in. x 48 in.

48 in. x 48 in.

48 in. x 52 in.

Load Dimensions: 40 in. x 48 in.

48 in. x 48 in.

48 in. x 52 in.

Total height:

288 in.

Total weight:

1000 – 2000 lbs

Pallet capacity:

16,000 – 20,000

Year Installed:

2009

kill white flies, prevent weed growth before emerging from the ground, etc. The typical turnaround time for a raw ingredient to first enter Desert From Birth to Earth

are in need of supply. The chemical

Depot, get mixed and then shipped

Desert Depot’s functionality has

is then loaded onto a tractor trailer

out to retailers, is approximately six

been designed around its customer’s

truck and moved 10 miles down the

months. All orders ship the same day

needs. While storing the life blood of

road to a sister plant acclimated for

their releases are sent. At any time,

its customers’ business, the company

synthesizing raw ingredients. Here

the company stores between 16,000

also performs much of the logistical

at the sister plant, the peripherals

and 20,000 pallets with an inventory

processing of raw goods into finished

are mixed and prepared by trained

accuracy of 99.9 percent, according

products, ready for consumer use.

personnel. The final product is then

to customer auditors, and inventory

The raw ingredients belonging to

transferred back to Desert Depot in

is continuously updated in real-time.

one of Desert Depot’s chemical man-

its final state, ready for the retailer

Also, insuring that customer prod-

ufacturers may arrive in a variety of

to move it on to the consumer. Each

ucts are always accounted for and

containers ranging from super sacks

product goes on a different plant for

has a cradle-to-grave history, every

to drums. It is then stored until they

a different reason – to stop mildew,

pallet is tracked with a license plate.

www.interlakemecalux.com•

23

record R Desert Depot

Desert Depot’s fleet of forklifts were a priority from the outset of the installation. [Opposite] The height of the warehouse allowed double-stacked pallets on the rack’s top level.

Wasted Outgoings Despite serving some of the largest players in the industry, Desert Depot’s General Manager Dick Ponschock still felt branches of the business could be trimmed.

Having been with Gowan

since 1997 and taking over Desert Depot’s combined 215,500 square feet of facility space 10 years later, Ponschock recognized that their third space, a nearby 57,000 square foot warehouse they were leasing, was costly and inefficient. He made it his objective to plan his way out of it. Plans couldn’t be set into motion however until the lease on the space had elapsed. With 40 years of industry experience and a doctorate in organizational management, Ponschock analyzed the current layout in his main space and saw he could change, among other things, the facility’s floor plan in order to increase overall storage density.

“I knew there were better ways to renovate [the] current space than spending rent money on another warehouse,” Ponschock said. “I started looking toward the roof and thought there was a lot of cubic feet wasted in my warehouse.

5,000 lbs. cushion forklifts. Narrow

integral. The system needed to allow for

We might be full on the square foot, but

aisles weren’t an option.

both very narrow and very wide pallets

what if I could go up 1.2 or 1.8 number

knew there were other approaches,

of pallets… and store everything inter-

but none of them were too enticing.

nally without affecting service levels?”

Knowing there were alternatives to ev-

Pragmatic Answers

Ponschock

to be stored.

erything, the design needed to be ready

After a year of analyzing feasible solu-

The key to the renovation was to avoid

to handle inevitable future growth and

tions, Desert Depot awarded the over-

changing the company’s current prod-

not simply that of their current inven-

haul of its 103,200-square-foot space to

uct flow or material handling equip-

tory. With Desert Depot’s pallet sizes

its longtime material handling provider

ment, which was made up of standard

being continuously in flux, flexibility was

Naumann Hobbs. Having the Southwest’s

24 •interlakemecalux• NEWS

Desert Depot R

record

The new pushback system nearly mirrors the previous configuration, giving the desired extra storage density without consuming vital floor space and fully maximizing previously untapped vertical cubic footage.

from the back, that [layout] would have really handled well, but then, I lost some aisle space. So, push-back ended up being the most efficient from a warehouse space element.”

Push-back offers high-density, multiple product storage solutions that optimize all of the available space. Because Desert Depot didn’t want to change their forklifts, the telescoping carriages used in push-back utilize gravity to move rearlargest material handling provider in its

“The density was one of the main fac-

placed pallets to the front, so drive-in

corner, the distributor set about conduct-

tors,” Ponschock explained of the prelimi-

rack or telescoping forklifts are unnec-

ing an efficiency study for pallet loca-

nary plans. “We also looked at many al-

essary. The design allows all the stored

tions Desert Depot’s main facility and its

ternatives even with racking itself.” Geoff

products to be accessed from a single

off-site storage facility and then modeled

Nance, the general manager of Naumann

aisle in a first-in/last-out order. Also,

their findings into CAD drawings. Shortly

Hobbs, noted that his experience with var-

since Interlake Mecalux offers beams and

thereafter, Naumann Hobbs determined

ious rack types compelled him to choose

frames capable of supporting two-, three-,

that push-back would be the ideal

push-back as the best solution to Desert

four- and five-deep push-back rack, they

solution to eliminate the unwanted off-

Depot’s desire to consolidate. Ponschock

can be implemented in a variety of ap-

site location.

added, “If we laid out the warehouse

plications, despite given space.

www.interlakemecalux.com•

25

record R Desert Depot

Push-back offers high-density,

didn’t have to shut down an area,”

multiple product storage solutions that

“We shut down pieces of an area,

optimize all of the available space.

Ponschock noted of the installation. but we didn’t shut down an entire area at all.” This process continued until the installation was completed nine weeks later. “We worked all the

Construction

the racks were designed to accom-

time – all day, every day,” Nance

Hobbs installed 16-foot, three-tiered,

modate a variety of GMA pallets

said. Completed in 2010, the new

three- and four-deep pushback sys-

with weights ranging from 1,000 to

storage system accommodates well

tems, and a five-deep system that was

2,000 lbs. During the construction,

over 16,000 pallets, nearly double

modified for a sixth point, allowing for

Desert Depot maintained normal

previous capacity.

more than 7,600 pallet storage posi-

daily business operations by system-

tions. The height of Desert Depot’s

atically clearing out old rack and in-

When compared to the yellow

space also allowed for a second set of

stalling the Interlake Mecalux beams

safety lines marking where the old

pallets to be stacked onto the highest

and uprights along with the push-

rack sat, the new push-back system

tier. Industrial rollers were installed

back mechanism, re-filling it with

nearly mirrors the previous con-

on another pushback system, and all

product. “It was great to see that we

figuration, giving the desired extra

Thriving in the Desert A material handling company still reinventing itself after 60 Years.

Amidst the sprawling desert, speckled with serene mountain terrain, lies the home office of Naumann Hobbs. The once family-owned company has evolved into the Southwest’s oldest and largest provider of material handling equipment and services. With age has come innovation and advancement, having started in 1949 in the forklift business, eventually incorporating warehouse, storage and construction solutions. The company expanded into Las Vegas in 1997 with the creation of Inland/Hobbs Material Handling, eventually spreading throughout Nevada and into Southern Utah. Nine years later in 2006, Naumann purchased Hawthorne Lift Systems, giving the company a foothold in California and completing the Naumann Hobbs family. Hobbs’ tireless dedication toward meeting their customers’ material handling needs hasn’t gone unnoticed. They are a repeated nine-year recipient of Arizona’s Corporate Excellence Award and have been recognized by Mitsubishi and CAT.

26 •interlakemecalux• NEWS

Desert Depot R

record

storage density without consuming vital floor space and fully maximizing previously untapped vertical cubic footage. However, they opted to not fully rack the entire warehouse, leaving an area open for incoming active ingredients. Since they arrive in drums, stackability is an option without having crushing or safety concerns.

Nearly two years after the installation was completed, Desert Depot has seen the true value of their renovation double. The company continues to be a logistics safe-haven for its clients.

Their recent completion of Desert Depot’s 103,000-square-foot

existing space. Though, the road taken had many detours, noting

facility in Yuma, AZ, with Interlake Mecalux push-back rack illustrates

that he went through four managers until finally finding some-

why they have survived and flourished for over six decades. Formerly

one who understood his vision for the tenured company.

family-owned, Naumann Hobbs is now structured with an employee stock ownership plan. The distributor still primarily services produce

Naumann Hobbs installed the Interlake Mecalux push-back

warehouses and medium-sized firms like Desert Depot since the

frames into the Yuma warehouse. Desert Depot already had

late ‘90s. When the opportunity arose to help change the day-to-

selective rack in place – selective and push-back unload in a

day function and storage capacity of Desert Depot’s warehouses,

similar manner – but push-back offers greater storage density.

Naumann Hobbs stepped up despite concerns from their partner

Naumann Hobbs won this particular bid and implemented a

company that their off-site warehouse couldn’t be eliminated.

study of Desert Depot finding a modified push-back system to be the best way to eliminate the off-site 52,000-square-

“They were very concerned that we couldn’t do what we

foot warehouse, while increasing total storage capacity.

said we could do. You are talking about someone pulling a big trigger and putting their career on the line as a com-

”[Push-back rack] is beautiful to work with,” Nance said.

pany,” Naumann Hobbs’ General Manager, Geoff Nance

Desert Depot saw an immediate return on investment from

said. “[The installation] was upwards of a million dollars.”

its rack installation, given that their storage capacity nearly doubled upon completion. “They are a top-notch organiza-

But Nance had confidence that his company could complete the

tion.” The two are currently discussing the addition of truck

ambitious task and recognized the potential of Desert Depot’s

locks on all of the docking positions at Desert Depot.

www.interlakemecalux.com•

27

record R Microlan

A corrugated box manufacturer automates its warehouse and doubles its storage capacity.

Microlan: Thinking Outside the Box

by Marta Jimenez-Lutter

L

ocated Located in northern Madrid, Mi-

turers by highlighting its great products and

crolan started manufacturing cardboard

outstanding customer service. The company

boxes in 1976. Today, the company is a mar-

crafts all of its products on demand, follow-

ket leader in the flat-stamped corrugated

ing the customer’s specifications. To make

cardboard box sector, creating custom-made,

sure the quality of its products exceeds the

high quality boxes for a variety of industries.

expectations of its clients, Microlan has consistently invested in state-of-the-art ma-

28 •interlakemecalux• NEWS

From its inception, Microlan focused on dif-

chines to manufacture corrugated boxes, as

ferentiating itself from other box manufac-

well as the latest in printing systems.

Microlan R

record

Microlan’s attention to detail and exceptional quality secured its position in both national and international markets. Microlan has clients spanning from France and Portugal to Cuba, where it controls 90 percent of the market for Pernod Ricard, the French manufacturer of high quality spirits. Other brands like Coke, dairy giant Pascual, and one of the oldest Spanish beer manufacturers, Mahou, trust the production of their boxes to Microlan.

The success of their business meant that by late 2010 the company found itself with a 96,875-square-foot warehouse needing to be modernized. Rather than expanding the dimensions of the warehouse, Microlan decided to automate the space they had.

Automation would allow them to utilize their existing floor plan in a more efficient manner without going through the disruption and cost of building an addition.

Miguel Angel Saavedra, head of the automated warehouse solutions division for Mecalux Spain, explained the manner in which the installation process for this project was scrupulously planned. “The plant is a fully functioning manufacturing facility that stores products in the middle of being turned into custom boxes,” he said, adding that Mecalux did not want to Francisco Sahagun, factory director for

they want on the box and we have to

disrupt the manufacturing process during

Microlan, explained the importance of

transfer it and adapt it to the printing

the complicated installation. Microlan sees

their machinery when trying to achieve

system.” The process is completed me-

a constant daily movement of more than

the highest quality possible. “The boxes

ticulously, leaving no room for error or

240 pallets that are produced, printed and

are like custom suits, they are made to

misrepresentation of the product. One

shipped to the customers on a set schedule.

order,” Sahagun said. “The client orders

of the worst mistakes a company like

“This meant that the implementation of

a specific box with a particular image

Microlan can make is misspelling Coca-

any changes had to be executed in stages

and we make exactly what they have

Cola’s name or printing a Pernod Ricard

because production could not be halted,”

ordered. They give us the information

box using the wrong font.

Saavedra said. “Mecalux established a

The success of their business meant that by late 2010 the company found itself with a 97,000-square-foot warehouse needing to be modernized. www.interlakemecalux.com•

29

record R Microlan

The Microlan plant is managed by the client’s WCS, which is a programmable logic controller that communicates with the Mecalux Group’s Easy WMS software.

delivery system on the weekends to avoid

a concrete company was called to dig

delivery of the stacker crane and the

disturbing the factory production.”

the hole for the automated section. A

shelving units over several weekends. The

tarp was erected to separate the con-

new pieces would be delivered Saturdays

Automation Operation

struction area and keep the noise and

and Sundays and stored in the pit so Me-

Mecalux planned an automated installa-

dust out of the production plant. Miguel

calux workers could have them on Mon-

tion measuring over 26 feet high to ac-

Saavedra explained how the hole for the

day. That way we did not bother Microlan

commodate the level of pallets that Mi-

new storage system was used to keep

factory workers during regular produc-

crolan needed to store. The problem was

the new construction from disrupting the

tion times Monday through Friday.”

that the municipality of San Sebastian de

manufacturing process “The pit was very

los Reyes, where they are located, did

convenient during construction, as it was

The company also had to make sure the

not allow that construction height, so

used to store all the materials and keep

system was working correctly before

Mecalux designed and constructed a pit

them away from factory activities while

they made the transition. If something

6.5 feet deep to make up for the differ-

the warehouse was being remodeled.”

wasn’t working properly, they would

ence. A section of the factory that con-

Saavedra also explained how material

have backed up orders and unfulfilled

tained conventional rack was sectioned

delivery was organized to avoid disrup-

deadlines, resulting in subsequent eco-

off, the old units were taken down and

tion of production, “We spaced out the

nomic loss.

30 •interlakemecalux• NEWS

Microlan R

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Automation would allow Microlan to utilize their existing floor plan in a more efficient manner without going through the disruption and cost of building an addition.

TECHNICAL DETAILS

Single Mast Stacker Cranes:

1

Warehouse Management System:

EasyWMS, Galileo

Space for automated storage:

6,815 sq.ft.

Pallets per bay:

3/4

Number of modules lengthwise:

31

Height: 4 levels Extraction System:

6 (3+3) telescopic fork

Number of pallets moved per day

244

Total space of warehouse:

96,875 sq. ft.

Number of Aisles:

1

Width of Aisles:

9.19 ft.

www.interlakemecalux.com•

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record R Microlan

The growth of the business required them

The exit operation is even easier: when an

to have a better organizational system to

WCS, EasyWMS generates an extraction

locate, retrieve and move the materials

indicated table. With the installation of

needed for the boxes.

extraction order is received by the client’s pallet order for the requested pallet to the the automatic warehouse, the process has been streamlined and there is no longer a need for forklift transport.

The final phase will be the integration of

the corrugator in the production area and

The pallets are placed and extracted from

the systems with the Mecalux warehouse

takes them to the Mecalux area through a

the storage shelving by a stacker crane.

management system, EasyWMS. The soft-

system of conveyor belts. When they reach

As Sahagun explained, they needed a very

ware represented the final piece, allowing

the storage area, they are placed on one

specific type of stacker crane, one that

the warehouse to reach full integration and

of three intake tables. The WCS sends this

would be able to reach in 6.5 feet and

realize 100 percent functionality at the end

information so EasyWMS can register it in

lift loads weighing over 5,000 pounds,

of October.

the system, locate a space in the shelf for

all while making sure not to damage the

it, and generate an order to store the pal-

product. Mecalux was able to manufac-

Automate the Old,

let. The Mecalux automated area stores the

ture a single mast stacker crane accord-

Optimize the New

cardboard used for the boxes before being

ing to these specifications. The specially

Before Mecalux installed the automatic

printed and where they return after it is

designed crane is able to transport those

warehouse, Microlan operated using a basic

printed, waiting for the die-cast.

5,000 pounds in a very gentle and seam-

process flow. When the cardboard came out of the corrugator machine, it was piled on pallets and transported with a forklift to an open area in the warehouse, stacking the pallets on top of each other. The growth of the business required them to have a better organizational system to locate, retrieve and move the materials needed for the boxes.

The plant is now managed by the client’s warehouse control system (WCS) and it communicates with EasyWMS through a programmable logic controller (PLC) managed by the Mecalux Group’s Galileo software. Microlan’s WCS sends the information to the Mecalux PLC both for entry and exit of pallets into the warehouse. Galileo reads this information in its PLC and sends it to Easy which takes the corresponding action: entry or exit.

Mecalux also automated the flow of merchandise around the warehouse. A transfer cart picks up the piles of cardboard from

32 •interlakemecalux• NEWS

Microlan R

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The specially designed stacker crane (top) covers a four–level high area and distributes goods that are then carried through a warehouse space almost 270 feet long.

less way. The space dedicated to the auto-

able to double its storage capacity, which

mated storage is 262 feet long by 26 feet

will give them some flexibility in case of

wide and has a storage area that raises four

a breakdown in the system. “Before, we

levels high.

were able to store boxes for the production of just one day and now, with the

Microlan Scape

new warehouse, we can store materials to

Sahagun indicated that the warehouse

last us almost two days,” explained Saha-

is now more open, clean, organized and,

gun. “This is very important and it gives

most importantly, completely automated.

us more options […] we are better pro-

These changes have resulted in a more

tected.”

efficient production flow and better organization of stored items in the manufac-

With over 130 employees working toward

turing process. Sahagun said the instal-

growth and innovation, the new automated

lation of the new system went without a

warehouse system will enable and promote

hitch, the project was on time and without

the expansion of the company for years

any incidents and the company has been

to come.

www.interlakemecalux.com•

33

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Bringing It All Back Home

An Alimerka expansion resulted in a brief profit dip and the need to reshuffle company operations. With help from Mecalux, the supermarket chain maximized its network by re-consolidating it under one roof.

By Marta Jimenez-Lutter

I

n 1986, Alimerka opened its doors in the northwestern Spanish region of Asturias.

With 14 employees, the supermarket chain began its operations under the leadership of its founder Luis Noe Fernandez. Today, Alimerka ranks sixth among companies with the largest net revenue in Asturias. Its staff has grown 10 percent annually over the last 25 years and it now has nearly 5,600 employees – the largest private employer in the region – with over 185 stores, greenhouses and a center for the production and distribution of frozen dough.

34 •interlakemecalux• NEWS

Alimerka R

record

Alimerka, the sixth most profitable company in the Asturias region, an area about the size of Iowa City, Iowa, employs about 8 percent of the region and has the storage capacity to distribute to the remaining 92 percent.

Fresh and natural products have been the

The fresh bread sold at their stores comes

20 Years of Growth

main concern for the company long before

from another partner, Masas Congeladas,

For the past two decades, Alimerka

the trend toward organic produce and meats

where the dough is manufactured and

has counted on Mecalux to provide

took off. The Alimerka group manufactures

shipped frozen to the supermarkets to be

storage management solutions. With

500 of the products it sells and provides

sold freshly baked every day. The company

five logistics platforms built by the

fresh fruits and vegetables through a part-

has also been providing free range chicken

storage company in the towns of

nership with Codefrut-owned greenhouses.

and fresh meats to their customers for years.

Colloto, Benavente and the newest

www.interlakemecalux.com•

35

record R Alimerka one in Lugo de Llanera, Mecalux has

of volume and work that we were ex-

been both witness and partner to the

periencing.” It wasn’t long after that

growth of the supermarket leader.

the company’s expansion proved to be a restrictive strategy. In an effort to con-

By 2006, Alimerka identified that the

solidate store shipments, the company

company’s unprecedented growth was

expanded its network, but in so doing,

exceeding its storage space, or as Emilio

also increased the number of product

Llano, Alimerka’s director of logistics,

transfers from one satellite storage site

explains: “Limitations of space in our

to another. This process proved time

installations made us incorporate satel-

consuming, inefficient and an impair-

lite warehouses to absorb the growth

ment to additional growth.

Mecalux and Alimerka gathered all the satellite storage centers that were located in different spaces and united them under one roof.

In order to help Alimerka save time transferring shipments from one satellite station to another, Mecalux analyzed every facet of their current location, storage and distribution methods and determined that the food company would run out of storage space and room for its personnel within the year. The study was presented to Fernandez with a proposal that would reverse the decision to create satellite sites, instead bringing in a hybrid system, mixing dynamic rack with selective rack and having each piece integrated using Mecalux EasyWMS software.

Building Down, Not Out When Mecalux started planning the construction phase of the warehouse, they found that the building code of the municipality of Lugo de Llanera limited construction heights to 45 feet. This posed a problem since the elevation needed for an automatic warehouse was 69 feet 36 •interlakemecalux• NEWS

Alimerka R

record

The hybrid systems implements into the facility allowed Alimerka to condense its satellite locations and function in one space using Easy WMS software.

TECHNICAL DETAILS Pallets per day:

7,200

Warehouse:

312,153 sq. ft.

Production Plant:

53,819 sq. ft.

Stacker cranes:

4 single mast

Conveyor belts:

42

Warehouse Managment System: EasyWMS system with RFID Levels of conventional rack:

6

Levels of dynamic rack:

5

high. Having to make up the differConventional storage for dry food 5 to 6 levels of dynamic rack

ence, Mecalux created a plan to dig the necessary 23 feet below street level to be able to accommodate

Conventional storage for fruit 5 levels of

dynamic rack

the height they needed and comply with the municipality building codes. Once the plan was designed,

Frozen storage 5 levels of

dynamic rack

conferred and agreed upon by all necessary parties, the foundation excavation was underway.

Mecalux and Alimerka gathered all the satellite storage centers that were located in different spaces

plant produces 1,763 pounds of

full control over the stock, produc-

and united them under one roof. The

baked goods and 13,227 pounds of

tion and order status in real time.

logistic center was divided in four

dough per hour.

The system guides each product to their correct location according to

sections according to the different products stored: dry products, fish,

To establish a system of synergy

their nature. In this way, the opera-

meats and fruits and vegetables.

between all of the new sections,

tion of the warehouse was faster, be-

Mecalux installed a radio frequency

ing able to handle more than 7,200

In a lot over 1 million square feet,

device connected directly to its Easy-

pallets a day with a traffic flow of

the company began construction of

WMS software with a pick to voice

250 vehicles. By synchronizing the

a 312,153-square-foot warehouse

system allowing the hands free ma-

reception time, expedition time and

with a 53,819-square-foot annex

nipulation of the orders. The installa-

supply chain, the company was able

for the production and distribution

tion of this warehouse management

to lower its operating costs and in-

of frozen dough. The frozen dough

system enabled Alimerka to have

crease its efficiency. www.interlakemecalux.com•

37

record R Alimerka

With Alimerka’s New

picking areas where the workers per-

improved organizational flow and

form the picking operations requested

logistics tasks.” He also highlighted

by the EasyWMS system. The other

Alimerka’s ability to serve its clients

clients receive all

stacker crane is dedicated to move

more efficiently as the best part of the

half pallets and take them to the pick-

new warehouse.

their products with

ing area. There are also 42 conveyor

guaranteed freshness.

belts that allow the distribution and

Llano is proud to point out that with

transportation of products according

Alimerka’s new state-of-the-art cold

to the demand.

storage system and a fleet of refrig-

cold storage system,

erated trucks, its clients are sure to Armed with its EasyWMS system, Me-

The different sections of the ware-

receive all their products with guaran-

calux installed four single-mast stack-

house were completed in two phases:

teed freshness.

er cranes that move along the aisles

the frozen dough and frozen food sec-

and perform functions of entry and

tion was completed in 2010; every-

Alimerka’s warehouse structure was

exit of the merchandise for full pallets,

thing else was completed in 2009.

designed to assume important growth in years to come, so the supermarket

half pallets or individual box preparation. Three of these stacker cranes

Llano listed the advantages of the

stalwart is now able to grow its busi-

take the merchandise to carton flow

new warehouse as having “vastly

ness without expanding its space.

Mesh zone enclosers protect against the possibility of loose products, pallets or materials shed by the action of machines.

38 •interlakemecalux• NEWS

t h e m a ny faces of

ALAN

Join us. Support humanitarian relief.

A corporate executive making an online donation. A truck driver delivering critical supplies. A volunteer offering a bottle of water to a thirsty child. These are just some of the faces of the American Logistics Aid Network — ALAN. Our goal is to bring supply chain professionals together — helping others in need, finding solutions in times of crisis. We provide a central point of contact during natural disasters and an effective process for distributing donations... putting resources in the hands of those who need them as efficiently as possible.

Our website provides a convenient portal to facilitate donations. Whether you can provide logistics expertise, supplies, vehicles to haul them, or local warehouse space to store them, we can match your resources with regional needs.

Become one of the many faces of ALAN. As a non-profit organization, we depend on people like you to continue our good work.

We need your help — with product or service donations, the gift of time or talent, or financial support. Sponsorship opportunities are available at a variety of levels.

Learn more at www.ALANaid.org.

www.ALANaid.org

record R Amagosa

Complex Flexibility Logistics distribution company Amagosa expanded its warehouse operations without expanding its floor space.

by Marta Jimenez-Lutter

C

reated in the 1980s, Amagosa Distri-

Like many small family companies, Ama-

bution and Logistics is a family-run

gosa’s business took a great amount of

company located in Badajoz, in the South

hard work, yielding only minor benefits at

of Spain. The company takes its name from

the outset. During the late ‘80s and early

the founder’s wife Ana Maria Gomez San-

‘90s, the company was earning around

chez (A-Ma-Go-Sa), but is led today by

$417,000 in revenue. The flashpoint for

the founder’s son, Alfonso Lozano Gomez.

change came once they were assigned as

What started as a small logistics opera-

official area distributors for Coca-Cola

tion, distributing some wine and a couple

and Heineken in 2000. The hard work

of soft drink brands, grew over 25 years

continued and their profits increased.

into a major distribution business that not

Nowadays they have an average profit of

only serves other distributors, but marquee

$16.5 million per year.

clients like Coca-Cola and Heineken.

40 •interlakemecalux• NEWS

Amagosa R

record

Amagosa sped up the

its EasyWMS software. Amagosa targeted

responsible for overseeing automated

installation process and

a parking lot adjacent to the existing plant,

installations for Mecalux in Madrid, sug-

put in the second stacker

for the construction of the new warehouse.

gested that they put in place the structure needed for a second stacker crane at the

crane months in advance, partially so that it could

Construction of the new facility began near

same time as the rest of the new instal-

rent out space and ser-

the end of 2010 and continued through

lation, “When Mr. Lozano approached us

vices to other companies.

June 2011, a process that might have

with the idea for a second stacker crane

taken longer had there not been a built-in

down the line,” Saavedra said. “I had to

flexibility to the construction plan. Mecalux

encourage him to do the preliminary in-

As the company grew, it had to adapt its

cleanly added elements to the original in-

stallation with the other stacker crane. It

installations to accommodate expansion.

stallation plans as the project developed;

would be much more cost efficient this

By 2009, Amagosa had run out of space

the biggest of which came when Amagosa

way and less disruptive for their regular

and needed to reorganize their logistics op-

decided to install two stacker cranes in-

warehouse operations.”

eration. The company’s main goals were to

stead of one. Amagosa would install the

organize products efficiently and eliminate

first stacker crane immediately and the

This proved to be a beneficial idea. The time-

human error as much as possible. Amagosa

other one a year later. Miguel Saavedra,

frame for the second stacker crane’s installa-

looked to Mecalux for direction on how to improve its newest management challenges. Mecalux proposed to change the old rack units for a new automated warehouse, equipped with a stacker crane, two Clasimat units and inventory managed by

The company’s main goals were to organize products efficiently and eliminate human error as much as possible. www.interlakemecalux.com•

41

record R Amagosa

“We have achieved great storage capacity and we want to try and make our warehouse a logistic center for other companies.” ~Lozano Gomez

The Mecalux Group’s Clasimat VLMs easily integrated into Amagosa’s more traditional upright aesthetic.

42 •interlakemecalux• NEWS

Amagosa R

record

be helpful during the

companies,” he said, explaining that, “we have

busy time of the sum-

a lot of room left now that we’ve automated

mer months, when the

the storage and can help out other compa-

machines have to work

nies that need an efficient way to manage

non-stop to fulfill all the

their inventory.”

picking orders. On the other hand, there was a

Whether it be manual, automatic or Clasimat,

unique opportunity to

only one type of SKU is stored; the products

utilize their state-of-

in the Clasimat are not the same as the ones

the-art facility to per-

in the automatic or the manual. Lozano Go-

form the logistics for

mez explained that there are 700-800 SKUs

other companies. This

received, stored and distributed in the ware-

would entail renting

house. Some products are received in pallets

out both space and

and distributed in boxes; a few others are

tion changed when Amagosa quantified the

logistics services to other businesses for them

distributed in pallets as well. Some products,

benefits of its first stacker crane. Amagosa,

to store their products in the new automatic

however, are received and shipped in small

impressed by the immediate rise in efficiency,

warehouse, using the second stacker crane and

quantities; these SKUs are stored in Clasimat.

decided to forgo the initial plan to install the

the matching area of the new facility. Lozano

Lozano explained the reasoning for this, “We

second crane in June 2012, opting instead to

Gomez said that he saw a business opportunity

use the Clasimat units for products with low

install the second stacker crane several months

for growth in their new installation. “We have

rotation that are received in small quantities.

ahead of schedule.The reasoning behind it was two-

achieved great storage capacity and we want to

A 12-year-old Chivas Regal is not ordered or

fold: on one hand the second stacker crane would

make our warehouse a logistic center for other

stored in whole pallets; our clients order one

www.interlakemecalux.com•

43

record R Amagosa

Top 10 advantages of Amagosa’s new warehouse: 1.

Efficient use of space and increased storage capacity

6.

Fast preparation and shipment of loads

2.

Maximum access to stored products

7.

System reliability

3.

Precise and constant inventory control

8.

Practically non-existent maintenance costs

4.

High availability and productivity

9.

Reduced operations and labor cost.

5.

Ability to track loads from beginning to end of storage cycle

10.

Minimum impact on the environment.

or two bottles at a time. This storage

that the order is ready and frees the dock.

house, which allows for 15 trucks to be

system saves unnecessary movements of

The merchandise is extracted depending

loaded at the same time.

stacker cranes.”

on its ability to be piled up; the heavier merchandise comes out first and goes in

With the automation of the facility, Amagosa

The new warehouse system is complete-

the bottom, with the lightest loads going

was able to compress 2,000 m2 (21,527

ly automated. The product is received

on top.

square feet) of storage into an efficient auto-

in complete pallets and stored in the

matic system, occupying only 700 m2 (7,534

automatic rack. When the orders are is-

In total, a distribution center was in-

square feet). So, while the new system occupies

sued by the client, the EasyWMS system

stalled with eight storage levels, capacity

less space, the automation allows the company

creates a list for picking. Usually the cli-

for three pallets per storage bay and 25

to handle more pallets more efficiently.

ents order boxes of cola or beer, not pal-

modules aligned lengthwise. The new sys-

lets, so the requested amount of boxes

tem would allow for storage and manage-

With a fully integrated automated space

is extracted from the pallets and these

ment of 2,400 pallets with a double-deep

and a new business venture providing lo-

are then returned to their place in the

load manipulation system. Fifteen picking

gistics to other companies, Amagosa is

automatic shelves. In the Clasimat and

stations were installed at the end of the

equipped to face the next 30 years of de-

manual warehouse, the same operative

aisles in the automatic part of the ware-

velopment and expansion.

system is in place for the SKUs stored.

Amagosa’s Newfound Efficiency In the dock area, pick-to-light devices have been mounted in each bay. This system of display devices are connected to the EasyWMS management software.

.319 pallets

The extraction orders are sent from the WMS to the displays, so the operator

.079 pallets

knows at all times the quantity of units

per sq. ft.

per sq. ft.

to be extracted and the position where they are located. Once the job is fin-

Before Mecalux: 21,527 sq. ft. was used to

After Mecalux: Only 7,534 sq. ft. was used to store

ished, the operator must press a button

store the system allowing Amagosa to produce

the new system, yet Amagosa still produced 700

on the side of the display to validate

1,700 pallets per day.

more pallets per day than they had previously.

the order or correct the stock if there is not enough material. This also indicates

44 •interlakemecalux• NEWS

Amagosa R

record

By automating part of Amagosa’s storage facility with narrow–aisle stacker cranes, the company was able to efficiently store and turnover more goods using less floor space for storage.

Mecalux In Spain

Having originated in Spain, with a 2,150 square foot workshop in Barcelona in 1966, the Mecalux Group still calls Spain home. Mecalux has expanded its sales offices worldwide, in over 70 countries, “...offering advanced storage and automated warehouse solutions to some of the biggest companies around the globe.” In the 1990s, the Mecalux group opened its 161,500 square foot logistics warehouse in Barcelona and eventually made it the home of the Mecalux 5 showroom, where the company displays its progressive R&D prototypes.

The last decade has been a whirlwind for the company with its expansion into both the software and automation industries in addition to the formation of Interlake Mecalux in the United States. With plans of setting up new sales offices in untapped regions around the world, slowing is not in sight for the Mecalux Group.

www.interlakemecalux.com•

45

forefront F fuel cell technology

Fueling Sales of Fuel Cells Fuel cells have flown past most other forms of alternative energy on the wings of their value to the auto industry.

Recent trends show it’s been the materials handling industry – not automobiles – spinning the propeller.

by Adam Shafer

F

46 •interlakemecalux• NEWS

u el c ells a re lea d in g th e wa y

a b le fu tu re. I n a n ut she ll, t he

in a ltern a tiv e en erg y in n o va -

U.S. c o n su m es a q u a r t e r of t he

tio n s, th e U.S. is lea d in g th e wa y

w o rld ’s o il su p p ly d espit e con-

in p a ten ts o n fu el c ell tec h n o l-

tro llin g o n ly 3 p erc ent of t he

o g y, a n d th e la st th ree y ea rs

w o rld ’s reserv es a n d const it ut ing

h a v e p a tc h ed to g eth er a m ig h ty

o n ly 4 .6 p erc en t o f E ar t h’s popu-

b o o n o n fu el c ells in d u stry - w id e.

la tio n . With th e u p wa r d t r e nding

Am eric a is in v estin g a rela tiv ely

c o sts o f ta p p in g in to for e ign oil

la rg e a m o u n t o f m o n ey in fu el

reserv es o u tp a c ed o nly by t he

c ell resea rc h in o rd er to o ffset

p erc en ta g e o f im p o rte d oil t he

th e o il it c o n su m es a n d w ill c o n -

U.S. is p ro jec ted to consume,

tin u e c o n su m in g fo r th e fo resee-

Am eric a n in d u stries h ave st ar t e d

fuel cell technology F

forefront

Figure 1: THE THREE FUEL CELLS Powering Future Warehouses Proton Exchange Membrane (electrolyte) Cathode (+) distributes oxygen Anode (-) distributes hydrogen

Polymer Exchange Membrane Fuel Cell (PEMFC) • •

Leader in transportation applications Low Temps (140-176°F)

Tiggy Gallery!/Shutterstock

Interconnection l Fueow fl

depl o y i n g , o r d et e rm in in g h o w

in d u s try is h id d en b eh in d m a n y

to depl o y, fu el c e ll te ch n o lo g y.

o th e r

Tho u g h i t w i l l a l m o s t ce rta in ly

in d u s tri es. “ Yo u see a d va n c es

be a u t o mo b i l es t h a t e v e n tu ally

in f u e l c ell tec h n o lo g y fo r th e

bring fu el c el l s i n to th e h o m e s

a u to m o tiv e

of a vera ge c on sum e rs, it h as s o

s ays, “ an d it en d s u p o n th e

far p r o ven t o b e th e wa re h o u s -

f ro n t p a g e. Bu t I b eliev e m a teri-

i ng a n d m a nu fa c tu rin g in d u s -

a ls h a n d lin g is lea d in g th e wa y

tri es b r i n g i ng fu e l ce lls to th e auto mo t i ve i n d u st ry.

m o re

c o n su m er- d riv en

in d u stry,”

J en sen

Solid Oxide Fuel Cell (SOFC) •

Capable of providing electricity for factories/towns

•

Hot Temps (700-1000°C) make it better to be continually used

w ith f u el c ells fo r th e a u to m o -

•

Longest operating life

tiv e in d ustry.” J en sen m a y h a v e

•

The steam produced by the fuel cell can be channeled into turbines to generate more electricity (CHP)

a p o in t. N o t o n ly d id Cro w n Eri c Jensen , t he d ire cto r o f re -

u n v e il a w h o p p in g 2 0 p ro d u c t

sea r c h

a nd

for

m o d e ls th a t a re a b le to ru n o n

C ro w n

E q u i pmen t,

d ev e lo p m e n t

le ad in g

f u e l ce lls, b u t m eg a c o rp o ra -

ma n u fa c t ur er o f e le ctric lif ts,

tio n s like Wa l- Ma rt, Co c a - Co la ,

sai d i n a n i nt er vi e w e arlie r th is

S ys co a n d Fed E x h a v e a lrea d y

yea r t ha t t he m a t e ria l h a n d lin g

in v e s te d a sig n ific a n t a m o u n t

a

Air electrode Electrolyte Air flow

Though it will almost certainly be automobiles that eventually bring fuel cells into the homes of average consumers, it has so far proven to be the warehousing and manufacturing industries bringing

Molten Carbonate Fuel Cell (MCFC) •

Best for large, stationary power generators

•

100-104°C cooler than SOFC– therefore requiring cheaper, less exotic building materials

•

Also utilizes steam, but likely produces 14-40% less than SOFC

fuel cells to the automotive industry. www.interlakemecalux.com•

47

forefront F fuel cell technology

43% (996 fuel cell patents registered)**

Worldwide Fuel Cell Patents

47% (520 fuel cell patents)*

JAPAN 31%

of Rest World the

GERMANY 7%

U.S.A

of Rest World the

U.S.A

KOREA 5% *1,100 total fuel cell patents **2,316 total fuel cell patents registered SOURCE: U.S. Department of Energy

of fu n d s to in co rp o rate f u e l

li ft tru c ks a m o re v ia b le o u tlet

as energy storage devices (like bat-

c el l l i ft t ru ck s in to th e ir f le e ts.

f or fu el c ell tec h n o lo g y is th a t

teries). Similar to batteries, fuel cells

In No r t h A m e rica , th e a p p rox i-

li fts a re sm a ller, c a rry less d a ily

break down two dissimilar metals by

ma t e ra t i o o f f u e l ce ll p o w e re d

ri sk a n d a re n o t p ro d u c ed in th e

mingling them into an electricity con-

l i ft t r uc ks to f u e l ce ll p o w e re d

s a m e q u a n tities a s a u to m o b iles.

ducting liquid. Unlike batteries, which

cars is about 5:1 and none of

F u el c ell tru c ks h a v e a q u ic ker

contain limited electricity-creating

t hose c ars are ava ila b le f o r

turn a ro u n d in d ev elo p m en t a n d

chemicals within each unit, fuel cells

c o mm er c i a l s ale. L if t tru ck s

e a sier lev era g e to w ed g e itself

generate their own chemicals and get

h a ve t h e a d d e d b e n e f it o f n o t

into th e b a ttery m a rket. Th e re-

repurposed through the cell to create

n egot i a t i n g th e s am e trick y

s u lt h a s b een a q u ic kly ex p a n d -

an infinite amount of energy. The heat

fu el i ng s tru ctu re au to m o b ile s

ing fu el c ell lift m a rket b ein g

and water fuel cell by-product is bro-

d o; w i t h f u e l ce ll lif t tru ck s,

clo sely sc ru tin iz ed b y th e a u to -

ken down into hydrogen and oxygen

u ser s esse n tially in h e rit a g as

mo b ile a n d a v ia tio n in d u stries.

and converted into more energy.

st a t i o n w ith th e p u rch as e o f

A n d w h a t th ey ’re sc ru tin iz in g a re

ever y t r u ck . “ Th e o p e rato r o f

ho w ex a c tly fu el c ells w o rk a n d

Among the various fuel cell types,

t he fu el c e ll als o o w n s th e lif t

ho w th ey c a n b e o p tim iz ed fo r

three have emerged as the best

t r u c k a nd th e f u e l s u p p ly,”

the m a ss m a rket.

suited for the material handling in-

Jensen sa ys. “ I n th e au to in -

dustry: Polymer Oxide (PEMFC), Solid

d u st r y, t h e y b u ild th e ca r an d

Cell Division

Oxide (SOFC) and Molten-Carbonate

h op e t h e re ’s a f u e l s u p p ly

Fuel cells are energy conversion de-

(MCFC) fuel cells (See: Fig.1). PEM-

a va i l a bl e.” Pa rt o f w h a t m a ke s

vices (like standard engines) disguised

FCs are being developed by the U.S.

While PEMFC systems have become lighter and smaller as improvements are made, they are still too large and heavy for use in standard vehicles. Warehouses, however, can spare the space.

48 •interlakemecalux• NEWS

fuel cell technology F

forefront

Michigan 30% (130 patents) New York 5% (24 patents) Connecticut 5% (22 patents)

The U.S. holds 47% of the world’s 1,000 fuel cell patents registered

Thirty of the 50 U.S. states, own at least one fuel cell

between 2002-2012

patent. Some states like Oregon, Ohio and Florida have made fast leaps in fuel cell development in the last decade. The map at left illustrates the country’s patent-leaders.

California 13% (51 patents)

Department of Energy as the likeliest candidate for transportation applications (both lift truck-type warehouse machinery as well as long distance transportation trucks). SOFC and MCFC fuel cells work best in stationary power generation plants on a scale most similar to the one cur-

Storage space may be setting the pace in the race among fuel cell automobiles, fuel cell lift trucks and fuel cell storage spaces, but it is a minor issue compared to institutionalized support of the technology as a whole.

rently being overseen by the gas turbine in your city’s power plant. These latter cells present a unique oppor-

Successfully hooking a new technol-

high temps), still malfunction in low-

tunity for stationary power suppliers

ogy into the market is harder than

humidity and sub-zero temperatures

like warehouses to develop fuel cell

a teen convincing an overprotective

(hydrated membranes freeze in cold

utilization in ways moving objects

father he’ll be gentlemanly during a

storage units), and still struggle with

have yet to achieve: primarily within

date with his daughter. The difficulty

the ever-present problem with infra-

storage spaces.

lies not only in giving an underdevel-

structure. It’s one thing to want your

oped technology a voice in a normally

warehouse operating on fuel cells, it’s

FC in the Field

bearish market, but in also convincing

quite another to spearhead the move-

In theory, it would be difficult to make

the market to invest in the technol-

ment.

the case for choosing limited energy

ogy anyway. To date, fuel cells are still

sources over energy sources that would

expensive (approximately four times

Indeed, it takes a great deal of capital

never need replacing. Efficiencies with

more expensive than a diesel genera-

investment (and faith) before most of

facility personnel, lower electric costs,

tor’s per kilowatt price tag and more

the material handling industry will see

smaller total energy consumption, and

than 10 times that of a natural gas

increased productivity from fuel cells.

almost every bill warehouse owners

turbine’s price). Fuel cells are also

It is important to note, however, the

pay would decrease upon the adoption

still less durable than desired (mem-

many early adopters whom have seen

of fuel cell technology.

branes can corrode or degenerate at

efficiencies rise as operating costs

www.interlakemecalux.com•

49

forefront F fuel cell technology

What does it cost to keep a battery class forklift running?

A s l i f t t r u c k s a r e o n e o f t h e q u i c ke st e m ergi ng m a rkets f o r f uel c el l a ppl i c a ti o n, l ets ex a m i ne t h e c o st o f N OT a d a p t i n g y o u r fl e e t .

L a bo r c o sts per swa p: $8.43 L a bo r c o sts f o r a y ea r’s wo rth o f swa ps: $9,230.85

A v e ra g e ba ttery c o st p e r y e a r: $ 9 , 9 0 0 R e q u ir e s 3 b a t t e r y s wa p s p e r d a y o r 1, 095 s wa p s p e r y e a r.

Yea rl y ba ttery m a i ntena nc e per y ea r: $ 8 1 0

C o s t o f e le c t r i c it y p e r y e a r : $2, 340

“ Ou r dem a n d f o r l i f e c y c l e i s g r ea t er t ha n th e a u to i n d u s t r y.

O ur m a c h i n e s w i l l e a s i l y c l o c k 2 0 ,0 0 0 h o u rs b e f o re th e y ’r e re t ire d. A c a r w i l l ty p i c a l l y g o 5 - 6 0 0 0 h o u rs.”

-Eric Jensen, Director of new cell technology research and development for Crown Equipment Corp.

R equi red y ea rl y m a i ntena nc e o f three ba tteri es* : $ 4 9 5

A forklift truck operating 24 hours a day, 365 days a year.

*As only 1/20 of purchased batteries need replacing from year-to-year, realistically, this number will realistically be either $3,300 or $0.

Ann u al m ai n t e n an c e c o s t o f a t rad i t i o n al b at t e r y c l as s f o r k l i f t : $27, 276 .4 1

F uel c el l po wered v ehi c l es reduc e m a i ntena nc e c o sts to approx i m a tel y : $ 7 , 6 0 0 (6 6 %).

• 1 . 5 x l o wer m a i ntena nc e c o sts • 8 x l o wer ref uel i ng/ rec ha rgi ng l a bo r c o sts • 2 x l o wer net va l ue o f to ta l sy stem c o st

SOURCE: Robert Leonberger - Barloworld Handling, Gagan Singh - Oorja Protonics, Argonne National Laboratories, U.S. Department of Energy.

fall. Martin Brower, the world’s larg-

refueling, resulting in less fuel needed

est restaurant distributor, invested

per kilowatt hour of electricity. The re-

in 15 methanol-powered fuel cells

sult is the potential to effectively lower

in one of its largest California fa-

the total logistical and operational cost

cilities. With relative immediacy, the

of the average warehouse. Foodservice

company saw its distribution costs

distributor US. Foods invested in 40 of

decrease after the initial investment.

the same methanol fuel cells after a month-long trial period in which the

Direct Methanol fuel cell systems

distributor increased productivity from

(DMFC) quietly generate efficient

not having to service and maintain

electricity without any toxic emis-

battery-powered lift trucks multiple

sions generated. Highly efficient

times a day. In 2009, Nissan’s Smyrna,

DMFC power plants require minimal

Tenn., plant replaced battery pow-

50 •interlakemecalux• NEWS

fuel cell technology F

forefront

ered forklifts with fuel cell lifts and shaved off 35 daily wasted personnel hours caused by battery maintenance and 1,500 daily kilowatt hours sucked up by the battery chargers.

Fuel Gauge A single fuel cell produces about 0.7 volts of electricity. Considering it would take at least 58 fuel cells to generate the same wattage as the least incandescent light bulb in your home, it’s clear why fuel cells must be combined into stacks and why those stacks eat into the space necessary to store the power supply automobiles. A dozen horses may carry a carriage farther and faster than one horse, but the barn must be a great deal bigger, too. Bipolar plates are used to connect one fuel cell to another and are subjected to both oxidizing and reducing conditions and potentials. This suggests that fuel cell technology in warehouses may

zip ahead of similar vehicle technol-

Storage space may be setting the

ogy because space is less of a concern

pace in the race between fuel cell au-

in the former. While PEMFC systems

tomobiles, fuel cell lift trucks and fuel

have become lighter and smaller as

cell storage spaces, but it is a minor

improvements are made, they are still

issue compared to institutionalized

too large and heavy for use in stan-

support of the technology as a whole.

dard vehicles, Warehouses, however,

Technology cannot weave itself into

can spare the space.

the industrial fabric without support

Many organizations are working to develop consistent, harmonized codes and standards for fuel cells and hydrogen, but they’re not here … yet.

Gualtiero Boffi/Shutterstock

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forefront F fuel cell technology transition from forklifts to cars

Realistically, full adoption of fuel cells into warehouses or storage spaces isn’t practical – and in some cases, impos-

Fuel Cells

sible. The legislation on fuel cell powered products is almost non-existent, hydrogen is a widely underdeveloped resource for mass consumptive handling and most of the businesses that can afford a large percentage of fuel cell adoption still don’t have organized plans detailing how to implement and maintain it successfully. Many organizations are working to develop consis-

Industrial

Automotive

tent, harmonized codes and standards for fuel cells and hydrogen, but they’re not here … yet. That’s the point; an

Hydrogen Refueling Systems

arrival of fuel cells, although not imminent, is pending. Pioneers are amassing; the shift has taken hold. According to a report filed by the U.S. Department of Energy in 2010, “The National Fire Protection Association published the 2010 code for compressed gases and cryogenic fluid […] the DOE Hydrogen Program supported workshops that reached more than 300 code officials and published several online courses.”

Fuel cells are expensive and offer little incentive for the small markets to in-

Nissan’s Smyrna,

from government and educational insti-

vest. And herein lies the problem: in

Tenn., plant replaced

tutions. Such recognition would serve

order for costs to go down to a level

not only as a hat tip to investors that

in which small companies can afford to

battery powered

fuel cells are a good bet, but also as

invest, more companies need to adopt

the pathway to lowering fuel cell pro-

the technology. Lowered costs, how-

forklifts with fuel

duction costs. Bob Simon, director of

ever, aren’t likely without more early

cell lifts and shaved

process solutions for GENCO ATC, one

adopters working out the kinks. Never-

of America’s largest third-party logistics

theless, the solutions are nearby; close

companies, said in an April magazine

enough that warehouse owners and

interview that “without programs and

manufacturers should already be taking

personnel hours

incentives, it will be hard to overcome

notice, crunching numbers and prepar-

some of the reservations in the industry.

ing for alternative fuel sources to fuel

caused by battery

Customers are willing to be leaders, but

alternative operation methods sooner

they don’t want to be pioneers.”

or later.

off 35 daily wasted

maintenance.

52 •interlakemecalux• NEWS

forefront F 3-D printing

The Dueling Promise of 3-D Printing Additive manufacturing is quietly looking to break into the material handling industry, leaving those inside it to decide what to do next.

By Adam Shafer

G

enerations of warehouse owners

radio-like transition into full personaliza-

have dealt with faulty machin-

tion. Those inside the material handling

ery by identifying the malfunctioning

industry have thus far not felt the tug

piece, contacting its manufacturer to

of urgency from additive manufactur-

send them a replacement, then wait-

ing (AM). All signs point to a future in

ing while that piece (and many other

which such manufacturing will play a

identical pieces) ships to another closer

significantly larger part in the industry’s

warehouse. From there, it is delivered in-

outlook. Until that point, 10-15 years

dividually back to the warehouse owner.

from now, it’s up to warehouse owners,

Skip ahead a decade or two from now

logistics businesses and manufacturers

and the manufacturing landscape will al-

to decide how they want to proceed.

most certainly not function this way. It’s

54 •interlakemecalux• NEWS

a small reality now, as we still live in a

By the mid-1980s – in lock step with

mass production-led world, but it won’t

the development of personal computers

be long before manufacturing enters a

and industrial lasers – rapid prototyping

3-D printing F

forefront

facturing believe it will be deployed in tandem with mass production and used to build geometrically complex, personalized, multi-material pieces on a significantly smaller scale. Already AM has a market presence as corporations like Siemens and Boeing use the technologies for the manufacture or laser sintered hearing aid shells, molds for clear braces and replacement parts for F-18 jets. It is a limited list, but like large paws on a puppy, it’s a harbinger for how big this beast can get. AM produces mostly prototypes or add-on parts, but it is only a matter of time before the process will be able to produce the entire part.

The trajectory of 3-D printing suggests that the manufacturing process will eventually create replacement parts for weapon systems, marine products and land and air vehicles. From there, not only will new products be made that were previously thought to be impractical because of risk or manufacturability, but also new methods of producVladimir Nikitin/Shutterstock

tion and dissemination will be made available, too. Many companies will

revolutionized manufacturing despite

then use liquid binding, laser sintering

discover that additive manufacturing

never having produced anything custom-

or photopolymers to fuse the filament

can serve as a strategic bridge between

ers would ever see.

layer-by-layer into a software-de-

a finished design and production tool-

signed three-dimensional object (fig. 1).

ing, allowing them to deliver products

The quick and dirty three-dimensional

to customers quicker than before. Until

plastic facsimiles of larger, more intri-

Trajectory

the cost-per-unit – and in many cases,

cate products served only as disposable

If the concept is simple, the ramifica-

the speed with which these pieces are

models; It was a tactile artist’s render-

tions across multiple industries are

manufactured – can compete regularly

ing. If the blitzkrieg of additive manu-

not. Additive manufacturing is, by most

with mass production, there is little

facturing does end up hitting the indus-

estimates, at least a decade or two

risk of rapid manufacturing eclipsing

try, the result will not be meek facsimiles

away from rebooting the industry com-

traditional methods. Still, discounting

of the real thing, but of the products

pletely – which is either an optimistic

the new development because custom-

themselves. The concept of 3-D printing

look or a pessimistic one depending

ers cannot yet buy it at Wal-Mart is like

is simple: engineer building materials

on what side of the technology you’re

ignoring the tornado until it gets closer

down to their finest powder-like state,

on. Those bullish on additive manu-

to the house.

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55

forefront F 3-D printing

An example of the software input necessary for advanced additive manufacturing.

Kinko’s was making copies and print-

Terry Wohlers, whose research firm

ing pages on the University of South-

specializes in AM growth, predicts that

ern California campus 25 years before

30 percent of all items printed in three

it became the leading retail copier,

dimensions will be used as final prod-

merged with FedEx, and changed

ucts by 2020 – quadruple the percent-

business

capabilities

age produced in 2010. By the time to-

forever. Personal computers existed

presentation

day’s newborns reach fifth grade, 3-D

in the 1940s but weren’t common in

printing will be a $5.2 billion-per-year

the average home until 1982 and then

technology. Industry leaders like John

symposium of experts in 2008, Braun

weren’t the backbone of commerce

Braun of Alchemy Models Incorporated

called to mind the construction of a

until a generation after that. In these

believe the eventual endpoint for addi-

space station on the moon using the

cases, the businesses willing to assimi-

tive manufacturing will involve build-

surface’s dust particles sintered to-

late these empowering technologies

ing with natural materials that have

gether. For the cost of a manned flight

thrived. Those that kept them at arms

thus far been unusable. As part of a

to the moon, a 3-D printer and some

length did not.

response to a presentation given to a

snacks, Braun posits that manufacturing could begin without the hefty cost of transporting building materials. The

After each layer, the piston below the build chamber lowers the

reality of such an endeavor remains

powder bed, preparing for the next layer.

largely in the imagination of a distinct minority, but scaling the idea down to

The cycle continues until the model is complete.

a more regional level in the next couple decades will raise fewer eyebrows.

When finished, the model is suspended in powder to cure. At

Imagine rebuilding in impoverished

the end of curing time, the machine automatically vacuums most

nations like Haiti or Rwanda if additive

of the powder from around the model and recycles it for use in

manufacturing could transform sand

subsequent builds.

and dust into buildable filaments like they’ve begun doing with glass, plastics and certain metals. Now imagine

56 •interlakemecalux• NEWS

3-D printing F

the adaptation construction, storage and transportation companies would have to go through if their shipping materials were already on-site?

The most historically successful way to proceed at the precipice of shifting trends for manufacturers, freight

forefront

“By the time today’s newborns reach fifth grade, 3-D printing will be a $5.2 billion-per-year technology.

”

~Terry Wohlers

companies and storage providers has

packaged and shipped globally, but

than a century will ultimately make 3D

been to absorb it into their business

differences between shipping boxes of

printing a known commodity around

model or plan to compete beside

metal filament and billets of raw mate-

the world. That development is merely

it. The question for freight compa-

rial are as evident as the differences

a whisper now, but there is a growing

nies, who primarily handle each step

between a quart of milk and the cow it

crescendo of certainty that includes

within the supply chain, are what to

came from.

the ability to put the tools in immediate proximity to the customer instead

do when raw materials and polished parts are no longer transported, but

Quality Goes Up, Cost Goes Down

of distant manufacturing facilities. Also

downloaded. What will be held inside

Accessibility and personalization of

included is the belief that AM develop-

storage warehouses when mass pro-

products have been the two most

ment would increase fuel and carbon

duction is no longer necessary? And,

highly leveraged attributes of addi-

emission efficiency due to lighter parts

what do manufacturers make if the

tive manufacturing in the technology’s

and create a more efficient use of raw

consumers make their own products?

early stages. Forcing mass production

materials and manufacturing processes.

The printers and the filament used for

to give a little elbow room to personal

Most machines are designed for speed

additive manufacturing would still be

manufacturing for the first time in more

and for specific part sizes. To achieve the

Fabrication powder bed CAD system reader

Laser

Object being fabricated

Powder delivery system

Fabrication floor

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forefront F 3-D printing

Subtractive Manufacturing

A Simple Mathematical Equation

+

Additive Manufacturing

Metal Sheet

= Grommet Machine

+

Grommet Sheet

Unused Material

Grommets

Unused Material

= 3D Printer

Metal Filament

Additive Manufacturing vs. Subtractive Manufacturing Additive manufacturing’s product formation also provides a threat to subtractive manufacturing. Current products, designed to be machined and molded from solid billets, use excessive material and often force a majority of the metal to be cut away in order to form the piece. No part of that cut away material can be reused until it is repurposed at a later date. 3-D printers fuse together only the material powder necessary to create the object – or about 10 percent of what it would take for a machine to manufacture the same part. Any filament powder remaining can be reused immediately.

first two, each part usually gets saddled

metal parts. The concept of building

ens the profitability of each business. For

with additional materials necessary for

an additive manufacturing machine

the next 10-20 years, the construction,

the machine to function. Without the

that can make other AM machines

manufacturing, logistics and storage in-

constraints of bulky machine parts, ad-

is in early stages of development,

dustries will all find themselves in a game

ditive manufacturing is able to design a

but could provide manufacturers and

of chicken with each other determining

lighter product with fewer redundant

storage owners huge incentives down

whether to embrace change and innova-

materials. Printers can also build 24

the line if retooling each machine re-

tion or resist both and risk being massively

hours a day while being left unat-

mains easy in the face of new growth.

behind the times. Behrokh Khoshnevis, an

tended and are capable of producing

engineering professor at the University of

smaller metal components in a mat-

The Difference Between

Southern California, remarked on the frag-

ter of hours or days as compared to

Awareness and Trust

mented nature of the construction indus-

the traditional days or weeks it usu-

The industry’s lethargic attitude toward in-

try as being affected primarily by its use of

ally takes to produce similar sized

novation investments is also what threat-

primitive machinery.

58 •interlakemecalux• NEWS

3-D printing F

forefront

“Companies face fierce competition to

speed and lower cost systems and materi-

survive because they lack economically

manufacturing back to high-wage econo-

als, it is possible 3-D printing would bring

viable alternatives, and building code

mies, especially in the interim when addi-

compliance allows little room for experi-

by the material handling industry, before

mentation or innovation in construction

their own hands.

tive manufacturing is still mostly owned private persons take manufacturing into

” ~Behrokh Khoshnevis technologies.

Just a Fad The inability to guarantee material properties for any given process is perhaps additive manufacturing’s

“The low cost and the low de-

Additive manufacturing technologies, in

biggest roadblock going forward. AM

gree

of

tools

allow

sophistication

such

theory, would allow wiggle room both

products have been refined only to the

company

economically and physically. Without the

point that they closely resemble mass-

to engage in construction activi-

need for production tooling, the flexibility

produced bolt-and-weld productions.

ties,” Khoshnevis said. ”Companies

and reconfigurability of any given system

Ultimately, however, they don’t usu-

face fierce competition to survive

means that the same machine can be

ally meet the mechanical properties

because they lack economically viable

used for the manufacturing of different

required to comply with specific struc-

alternatives,

any

and

small

of

code

components of the same piece instead

tural needs. Would you board a cross-

compliance allows little room for

of one piece per machine. This opens up

country flight on a plane constructed

experimentation

the potential for localized production, es-

of parts only closely resembling those

pecially in low volumes. With increases in

of other planes? Not likely.

or

building

innovation

in

construction technologies.”

the distance between you and a computer

Additive manufacturing is still fairly young. It took nearly 40 years for computers to become commonplace and now they are prominent in our lives.

There are 3.8 million square miles in the U.S. and 300 million existing computers. The farthest a person could get from a computer today is only 331 feet.

To put that into perspective. It’s about the distance

331 feet

1

33

How prominent?

t fee

from homeplate at Dodger Stadium to right field foul pole.

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59

forefront F 3-D printing

Gilles Lougassi/Shutterstock

Rex Brown, principal engineer for Hon-

norm until additive manufacturing or

turing, especially when considering

eywell, said in 2009 that he believes

some other innovative technology can

the limited capability those expensive

rapid manufacturing’s best usage will

compress and articulate CAD transfers

machines posses. The prices of the

fall short of competing with manu-

in the average on-site facility or busi-

machines capable of printing even

facturing processes demanding strict

ness office. The compression necessity

passable industrial objects (they range

build requirements. There is still a long

and security involved in the wireless

from $8,000 to well over $500,000)

way to go before the masses are con-

transfer of CAD drawings to database

are expensive enough to limit most

vinced of the technological capabili-

drawing machines just isn’t where it

educational facilities from adopting

ties of 3D printing. Not only will such

needs to be. Even if it were, it is less

the technology – an important step

processes require massive testing and

likely that CAD programs will become

in any technological advancement.

provability, but convenience will have

user-friendly enough for the average

There are some machines that cost

to come into play. Few would label to-

person to utilize it with the ease of a

only a couple hundred dollars, but

day’s material handling environment

personal printer, for example.

the capabilities of those machines are limited to primarily plastic molds

convenient in the larger context; massive machines in empty storage spaces

The cost of these machines is another

of small objects. Much like personal

spread out over great distances is

obstacle separating the material han-

printers, 3-D printers aren’t nearly

the norm and will continue being the

dling industry from additive manufac-

as expensive over its lifetime as the ink they use. The ink, in this case, is

By the time today’s newborns reach fifth grade, 3-D

the limited array of powder filaments.

printing will be a $5.2 billion-per-year technology.

ety of plastics are available, but until

Stainless steel, glass, silver and a varithe materials expand, additive manufacturing won’t touch mass produc-

60 •interlakemecalux• NEWS

3-D printing F

forefront

tion. It would be like asking people to

in a quicker and more assured pace.

print documents without using black

Establishing solutions and adopting

or blue ink.

additive manufacturing early will go a

Additive Manufacturing: Then & Now

long way in staving off the threat, as

1992

Speed is always an issue. Dr. Neil Hop-

would the opportunity for production

kinson heads a team from Loughbor-

companies or storage facilities to in-

ough University in the United King-

corporate additive manufacturing into

dom that has invented a method of

the maintenance of their products.

additive printing that uses infrared

Perhaps a portion of a corporation’s

absorbing filament and infrared heat-

warranty may include the necessary

ing to fuse each layer of filament to-

design software to print replacement

gether. With this process, his team is

parts, with localized technicians to

able to produce 1,000 small plastic

assist with the application. Even after

pieces (such as snowboard buckles) in

the technology is available, customers

each production run. Hopkinson also

will still want and need assistance ap-

predicts this number will increase by

plying it to their lives.

Manufacturing

Prototyping

2012

Manufacturing

10 or even 100 in the next five years.

Prototyping

Richard Hague, Hopkinson’s colleague

One Piece at a Time

at Loughborough, sees integration –

Ultimately, if manufacturing and stor-

not speed – as the technology’s ulti-

age are going to adapt to customiz-

mate challenge. “Regardless of how

able 3D printing, their rules are going

reconfigurable and flexible an additive

to have to change. If mass production

manufacturing supply chain may be,”

loses ground to AM processes, customer

Hague wrote in a 2009 white paper

service will play a larger role in mate-

on the subject, “the AM component

rial handling. Globalized commerce,

will still have to sit somewhere within

in turn, will bear ample fruit in some

a conventional business configura-

sectors and dry to dust in others. Ship-

tion.” The belief in this instance be-

ping will be replaced by downloading

ing that possessing the tools is not

and physical storage will give way to

enough, possessing the ability to use

cloud-based storage online. Businesses

them is equally important. This is the

open to adapting to these changes can

beam of hope the brightest minds of

thrive. The quicker storage facilities

the material handling industry would

adapt cloud storage options into their

do well to focus on going forward.

normal capabilities, the more attractive a turn-key service they will be able

Assuming the printers adapt to the

to offer. Such is the case with logistics

time demands a mass producing

companies; shipments of large heavy

world has made commonplace – and

quantities will always be necessary, just

in some sectors, like small furniture

not as commonplace. What will be nec-

and light clothing, it already has –

essary is the addition of smaller, more

manufacturing plants and storage

microcosmic logistical operations travel-

facilities can still offer something

ing shorter distances and offering more

these printers never will: the produc-

personalized solutions to end users. A

tion expertise and backlog of prod-

logistics company might lose some of its

uct to provide end-users their goods

necessity amid a decline in freight ship-

2032

Manufacturing

Prototyping

ments, but the opportunity to organize, transfer and stow will, in some capacity, almost certainly remain intact. No matter the technology, people still exist and those people still require materials that make their lives function. What 3-D printing offers is a change in method, not need. Businesses bogged down by the idea that their clients no longer need their services will disappear.

Eventually, additive manufacturing will find a footing within production industries. The trick for storage facility owners, manufacturers and anyone within the logistics industry will be to figure out a way to integrate 3-D printing into their business before it becomes a threat.

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61

forefront F cloud computing

The Clouds Roll in Despite the debate among warehouse owners over the merits of thirdparty software management, cloud computing remains poised to take the industry by storm.

by David Batka

62 •interlakemecalux• NEWS

W

hile cloud computing has re-

Amazon, hosts an Internet service and

ceived growing exposure in the

those parties allow customers access

last several years, its relevance to the

to it online, that access to the shared

materials handling industry has vault-

space is known as a cloud. Clouds al-

ed over other trends to become huge

low for reduced hard drive space on

on a scale comparable to the arrival

personal computers and instant access

of the World Wide Web. But, despite

to countless programs. The implemen-

the fodder, many still are confused

tation of third-party computing in the

about what cloud (or “third-party”)

material handling industry has devel-

computing actually is. When a third

oped in the form of warehouse man-

party, such as Google, MapQuest or

agement software.

cloud computing F

forefront

Cloud computing allows for reduced hard drive space on personal computers and instant access to countless programs. The implementation of third-party computing in the material handling industry has developed in the form of warehouse management software.

Outsource IT

enues. Cloud networks are also advan-

The The pros and cons of cloud comput-

tageous to those small companies who

ing are still at a unique balance. Clouds

can’t afford an IT team or those whose

offer clients lower operating costs and

IT departments are overloaded. Com-

increased availability of programs that

panies like Rack Space offer servers fea-

may have been previously too costly. By

turing Linux and Windows through the

outsourcing the program and its storage,

cloud for as little as 1.5 cents per hour.

IT costs, and the cost to store and run

With third-party computing, all actions are performed through the Internet on the host’s website and then saved to the third-party’s massive hard

the programs in-house, are drastically

Before cloud computing, if users wanted

decreased. This can be beneficial to both

access to a program or application, they

small companies and larger Fortune 500

would have to purchase it along with

ones because fixed hardware solutions

its licensing. This process became more

would be eliminated, and IT resources

complicated when that program or ap-

would be allocated towards other av-

plication was networked through an ofGoodluz/Shutterstock

drive, rather than the user’s personal computer memory. This is beneficial because the data can be accessed from any Internet compatible device like laptops, desktops, smart phones or tablets. This makes the office truly mobile, allowing colleagues – in other states or away on business – immediate access to any shared file.

Given the small memory of tablets and smart phones, cloud computing is ideal for field work when only cellular data service is available.

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63

forefront F cloud computing

Clouds offer clients lower operating costs and increased availability of programs that may have been previously too costly.

Fenton one/Shutterstock

fice or an entire company. To license

Dark Horizons

cloud remains a largely unchallenged

50 desktops loaded with Microsoft

There are also serious risks customers

sticking point. Many companies (and

Office, it would have cost a business

will need to weigh before adopting third-

cloud owners) have vague or undeter-

roughly $18,000. While the licensing

party computing into their business. The

mined policies regarding ownership. If a

cost is comparable with third-party

lack of privacy remains the biggest de-

client does not have direct access, the

computing, programs within the cloud

terrent for customers weighing the pros

argument has been made that they also

are on-demand. Businesses receive all

and cons of cloud computing. A client

do not have the rights to it either. If a

the updates and latest versions of the

no longer has direct physical access to

subscription isn’t paid, service can be

program for free because they are on a

the hardware on which their programs or

terminated. For companies that operate

subscription basis, or they can choose

data are stored. Since the programs are

their entire business through third-party

a scaled version of the application or

hosted through a third party, the connec-

computing, this could be crippling. If

software, lowering costs dramatically.

tion is thus bridged through a server. So,

cloud storage is outsourced to private

This subscription basis cuts down on

if the software or server malfunctions,

companies overseas, public domain ma-

future upgrades and IT costs because

the third party host troubleshoots the

terial may no longer be free, as some us-

an IT department doesn’t need to in-

problem rather than the client’s IT per-

ers may not subscribe to the particular

stall the new firmware updates; the

sonnel. The time delay could possibly be

company’s service – the company now

host of the program performs all trou-

significant and, in turn, cost money. The

has control of that specific information

bleshooting and upgrading.

question of data ownership within the

hosted in its storage space. Subscribers

Milestones in the Evolution of Cloud Computing

1960s Computer sc i ent i st Joh n M cC a rth y th e o rize s

1999

1982 1982 I n te rn e t P ro v id er

I P S is s tan d a rd iz ed .

S e cu rity is

c o mputi ng u sed i n a sh a r e d p u b lic m a n n e r

64 •interlakemecalux• NEWS

s tan d a rd iz ed

Sa lesfo rc e.c o m in tro d u c es fir st

1990s 1990s

G rid c o m p u tin g em erg es.

G rid c o m p u tin g em erg es

oonnlin linee wweb ebsite site aapppplic licaatio tion n.

cloud computing F

need to read the fine print before en-

forefront

How cloud computing will be used in the next five years

gaging in any form of third-party computing. Some services have written policies stating that they will use the data 18% Infrastructure Software

stored on their servers however they please. Other services will charge a fee to transfer subscriber data to another

9% Applications Development

company, the same way a bank might

and Deployment

charge an ATM user a fee for pulling money from an account that does not

8% Server

belong to that machine’s bank. A user of cloud services is likely to accumulate and use more data storage the longer they remain a subscriber. Today, to transfer 30GB of data at $10 per GB

13% Storage

may seem reasonable. But, in 10 years, when a database has grown to one

52% Business Applications

terabyte, paying $10,000 for one’s own information seems rather absurd when that data could have been permanently stored in-house for far less.

With home use, Internet service pro-

IDC Market Intelligence Firm

vider’s bandwidth caps also need to be taken into consideration. ISPs are

back, and access to the information

puting is the primary vehicle. Compa-

increasingly capping monthly data us-

might not be as easily accessible as if

nies can charge as much as a dollar for

age or slowing bandwidths when they

servers were saved to an in-house hard

every gigabyte used past one’s prede-

become exceedingly high. Having to

drive. Certain companies charge for go-

termined limit, which for heavy home

constantly stream data back and forth

ing over a set bandwidth, and these ex-

Internet users, these overages can be-

between the cloud, this cap potentially

tra charges need to be taken into con-

come quite costly, given that streaming

may be met easily. If this occurs, Inter-

sideration when deciding to use cloud

a standard definition video consumes

net connection speed could be throttled

services, especially if mobile cloud com-

roughly half a gigabyte.

2002 Am a z on Web ser vi c es l a u n c h e s

2008 2006 G o o g le lau n c h es G o o g le D oc s

2009

E u c a ly p tu s a s th e first o p en

Mi cr osoft e nt e r s cloud

so u rc e a d va n c ed w ireless serv ic e

c omput ing wit h Azur e

a p p lic a tio n p ro g ra m m in g in terfa c e fo r p riva te c lo u d s

www.interlakemecalux.com•

65

forefront F cloud computing

Cloud computing makes warehouse operations undeniably easier, but security remains an issue with many companies contemplating the cloud.

EMERGING WAREHOUSE TRENDS Small and mid-sized companies are purchasing WMS at a greater frequency than their larger counterparts, according to Chicago Consulting. This move towards investing in warehouse management software by small and mid-sized companies is believed to have been spurred by the slow resurrection of the U.S. economy. The consulting firm also noted that larger companies are likely to follow within six to 12 months.

Smaller operations outgrowing their current management system are looking to upgrade,

Information theft hangs like a

The truly frightening aspect of what Lun-

cloud over companies considering

sford and his team had done was expose

adoption of such technology and

the relative ease with which important

illustrates that no infrastructure is

information can be accessed and warped

entirely threat-proof. IBM researcher

when stored externally. The nuclear plant

and many are doing so through cloud com-

Scott Lunsford proved this when

was powered by Supervisory Control

puting with their WMS. This option lets them

he hacked his way into a nuclear

and Data Acquisition software (SCADA),

avoid the cost of IT, while still staying com-

power station, which the plant’s

which controls infrastructures through-

owners claimed was not only im-

out the U.S., such as water distribution

probable but virtually impossible.

systems, oil pipelines and even subways.

also with companies using WMS is a closer

“It turned out to be one of the

French securities team VUPEN did a simi-

scrutiny of their labor management to in-

easiest penetration tests I’d ever

lar move when they discovered a way to

crease their warehouse efficiency. Many more

done,” Lunsford told reporters. “By

exploit Google’s Chrome browser. The U.S.

the first day, we had penetrated

Federal Bureau of Engraving and Print-

the network. Within a week, we

ing’s cloud was hacked in early 2010 with

were controlling a nuclear power

programming that costs under $1,000

plant. I thought, ‘Gosh. This is a

(€733), affecting the Bureau’s four web-

big problem.’”

sites and causing them to shut down for

petitive with much larger businesses. A trend

companies are allowing operators to govern workers more for increased productivity.

With the notion of complete accessibility to data from virtually anywhere and with the spread of Internet accessibility in remote areas, there seems to be a silver lining for the future of cloud computing.

66 •interlakemecalux• NEWS

cloud computing F

several days. “I am not going to say this

forefront

byte sized

will scare users away from cloud computing,” says Thomas Krafft, director of marketing at database management solutions company, Objectivity Inc., “but it definitely brings into clear focus the is13,889 miles worth of stacked

sues surrounding security in the cloud.”

user-generated digital content.

When Amazon Web Service had an abrupt outage in April 2011, Netflix, whose service is hosted on Amazon’s Elastic Compute Cloud (EC2), weathered the storm and stayed functional.

Cleverly, their system was constructed

Stratosphere

with integrated redundancy and has its

Mesosphere

infrastructure distributed broadly and

Thermosphere

backed with components like fallback and stateless service, safeguarding the site against catastrophe. While Netflix

Exosphere

has deep pockets, companies considering implementing cloud solutions should still take a lesson here and implement their own IT security defenses by installing programs that break up data and monitor cloud traffic.

70 percent of the digital universe (880 exabytes/880 billion gigabytes) is generated by users.

Alternative Solutions

If all the world’s digital information were loaded onto 1-inch-thick, 1 terrabyte external hard

For those apprehensive about diving

drives and stacked skyward, it would extend over 13,889 miles (22,352 km).

head-first into third party computing and moving all their data out of

Imagine if our biggest cloud enterprises like Google and Facebook suddenly hit the“off” button.

house, there are still options that allow scaled universal accessibility. Software as a Service (SaaS) allows users ac-

Source: www.srh.noaa.gov; www.emc.com; www.amazon.com

cess to a specific program via the Web, but their entire system is not web-

can offer a free trial version for a pe-

manage physical hardware. You can

based. For example, a subscription to

riod of time, allowing users to see the

use it anywhere.”

a word processing program could be

added benefits of SaaS before pur-

acquired, so work can be done any-

chasing. EWON is a Belgium-based

Similarly, Interlake Mecalux offers a

where through an Internet connection.

business that connects and synchro-

subset version of its EasyWMS, Easy-

But a document like a spreadsheet,

nizes

using

WMS Autoinstall as a SaaS, which is a

for example, can be stored in-house,

the Internet. “As soon as your web

lightweight product for small and me-

still only accessible from a single

browser is up, you can use [a SaaS],”

dium warehouses managed by paper

computer or server. This form of use

Francis Vander Ghinst, the company’s

or radio frequency. This would allow

is also ideal for a company to pro-

sales manager in Brussels says. “The

multiple warehouses to have a cen-

mote their program, considering they

footprint is zero, so you don’t have to

tralized point of connectivity and data

industrial

machinery

www.interlakemecalux.com•

67

forefront F cloud computing storage, which gives the client the ability to access data from multiple warehouses, rather than simply the warehouse they are in. The increased efficiency and lowered time for logistical coordination offers unprecedented savings to warehouse management systems. This service allows a warehouse manager to know the quantity and location of a given product in another warehouse thousands of miles away, decreasing a possible glitch in communication. Further benefits of utilizing EasyWMS is the ability to scale the program to best suit individual warehouse needs without losing the option of scalable growth. SaaS offers aspects of the cloud that are very beneficial, such as on-demand access to programs or storage; though, it will not fully replace in-house storage. Rather, SaaS functions are ideal for those

them were using or considering cloud

handle their ever-growing amount of

who want to access only a specific

computing, citing the enticing prospect

information and desire to find a stream-

program from anywhere.

of reduced overhead and customizable

lined avenue to access data and applica-

storage space as the main compulsion

tions cost-effectively. Its low-cost advan-

Forecasting Clouds

for their interest in third-party comput-

tage gives organizations the agility to

In Gartner’s report, “Significant Bene-

ing. IDC estimates the cloud computing

scale their needs quickly through top-ti-

fits Realized with Supply Chain Man-

market take in $55 billion worldwide by

er infrastructures. Though, if warehouse

agement in the Cloud,” he states,

2014. Companies ranging from the re-

owners are struggling with moving their

“the advantages of cloud comput-

tail industry and the high-tech sector to

entire operation to a third-party, they

ing seem to far outweigh the nega-

manufacturing are embracing this new

could still utilize an outsourced server

tives in most consumers’ minds.”

form of communication. This shift in the

for backup purposes.

The report also concluded that out

weather towards third-party computing

of 130 companies surveyed, 124 of

has grown out of companies’ needs to

For those apprehensive about diving head-first into third party computing there are still options

It remains debatable whether third-party computing will entirely eliminate other in-house data storage. Security levels for clouds need to be tightened, dead bolted and triple-checked. With the notion

that allow scaled universal accessibility.

of complete accessibility to data from

Software as a Service (SaaS) allows users

of Internet accessibility in remote areas,

access to a specific program via the web.

future of cloud computing.

68 •interlakemecalux• NEWS

virtually anywhere and with the spread there seems to be a silver lining for the

From expansion plans through succession plans.

Opportunity at every step.

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Success is a journey of many steps. We work hand in hand to help you realize your goals in ways that can lead to more opportunities for your business. Strong relationships and a deep understanding of your business and industry help our dedicated client managers deliver relevant advice, expertise and a comprehensive range of commercial banking solutions including credit, treasury and liquidity. It’s a combination that can take businesses from up and comer to category leader. And yours from one era to the next.

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forefront F save energy and money

Smarter Warehouses Save Energy and Money Energy savings strategies used in automated storage mean lower electric bills.

by Marta Jiménez-Lutter

T

he material handling industry is find-

– it is transformed. When an automated

ing an increasing amount of technol-

machine is in motion, the kinetic energy

ogies applicable to creating a more useful,

created from this movement must go

efficient warehouse environment. Auto-

somewhere when the machine slows

matic warehouses save energy in many

down. When a stacker crane stops, its

ways; from efficient, lighter engines in the

kinetic energy is turned into heat. In a

AS/RS systems, intelligent motion calcula-

non-regenerative braking system, that

tions and regenerative power supplies to

heat dissipates and is lost. Regenera-

the simplest of all energy savings method:

tive braking – a still infant technology

turning off the lights.

only recently being absorbed by the material handling industry – recaptures

70 •interlakemecalux• NEWS

The Healing Power of

this energy and uses it to power up

Regenerative Braking

other machines within the same ware-

The principles of physics assert that

house. When an electrical motor, like

energy is neither created nor destroyed

the types propelling AS/RS, runs in a

save energy and money F

single direction, it converts electrical energy

into

mechanical

energy that can be used to perform the necessary functions of that machine (such as extending down narrow

aisles

or

reach-

forefront

The Mecalux Galileo software enables the system to organize the stacker crane’s motions.

This allows the timing of the ascent and descent, making a crane use the least amount of energy.

ing the top level of high height shelves).

Regenerative brak-

ing systems engineer the motor to operate in both a

forward and

then

motion switch-

ing to a reverse, effectively creating similar

heat to

that of the child’s prank known as a “mercy burn,” in which one person holds another’s forearm firmly in both hands, and then twists in opposite

car. What results from harnessing

the automated units would normally

each little flush of heat given off by an

destabilize the temperature in a freez-

AS/RS brake is a partially self-sustain-

er space, which would, in turn, cost

ing system that uses the machine’s

more money to restabilize. Regen-

momentum to create energy, which is

erative braking also conserves energy

then fed back into the system from an

across multiple units. Facilities with

outside power source.

more than one stacker crane use the energy generated by one machine to

Control Software, Control Energy

power the others. The energy recuper-

Regenerative braking doesn’t just

ated returns to the plant grid and it is

conserve energy in a single automat-

used to power lights, heat and cool-

ed unit either. If organized properly in

ing systems and to operate the stacker

a fully functional automated cold stor-

cranes. Control software, such as the

age warehouse, the heat given off in

Mecalux Group’s Galileo, enables the

the microwave EquivAlency

directions, creating heat friction on the arm. With AS/RS units, this forward, then backward motion allows the motor to also switch from an electricity converter to an electricity generator by redirecting the mechanical energy back into electricity.

In order for the motor to reverse rotation and generate electricity, the vehicle’s momentum must be the mechanical energy used to throw the motor in reverse.

The energy to start a stacker crane:

This is trickier in AS/RS systems than

75 kW = 107 microwaves

within motor vehicles, as the start and stop times for an AS/RS unit are extremely brief as compared to the coasting time of a car on a highway.

The energy to keep it running: 2.1 kW = 3 microwaves

Still, the energy necessary to power an AS/RS unit is much lower than a www.interlakemecalux.com•

71

forefront F save energy and money system to organize the stacker crane’s

botics innovation director for Mecalux

INSET: A single mast stacker crane lies horizontally on

motions. This times and coordinates

Spain said, “and everything that goes

the installation site, awaiting vertical alignment (below).

the ascent and descent of the crane,

down regenerates a percentage of en-

making it use the least amount of

ergy. If the expense of going up is 100

energy, and the descent of one

percent and we regenerate 60 percent

machine powers the ascent or startup

going down, it only cost us 40 percent

of another.

to go up and down.”

In a big installation with several ma-

The Mecalux Group’s software also

chines, Galileo ensures that each

sets a control system that continuously

stacker crane starts at a different time

calculates the time required for each

than the other stacker cranes. Me-

machine

calux’s Hayat installation in Turkey is

save the most amount of energy pos-

a good example of how this system

sible, the software tries to make one

works. With the warehouse’s total ele-

crane’s descent coincide with the ac-

vation near 140 feet, its stacker cranes

celeration of another, ultimately reduc-

move two pallets at the same time, so

ing consumption. Starting a machine

they carry large amounts of weight.

is the most costly expulsion of energy

The energy needed to move these

a stacker crane performs. Galileo soft-

heavy loads so high can be costly.

ware anticipates when each of the 15

Mecalux found a way to maximize the

cranes in the Hayat installation need

efficiency of the installation. “Regen-

to move, starts them individually and

eration in these circumstances is very

utilizes the power generated by one to

advantageous because what goes up

assist the next; continuing through the

must come down,” Luis Escobedo, ro-

cycle of 15 and repeating. Firing up all

72 •interlakemecalux• NEWS

to get to any position. To

save energy and money F

WORLD ENERGY CONSUMPTION BY END USER SECTOR

forefront

Smarter machines, integrative software, lighter

Residential - 14%

motors and advanced lighting are several of the ways

Commercial - 6%

Transportation - 27%

an automatic warehouse conserves energy, money and the environment while

Industrial - 53%

enhancing the productivity of storage spaces.

Source: www.srh.noaa.gov; www.emc.com; www.amazon.com

15 machines at once would almost re-

starts, it spends 75 kW, as much as

out it. There is usually an emergency

quire the warehouse to have its own

approximately 90 microwaves work-

light; though, it is rarely on. This ad-

nuclear plant.

ing at full power. Once the machine

justment alone can make the biggest

is running, it only needs 2 kW, the

impact in the client’s electric bill.

Heavy Metal

equivalent of just three microwaves

Due to the height of the Hayat instal-

working at full power.”

In the case of lighting, the intro-

lation, and the weight of the loads

duction of LED lamps for industrial

transported, the size of the crane’s

Light Saver

settings has further led to increased

engines was maximized to increase

Escobedo added that innovative en-

savings, since LEDs consume about a

their efficiency. Mecalux wanted the

gineering isn’t always necessary to

third of the energy of regular lights.

motors to be big; the bigger the mo-

conserve hefty amounts of energy in

These lamps also have a quick start,

tor the higher efficiency that can be

a warehouse. “If you want to reduce

as compared to their incandescent

achieved. They generate more energy

your energy bill, turn off the lights.”

counterparts, which can take up to

and are able to save more energy as

Darkening warehouse space is prob-

seven minutes to fully illuminate.

well, making up for the higher sticker

ably the easiest, most efficient way

price, which is usually 5 to 15 percent

to save money and energy in an au-

Smarter machines, integrative soft-

higher than regular engines

tomatic warehouse. In a convention-

ware, lighter motors and advanced

al warehouse, personnel with fork-

lighting are several of the ways an

Another way to save energy is to re-

lifts pick the pallets from the shelves,

automatic warehouses conserve en-

move weight from the engine instead

so the area needs to be illuminated.

ergy, money and the environment

of installing a larger one to the AS/

When the warehouse is 50 feet high

while enhancing the productivity

RS. Escobedo explained that reducing

and the lights are on the ceiling, very

of storage spaces. Mecalux is con-

the weight of the stacker cranes from

powerful lamps are needed to illumi-

stantly improving its software pack-

31 tons to 26, required less energy for

nate the area, roughly 700 watts per

age, motors and machinery design

the motor to start. Starting the ma-

107 square feet. In a fully automated

to meet the demands of its clients

chine uses more energy than moving

warehouse, no light is needed, since

and maximize the effectiveness of

it once it is running “When the motor

the stacker cranes can function with-

its machines.

www.interlakemecalux.com•

73

industry I fire prevention

Fire Works Matching the right storage facility with the right fire prevention system can make the difference between scorch and soot.

by Marta Jiménez-Lutter

A

well-designed, fully functioning

kler system is that the design matches

and properly installed sprinkler

the hazard. For example, plastic con-

system is the most important fire pro-

tent is the most likely storage charac-

tection a warehouse can have. Experi-

teristic to contribute to a class IV or V

ments at full scale have shown that

high-hazard commodity classification

vertically stacked combustible storage

(which denotes the most flammable

results in rapid fire growth. In fact, fire

products). The system installed must

grows three times faster in vertically

meet that classification and address

stored commodities than those stored

the particular challenges that storing

horizontally. This makes extinguishing

those products present. Below are the

warehouse fires extremely challeng-

most common systems used to pre-

ing because they spread quickly and

vent not only plastic fires but all other

have immense increases in heat re-

flammable products as well.

lease rates – or the measurement of a fire’s size and rate of growth – over a

Wet Pipe System

short period of time.

The most common and reliable fire sprinkler system is the wet pipe

The good news is that years of fight-

system. It is easily installed, main-

ing fires have produced a wide array

tained, modified and has a short

of sprinkler systems specifically de-

downtime after a fire. This system

signed to control and mitigate ware-

consists of pipes where water is

house blazes. The most important

constantly stored, so when it ac-

consideration when choosing a sprin-

tivates, the water is immediately

74 •interlakemecalux• NEWS

fire prevention I

industry

Valves for the industry’s most common fire suppression system, the wet pipe.

discharged. The disadvantage of

as with conventional fire sprinkler

this system is that it can have leaks

systems. They incorporate very large

if the pipes are damaged by im-

high-volume, high-pressure heads to

pact (from forklifts, cranes or pallet

provide the necessary protection with-

transportation), and it is not suit-

out the need for in-rack sprinklers.

able for cold storage with below freezing temperatures.

In-rack Fire Sprinkler System In-rack fire sprinkler systems are

Deluge System

specifically designed for the protec-

Deluge systems are also connected

tion of storage rack in warehouses.

to a water supply through a deluge

This system will not prevent a fire

valve that is opened by the operation

from starting; in fact, they rely on

of a smoke or heat detection system.

the heat generated by the fire to

When fire or smoke are detected, the

trigger them, but they will help

system is activated and water flows

contain the fire to a specific area

through the available sprinkler heads.

and extinguish it. This system is a somewhat more complicated

to

Early Suppression Fast Re-

implement, but it limits and re-

sponse (ESFR)

duces fire damage and loss of life.

ESFR high output, high volume

Compliance with fire safety codes

systems are located in ceiling spaces

is intended to provide a minimum

The most important consideration when choosing a sprinkler system is that the design matches the hazard.

Scott David Patterson/Shutterstock

www.interlakemecalux.com•

75

industry I fire prevention level of safety. When designing a

age environments, such as frozen

pressurized air or nitrogen instead

system, it is recommended to go

food storage facilities and unheated

of water. The disadvantages of this

with one capable of handling a

warehouses. It is a dry sprinkler so-

system include its complexity, lower

high hazard classification – be-

lution that does not rely on in-rack

design flexibility, higher costs and

cause once it’s installed, it’s very

components or anti-freeze, which

maintenance

expensive to change.

are prone to damage and difficult

to the wet pipe system. Also, with

costs

as

compared

to maintain. This system employs a

dry pipe, the fire response time is

Quell Fire Sprinkler System

“surround and drown” effect, pre-

longer, and there is a potential for

The particular needs of cold stor-

venting damage to the warehouse

pipe corrosion.

age facilities promoted the devel-

and the stored goods.

The Ecological Five

opment of systems suited for application in these environments.

Dry Pipe Fire Sprinkler System

Several

The quell fire sprinkler system was

The pipes in a dry pipe fire sup-

blazes have shown that fire defense

created specifically for cold stor-

pression system are filled with

strategies should consider the po-

catastrophic

warehouse

ADVANTAGES OF Water Sprinkler Systems Wet pipe – easy installation Deluge system – high discharge of water controls fire easily In-rack fire sprinkler – localized fire control Quell system – ideal for cold environments Dry pipe – suitable for cold environments

ADVANTAGES OF ECOLOGICAL Systems CO2 - fast, efficient, adaptable FE-13 – ideal for large room and low temperatures Heptafluoropropane – no water damage, no ozone damage Victaulic vortex – small drops with less wetting, safe for people Inegren – intact visibility for escape

Within the warehouse, allocation of certain flammable materials, such as paper products, need to be properly addressed with prompt and frequent trash removal and special handling and storage of flammable materials.

76 •interlakemecalux• NEWS

fire prevention I

tential impact on the exterior envi-

sidered. Smoke and ashes generat-

ronment. Among the environmental

ed by the fire can cause an adverse

consequences to take into consid-

reaction among the general popula-

eration, the noxious effects liquid

tion exposed to them.

industry

runoff can have on nearby streams, rivers, lakes or below-ground drink-

Some fire extinguishing systems like

ing water aquifers stands as the

the following five do not employ

most devastating. The toxic waste

water to put out fires. Foam is used

created by the contaminated water

whenever there is a possibility of a

can poison water supply for a com-

liquid fire; the distribution of a foam

munity and decimate the local flora

blanket over a flammable liquid will

and fauna. The fire plume carried on

snuff out a fire by eliminating the

by the wind to nearby residential and

fire’s oxygen supply and providing

business centers should also be con-

a cooling effect on the burning fuel.

CO2 fire suppression systems are the preferred extinguishant for a multitude

of

critical

facili-

ties. Fast, efficient and adaptable to a wide range of hazards, the

discharge

of

carbon

dioxide (a low cost clean agent) is non-damaging to property and elec-

Todd S. Holder /Shutterstock

trically non-conductive.

which lends itself to use in flood applications and in instances where

FE-13 fire suppression systems were

people are present in the space dur-

developed by DuPont as a chemical

ing discharge of the system.

refrigerant; its molecules at the flame front absorb heat from a fire

The chemical heptafluorospropane

in much the same way a sponge

is a replacement for Halon 1301,

absorbs liquids. It is an ideal ap-

which was deemed damaging to the

plication for large rooms with high

ozone layer in the ‘80s. This system

ceiling structures in low tempera-

is waterless and provides an envi-

tures, such as unheated storage

ronmentally safe, non-toxic product

warehouses. It also has low toxicity,

that requires no clean-up and can

The items stored in a warehouse are not the only components to take into consideration – equipment and supplies used within the facility are just as important.

www.interlakemecalux.com•

77

industry I fire prevention

Designating floor storage and staging areas

enough

to

suppress

combustion

approved for stored materials will make it easier

while stimulating breathing effi-

to enforce safety issues related to blocked aisles.

during discharge, so escape routes

ciency. This gas produces no ‘fog’ remain visible. The blend is stored

be used in rooms storing art or

oxygen feeding the fire. The smaller

in cylinders and produces zero ozone

history collections or any facility in

water drops mean that there is mini-

depletion, no global warming and no

which water damage from a sprin-

mal wetting, dispersing just one gal-

atmospheric lifetime. It is also ideal

kler must be avoided at all costs.

lon of water per minute per emitter

for any storage that cannot be ex-

in total flood applications, and the

posed to water.

Victaulic vortex fire suppression

nitrogen is safe to use with people

systems use both water and nitro-

in the room.

Within the warehouse, allocation of

gen homogeneously to extinguish

certain flammable materials, such

fires. The foil technology creates

Inegren is an environmentally green

as trash or aerosol cans, need to be

unique nitrogen and water sus-

three– dimensional fire suppression

properly addressed with prompt and

pension, producing droplets less

agent. It is a blend of three naturally

frequent trash removal and special

than 10 microns (0.01mm) in size,

occurring gases: 52 percent nitro-

handling and storage of flammable

a regular drop is approximately

gen, 40 percent argon and 8 percent

materials. The items stored in a

500 microns (0.5mm). This smaller

carbon dioxide. Inegren is safer than

warehouse are not the only compo-

water drop absorbs more heat,

carbon dioxide systems because it

nents to take into consideration –

while the nitrogen reduces the

reduces oxygen concentration only

equipment and supplies used within the facility are just as important.

Products like aerosol cans present particular challenges as well, espe-

THE EFFECTIVENESS OF WET PIPE SYSTEMS

cially when in contact with nitrogenbased systems. During a fire, aerosol 100% Total warehouses.

38% Warehouses with at least one form of fire extinguishing equipment.

30% Warehouses with wet pipe system.

27% Warehouses with wet pipe system that failed to operate because it was manually shut off.

cans can propel themselves across a warehouse, carrying a trail of fire behind them in what is called “rocketing,” propagating fire at great speed along their path and presenting a danger to the workers trying to evacuate.

Designating floor storage and staging areas approved for stored materials will make it easier to enforce safety issues related to blocked aisles. As with any safety system, they are only as effective as the methods of communication used to educate warehouse personnel of their existence.

78 •interlakemecalux• NEWS

industry I bolted rack

Taking the Dents out of Bolted Rack Why bolted rack is making slow, begrudging, long overdue inroads in the North American welded market.

by Adam Shafer and David Batka

80 •interlakemecalux• NEWS

F

or over 65 years, North America has

Welded products arrive in an end-us-

resisted the worldwide concept of

er’s facility assembled, and therefore

steel rack construction. Until 2001,

must be sturdier and invulnerable to

the United States was an entirely

damage. Contrarily, the stigma against

pro-weld country. A decade later, only

bolted rack has long existed that if a

a slight shift has been made to com-

product has bolts, it is only a matter of

bat the misinformation about bolted’s

time before those bolts come undone.

benefits. The tried and true method in

Neither belief is true. However slowly,

the States has always been to utilize

businesses are discovering the benefits

the welded side bracing of selective

of bolted rack. In the face of a strug-

upright columns, primarily on the per-

gling economy, the U.S. is looking for

ception that welded steel is stronger,

an alternative to the industry standard;

more reliable and cost less to install.

anything that will improve efficiency

bolted rack I

industry

The cross-bracing pattern of a bolted frame.

away with making misleading claims

in structure don’t just come down

without ever having to account for

to beam diagonals, the posts are

them. The largest difference lies in

different,” explained Linda Demke,

the rack connections; whether the

CEO at Interlake Mecalux, one of

uprights and beams are connected

the few companies manufacturing

and increase profits. The conven-

by bolts or by welds. Beam diago-

both welded and bolted product.

tional wisdom across all nations has

nals are the most visually obvious

Bolted posts were designed using

long been that if rack does what it

difference between the two styles

the metric system, while welded’s

is designed to do, customers won’t

of rack connectors. Welded strut

products were not, which is one of

care how the frame was construct-

patterns generally avoid connecting

the reasons the post sizes for bolted

ed. Reliability and affordability is

two struts on the same part of the

rack are slightly larger. “There is no

king, which leaves the customer

upright. Often with the k-bracing or

advantage or disadvantage,” Demke

to determine which is the more af-

wind-bracing of the bolted systems,

says. “They’re just different.”

fordable construction and if it does

two diagonal struts will share the

what it is designed to do?

same bolted hole in the upright. The

Assembly Differences

reason for this is simply because a

One of the oldest knocks against

Structural Differences

weld covering two different connec-

bolted connections is that a third-

The differences between the two

tions isn’t as strong as a weld cover-

party is in charge of assembling

racks are subtle enough that manu-

ing one. A bolt, however, can handle

them. The assumption being that

facturers on both sides have gotten

two connections. “The differences

a third party runs a higher risk of

www.interlakemecalux.com•

81

industry I bolted rack

Racks take abuse...repairing a bolted

a bolted rack is generally easier and

rack is generally easier and quicker

ing bolted to a welded market is all

than a welded unit.

quicker than a welded unit. “Sellabout serviceability,” Demke says, adding that in most cases, “it is easier to service a bolted frame if it’s damaged.” With a welded pallet rack, the

assembling the rack incorrectly.

ship bolted systems than welded ones

damaged piece needs to be torched

Rarely, if ever, is bolted rack mainte-

because the structure can be broken

or cut off. The loads are then removed

nance pawned off on a party not pre-

down, requiring less space on the

(which would happen with bolted

approved by the manufacturer or dis-

truck, which means more sections of

rack, too) and replaced with a repair

tributor. Many companies have trusted

bolted rack – almost twice the weight

kit often comprised of – ironically –

stocking distributors at the ready, car-

of welded – can be shipped at a single

bolted frame. And while not having to

rying its knocked down product. By

time. Then once the rack reaches its

remove beams is nice, it doesn’t add

doing this, the bolted rack manufac-

destination, its assembly requires little

to the overall efficiency of the repair

turers save on shipping costs, maxi-

more than a pair of sawhorses.

process, as most facilities disallow

mizing the containers in which the

repairs to welded rack during work

product is shipped. This gives these

Knocked Down, Drag-Out

distributors the ability to service the

Unquestionably, racks take abuse. Be-

market with whatever size installa-

ing hit with forklifts, constantly stor-

tion may be necessary, making bolted

ing and removing pallets and various

rack the ideal for smaller applications

other human errors all add to the wear

in which selective racking is to be uti-

and tear of a shelving unit, and the

lized. It’s far more cost-effective to

inevitability of repairs. But repairing

hours because it is necessary to shut

bolted Frame diagram

Horizontal bracing

Cross bracing

Frame Grade 5 bolts

Footplate

82 •interlakemecalux• NEWS

bolted rack I

down an aisle or existing area during

industry

The Advantages of Bolted

the cutting process.

Another misperception of bolted rack is that, without constant attention, the nuts will unthread from the bolt and the structure will fall. This was the false refrain singled out above all others by Greg Hajdus, a structural

Many companies have trusted stocking distributors at the ready, carrying its knocked down product. By doing this, the bolted rack manufacturers save on shipping costs.

engineer with Interlake Mecalux. “I’ve heard many times that if you have bolted frame, every once in a while

There is always the chance of a

you will have to go in and tighten the

faulty weld caused by human error.

bolts,” Hajdus says, “but that’s not

With bolted, every piece is machine

true. When you’ve got bolted frame,

manufactured and passed through strict

when it’s assembled correctly, you don’t

quality testing.

have to do anything with it. Ever.”

Servicing damaged bolted frames is made easier by not having to torch off the damaged piece.

quality testing. Additionally, the restraint provided by bolts and welds differs. Welding a brace provides it with a certain amount of end restraint.

The more end restraint, the more the carrying capacity of the rack. Reducing Even after being given time and space

the brace’s buckling length enhances

to perform the repair, the weld may

the restraint, however if a weld – of-

still be faulty. It may have been un-

ten applied by a human – is faulty, the

dercut, given too much or too little

rack’s capacity could be reduced to

heat, or a lack of added flux core; all

as little as zero, perhaps without the

of which are human errors common to

end-user realizing it. The same results

bad welds and broken rack. The prob-

would occur for a bolted rack with

lems with repairing welded rack and

faulty connections as with a welded

worrying about welder fluency don’t

rack, but the risk of it happening is so

exist with bolted selective shelving.

much lower. Bolted frames have well-

Every bolted piece is machine manu-

defined and highly controlled buckling

factured and passed through strict

length. In short, if a bolt is missing,

“When you’ve got a bolted frame, when it’s assembled correctly, you don’t have to do anything with it. Ever.

”

~Greg Hajdus

Structural Engineer

www.interlakemecalux.com•

83

industry I bolted rack

“ The quality of the welded connection is always somewhere between excellent to non-existent...you have to test it.

”

~Miguel Lopez Interlake Mecalux Sales Manager

Top: Olegusk /Shutterstock

you’ll see it. If a weld is bad, you

rack may cost more to install, but

selective shelving units bolts have ser-

probably won’t. Miguel Lopez, an area

customers save on the back end by

rated nuts, ensuring that this does not

market manager for Interlake Me-

not having to cover the costs of certi-

occur. May it be welded or bolted rack,

calux and one of the first to regularly

fied welders and on the front end by

regular warehouse maintenance is still

sell bolted rack in the United States,

saving on the shipment of the parts.

needed to ensure safety. One doesn’t

agrees. “The quality of the welded

Likewise though, if a weld breaks,

bring their car to a mechanic and ask

connection is always somewhere be-

the shelving’s structural integrity is in

for every bolt to be torqued down,

tween excellent to non-existent,” Lo-

jeopardy. Bolted units are safeguard-

so the fear of a bolted selective rack

pez says. “But you have to test it.” If

ed against such a catastrophe, even

coming apart is a moot point.

repairs are necessary, a warehouse’s

in the unlikely incident of a nut and

maintenance engineer can take care

washer coming off a bolt, the unit will

Even the type of steel – whether it

of them immediately with an adjust-

still hold because the bolt is in place.

is galvanized or not galvanized – il-

able wrench and socket set. Bolted

However, all Interlake Mecalux bolted

lustrates bolted rack’s superiority.

84 •interlakemecalux• NEWS

bolted rack I

industry

There has been a subtle shift in the market as major corporations have begun to install AS/RS systems structured around bolted rack...

Galvanized steel does not rust and therefore meets the regulatory codes for pharmaceutical and food industries. Galvanized steel however is more difficult to weld than bolted’s hole punch because the zinc coating gives off toxic fumes and weakens the coating’s integrity. Even if coated frames have been safely welded, the steel still needs a second dip to restore the coating; an unnecessary step with bolted rack. Because of these factors, many of the parts are welded together first, then coated.

Doing this creates difficulty in coating unexposed surfaces.

There has been a subtle shift in the market as major corporations like Wal-Mart, Target, CVS and Home Depot have all installed AS/RS systems structured around bolted rack – a small-but-substantial step in bringing such rack into the North American mainstream. That mainstream isn’t likely to turn its back on welded anytime soon. There will always be a market for welded. But a shared marketplace in which each customer’s budget, timeframe and storage are evaluated, is on the horizon, a vision long overdue for warehouse owners interested the best deal instead of the standard one.

www.interlakemecalux.com•

85

industry I comparative logistics

Inside the Margin of Success Your company’s logistical operations may be the last part of your supply chain, but far too few companies make it their first priority.

By Dave Batka

86 •interlakemecalux• NEWS

L

ogistics is the backbone of the sup-

Two main forms of logistics exist:

ply chain and focuses on perfor-

production and management. Produc-

mance and costs, but it can be trickier

tion logistics focuses on the processes

than walking a tightrope when deci-

within an individual business; ensur-

sions have to be made. Julius Caesar

ing the correct amount of product is

created the term “logista” to describe

being machine-produced, and that the

an individual who organizes troops

system is working efficiently. Compa-

and supplies during war time. To be

nies that produce different models of a

victorious in the battle of commerce,

product each year concern themselves

one needs to have every move of their

logistically with production, considering

business plan mapped out in advance.

when a new product line is soon to be

But, as history has shown, there is

released – they want to move the re-

no one way to win a war. Companies

maining goods from the previous batch.

within the same industry can go about

Logistics management, also known as

their logistical production in different

materials management, plans, imple-

manners, but still receive profitable

ments and controls the efficient move-

end returns.

ment and storage of goods and services.

comparative logistics I

industry

Logistics management follows a good

the main product to a single company

The New York company, on the other

from its initial purchasing in raw form

in China, while producing that prod-

hand, takes a varied approach; out-

to the time it reaches the consumers.

uct’s accessories through several dif-

sourcing the production of their main

ferent manufacturing organizations.

product to multiple overseas produc-

Comparative Logistics

These companies then ship the finished

ers as well as all of the accessories,

Electronics manufacturers based out of

products directly to the distributors and

similar to the Chicago company. Un-

Chicago and New York may produce

retailers whom, in turn, distribute to

like the Chicago company, however,

similar products and target the same

stores throughout different regions and

once the products are finished, New

audience, but their logistical manage-

sell directly to the consumer. Those re-

York’s goods are shipped to a single

ment operations are not likely to be

tailers and distributors, in this instance,

warehouse. To order either the main

similar. For instance, the Chicago manu-

are the first to have every piece of the

product or any of its accessories, con-

facturer outsources the production of

product in the same place.

sumers must visit specific locations or

logistical systems: Retail vs. Direct to customer Retail

ct

du

ro nP

Warehouse

i

Ma

ies

sor

Chicago Company

es Acc

Warehouse

Warehouse

Warehouse

Direct to customer

me

Ho ct

me

du

ro nP

Ho

ai

New York Company

M

Home

o

ess

Acc

ries

Warehouse Warehouse

Home

Hom

e

Hom

e

www.interlakemecalux.com•

87

industry I comparative logistics a single website such as Amazon. The

thus slowing production. However,

behalf, given that they do not need

website or designated vendors send

with outsourcing production over

to worry about implementing mul-

a request to the warehouse which

several different manufactures, the

tiple 3PL shippers to transport their

then ships the final product directly to

New York based electronics firm is

electronics to separate vendors and

the customer.

safeguarded against disrupting pro-

retailers; the outsourced warehouse

duction if a catastrophe should occur

would manage this aspect.

By the Chicago company keeping the

in one plant or another. Companies

production of their product central-

like Sony and Panasonic who have a

Fauxgistics

ized in one location, it decreases

significant portion of their produc-

New York’s retailers are all under

any logistical confusion and, if need

tion line centralized in one area were

the same company umbrella, which

be, allows for changes to be made

throttled and forced to shut down

gives the sales of their product more

quickly and efficiently. The opposite

part of its manufacturing when Ja-

cohesion and exclusivity, similar to

clearly applies then for the New York

pan was hit with an earthquake in

how designer clothing brands only

based electronics firm. By spreading

the spring of 2011. While the lull

offer their product in select high-end

the production of their main product

in production didn’t cripple either

stores. Though, they do risk the pos-

out over several different manufac-

corporation, smaller companies with

sibility of intellectual property theft,

turers, communication becomes cum-

this model may not have been able

such as Peerless Industries, an Illinois

bersome and convoluted, especially

to weather the storm. However, with

based company that produces flat

if any of these companies outsource

the New York company only distrib-

screen television mounts. “Knockoffs

production of their own parts to oth-

uting its product through specific

of our products started showing up

er manufacturers. Immediate chang-

stores or a single website, logistics

in markets here in our own back-

es that are needed may not happen,

is lessened on the manufacturers

yard,” stated Michael Campagna,

LOSS

Sony’s pre/post tsunami projections

Quarter earnings in 2011 were -$199 million.

Projected year end net total POST-TSUNAMI -$3.2 billion

-$3.2 billion

-$2.7 billion

-$2.4 billion

-$2.1 billion

88 •interlakemecalux• NEWS

-$1.8 billion

-$1.5 billion

-$1.2 billion

-$900 million

-$600 million

-$300 million

comparative logistics I

Peerless’ COO. “It wasn’t necessar-

gistics of running the distributors and

ily our supplier doing it—it was our

vendors day-to-day operations as the

supplier’s supplier.” Consumer elec-

New York based company does, and

tronics powerhouse, Apple, has also

with allowing this, the Chicago firm

been plagued with having their prod-

could possibly reach a broader spec-

ucts ripped-off and passed as genu-

trum of consumers. But, they lose the

ine for years. Phony overseas stores

feeling of exclusivity, which could, in

even opened up using the company’s

turn, detract from business.

industry

There is no universal way to go about conducting logistics for

trademark logo and had the same décor and ambience as their genuine

Though, as both of these models

counterparts. As reported by Reuters

show, there is no universal singular

in August, over 300 of these stores

way to go about conducting logistics

overseas came under inspection

for a business. What works for one or-

this year for passing Apple product

ganization may not necessarily work

clones with dozens of them being

for another. The key feature that both

shut down. Oddly, some of those em-

companies share is the notion of safe-

ployed in these stores thought they

guarding; though, they each do so at

truly worked for Apple.

different stages throughout the man-

a business, though the key feature that both strategies share is the notion of safeguarding.

ufacturing and shipping process. BusiConversely, the Chicago electron-

nesses need to weigh the pros and

ics firm gains the opportunity of not

cons of all their logistics decisions

having to control the managerial lo-

before implementing one set way.

Profit

Quarter earnings in 2010 were $320 million.

Projected year end net total PRE-TSUNAMI $870 million Difference between PRE-TSUNAMI and POST_TSUNAMI projection $2.46 billion

$300 million

$600 million

$900 million

$1.2 billion

$1.5 billion

$1.8 billion

$2.1 billion

$2.4 billion

$2.7 billion

www.interlakemecalux.com•

$3.2 billion

89

industry I semi-automatic warehouses

Semi-Automatic Solutions

As companies’ need to expand wrestles with their need to save, the three stages of partial automation have quickly emerged from the middle.

by Adam Shafer

B

90 •interlakemecalux• NEWS

alance is both hard to come by

peas not necessarily in the same

and inherently necessary in times

pod. The general consensus has long

of economic hardship. Just as ware-

been that either stashing finances

house owners look to contain costs

in the short term or shelling out for

to maintain their business, so too are

full automation with the intention of

they looking to upgrade their space

lowering long term costs were the

to maintain market positioning – two

two extremes devouring the middle

semi-automatic warehouses

I

industry

The general consensus has long been that either stashing finances in the short term or shelling out for full automation with the intention of lowering long term costs were the two extremes devouring the middle ground.

ground. But lately the middle ground has

Between 2000 and 2007, the industry

tities of goods to meet demand. These

become a necessity for warehouse own-

saw a demand for warehouse automa-

developments, for different reasons,

ers. Instead of spending for full automa-

tion. Developing economies like China

created a fruitful period for warehouse

tion or sitting tight until the storm blows

refined production at low cost, while

automation; everything from loose

through, some warehouses are benefit-

major manufacturing powers like Europe

products to complete pallets and boxes

ting from creatively and systematically

and America turned to more disposable

were being turned over at higher yields.

automating just portions of the facility.

products that necessitated larger quan-

By 2008, with the economic thrash-

www.interlakemecalux.com•

91

industry I semi-automatic warehouses

Every owner’s first step toward partial automation starts with evaluating where inefficiencies are most prevalent and then matching those inefficiencies with solutions that alleviate them.

says. “Nowadays, the majority of the automation investments are made only to warehouse management or to parts of a warehouse.”

What businesses have found with partial or “adapted” automation is that it enables them to reduce production costs without a big investment.

And not making a big investment in lean times allows businesses to remain competitive.

Order picking and product dispatch are two areas that often prove logistically inefficient and costly. Fernandez recognized partial automation’s ability to optimize order preparation through optimizing the ergonomic sensibilities of a warehouse using the product-toman concept in parts of the production process with the highest cost. Customers necessitate the most energy and ing brought on by the global reces-

they were throwing out the front door

time. Scheduling, estimating costs,

sion, the trends of the previous seven

just 18 months before, and a surplus of

planning delivery and communicat-

years were slowed, halted and then re-

warehouses developed without enough

ing each appropriate step are equal

versed. Hipolito Fernandez, one of the

product demand for those warehouses

parts mandatory and time-consuming.

Mecalux Group’s regional sales man-

to operate. “The warehouses that are

Partial automation is more than just

agers in Spain, explains that in 2008

being built today generally do not have

automating

banks were locking down the credit

complete

leaving

92 •interlakemecalux• NEWS

automation,”

Fernandez

the

half

of

other

your

space,

to

atrophy

semi-automatic warehouses

I

industry

Automatic for the People There are a variety of affordable semi-automated solutions to fit your storage needs while still remaining in concert with the market requirements. Each of these products offer full flexibility and room for growth without necessitating a large investment. warehouse

New range of mini load stacker cranes of medium

management software capable of

and high yield, capable of manipulating different

covering all needs regardless of the

cardboard or plastic boxes weighing up to 220 lbs

warehouse’s size or type of product.

per unit.

Clasimat (VLM): Automatic storage

MT0: Enable automation of palletized products

that can store small and medium-

with existing shelves in existing areas up to 49

sized products vertically up to 50

feet high, without big investments.

EasyWMS:

Powerful

feet.

MTB0: To automate warehouses without great reSpinblock: Automatic horizontal

quirements in the number of cycles, capable of op-

carousels, epitomizes the “product-

erating in double depth, increasing the warehouse

to-man” concept by enabling a

capacity and also with a small investment.

single worker to prepare up to 400 New range of stacker cranes for pallets, more ef-

lanes alone.

ficient and capable of storing palletized products up to 147 feet high.

Movirack: Palletized shelving on mobile bases doubles warehouse capacity without losing direct access to

Radio-Shuttle: Semi-automatic or automatic carts

any pallet stored.

reduce manipulation times in compact pallet storage.

– it’s about combining practices and using

how to reach those projections are the

principle ideal behind partial automa-

automation to better serve that function.

most difficult and overlooked detail of

tion – provides a gradual incline that

warehouse management. It is important to

starts today.

Every owner’s first step toward partial

think of your space as a work in progress.

automation starts with evaluating where

Installing one system without planning on

The demand for full automation has

inefficiencies are most prevalent and

future integration risks kneecapping future

had a significant chunk ripped from it

then matching those inefficiencies with

warehouse integration. Saving for the fu-

during the global recession, as the ma-

solutions that alleviate them. Projecting

ture often leads to stunted growth in the

jority of companies have opted to stop

your facility’s growth and then mapping

meantime. Building for the future – the

spending. Many customers looking for

Partial automation is more than just automating half of your space, leaving the other to atrophy – it’s about combining practices and using automation to better serve that function. www.interlakemecalux.com•

93

industry I semi-automatic warehouses warehouse solutions are also looking for a shorter ROI than they were five years ago. Turning to a half-manned, half-machine approach usually means less money involved and less return on the investment, but a much faster return. As Luis Escobedo, part of the Mecalux Group’s R & D department explained, in today’s economic climate, a fast ROI keeps financial resources available to companies while still allowing growth. “We see sale increases of products with high storage

What businesses have found with partial or “adapted” automation is that it enables them to reduce production costs without a big investment. density and high productivity,” Escobedo says, “and lower total cost of ownership than conventional manual warehouses.”

As businesses are starting to see some long overdue financial growth, the idea of developing a fully automated warehouse in stages is replacing the common practice of a one-shot facelift.

Stage 1 This is the first and least impactful step into the automation process. Think of it as categorization automation. Warehouse owners aren’t automating their products as much as they are automat-

warehouse operation. Consequently, it

facility had just installed a robust AVS

ing the labeling of those products. By

is much less costly to implement, and al-

network and fitted the personnel with

sparely incorporating only a few devices

lows for greater flexibility should future

voice picking applications to start the

such as automated verification systems

changes to the warehouse be required.

automation process of the warehouse,

(AVS) that improve the speed and effi-

Stage 2 might bring about a Spinblock

ciency of a dispatch area with barcode

Stage 2

or MTB0 unit that can be installed into

readers that capture multiple codes si-

Once an automated categorization

an existing space without affecting

multaneously. Starting small with simple,

takes place, the next destination on

other sections. If Stage 1 is the auto-

cost effective devices offers a way to op-

the development map would be to

mation of labels and categories, Stage

timize standalone processes to improve

install isolated systems used to opti-

2 automates some of the secondary

productivity and accuracy levels, without

mize small sections of the facility. If a

operations in the warehouse, allowing

having to re-engineer the rest of the

warehouse owner of a pharmaceutical

the bulk of the personnel to focus on

94 •interlakemecalux• NEWS

semi-automatic warehouses

I

industry

the main products. If one quarter and three nickels represents the products in your warehouse, the Stage 2 installation of a simple Clasimat or other self-contained automation optimizes the nickels so only the quarter need be operated through manual communications.

Stage 3 This level generates full synergy throughout the plant, but the method of achieving this synergy was developed by alternative means. Large companies opening storage facilities are likely to automate straightaway.

While whole and immediate automation is unlikely with the majority of warehouse owners, matching the end result of those large companies is much more of a reality. Each stage is an investment; Stage 3 completes that investment. Flexibility is king, especially in a volatile business climate and this is where the all-important automation mapping should reach its logical end. Movirack, Radio Shuttle and the like should all be incorporated into the space. The EasyWMS software the organizes the Stage 2 VLM can be rolled over

these whales also serve as the force

competitiveness

and incorporated into the new MT0.

driving all the smaller fish toward

full automation is the undeniable

The efficiency of the AVS will reach

survival. Smaller facility owners are

method to get there. But for many

its full potential now that it is scan-

finding that the only way to survive

companies in the last three years

ning in the massive materials loaded

the whale is to avoid getting swal-

total automation hasn’t been pos-

onto the Miniload AS/RS. By Stage

lowed whole by maneuvering in-

sible. It will be again, at some point

3, partially automated warehouses

telligently. Partial automation is a

in the future, but until the economic

have developed the facility growth

proactive investment in the future

situation permits this, partial is the

that might never have happened

that begins with a goal, a plan and

appropriate solution and one widely

by saving until full automation was

three stages of action. Ultimately,

spreading throughout the industry.

possible.

the ROI analysis of partial automa-

The result has been continual signs

and

efficiency,

tion became too attractive to be

of compromise between cost con-

Large corporations with significant

overlooked, especially as companies

tainment and growth; a compromise

e-business sales will always increase

worldwide identify every avenue for

that has provided both safety and

control and performance through

capital gain in this recession. For a

profit during a time where both are

automation, but the agape mouth of

storage facility to see its maximum

difficult to come by.

www.interlakemecalux.com•

95

industry I bar code readers

Readers Between the

Lines

The increasing capabilities of image-based ID readers are capturing more than just the attention of the materials handling industry.

By Dave Batka

96 •interlakemecalux• NEWS

W

hen the Ritty Model I cash reg-

business as the cash register and com-

ister came to market in 1879,

puter did; there are smaller innovations

businesses gained one of their first

making everyday functions easier. The

revolutionary pieces of technology.

introduction of high-speed, superior-

The Commodore PET and AppIe further

accuracy image-based ID readers (IBR)

overhauled commerce when introduced

has compelled the trend for business

in the late ‘70s, spurring multiple in-

owners to consider transitioning their

dustries to adapt to computing tech-

business toward a more scanner-ready

nologies. With dozens of new innova-

operation. Laser scanners have been

tions introduced into the market each

standard in the material handling in-

month – all claiming to be unsurpassed

dustry for decades: they are easy to

– selecting the technology with which

install, operate and use on multiple

to adapt is not as simple as it has been

barcodes to be read at high speed.

for previous generations. While no

With the advent and ease of Internet

current product is poised to revamp

shopping, coupled with the grow-

bar code readers I

industry

ing volume of products shipped from warehouses to vendors and retailers, logistical data has become paramount

not a scanner but a reader

in aiding organizations and reducing costs through automation. As a result, image-based ID readers are changing the way the material handling industry

Faded

does business.

Traceability Tracking a product through the pro-

Perspective

duction supply chain is integral, and this process relies on barcodes retaining a high visibility quality. But, with being handled numerous times and moved from one location to another, errors will occur with the barcode.

Scratched

Image-based readers record and give feedback on print quality, so producers can make adjustments to barcodes before the product is shipped. This feature keeps a supply chain running

Uneven

smoothly and decreases the allotment of extra man hours for errors.

Performance Proficiency is about speed and accuracy, and this is what to analyze when

Lector620/SICK, Inc.

Bad Print

considering making the transition from laser scanners to image-based readers.

The image-based card readers of the SICK

Image scanners were once thought

product family combine the latest technology

to be too expensive for businesses to

for rapid computing performance with

implement in their day-to-day operations, but with advanced microproces-

high-quality matrix sensors.

Warped

sors, imaging sensors and decoding algorithms, these scanners have not only become more affordable, but more

the entire image and reconstructing

can read upwards of 1,000 frames per

powerful than ever before. Conven-

any damaged or unclear sections in

second, which lets a variety of package

tional laser scanners operate through

an effort to override issues associ-

sizes be read and recorded moving at

light reflected off a printed barcode.

ated with unreadable barcodes. It uses

speeds upwards of 500 feet per minute

But, these types of scanners fail if

optics and codes printed with UV ink

(152.4m/min).

barcodes are printed improperly, dam-

to overcome conventional laser scan-

aged, or any number of common issues

ner hurdles. Given all of these factors,

Image-based readers also allow for

that arise (see fig.1). Image-based ID

image-based ID readers have an im-

one-dimensional barcodes to be read

readers work by taking a picture of

pressive read rate. Higher-end models

from 360 degrees, whereas laser

www.interlakemecalux.com•

97

industry I bar code readers

With the cost of image-

and these types of codes are heavily

of barcodes of any type. This ability

based readers dropping...

infiltrating industries such as phar-

allows an operator to configure the

maceuticals and retail where great

output method, making it much easier

amounts of information need to be

for the operator during use. Manufac-

stored. 2-D codes allow a product

turing and supply chains must take

are rapidly becoming old

to be tracked throughout the entire

into consideration the speed with

manufacturing and supply chain pro-

which goods move through assembly

technology.

cess. Image-based readers are ca-

and shipping. Doing so will determine

pable of reading poorly marked 2-D

which IBR best fits their needs, con-

codes and those on curved surfaces

sidering the ones that have a faster

readers need multiple passes or ad-

thanks to their ability to interpret

capture rate are more expensive. With

justments to read a barcode situated

advanced algorithms. Laser scanners

the increase of Internet shopping,

awkwardly. This allows image-based

don’t have this ability.

suppliers are shipping more products

traditional laser readers

readers to be utilized on shipping

– and read error mistakes – than ever.

lines where 1-D barcoded items are

Usage

If a supplier’s read rate is 96 percent

not always in the same orientation

While a warehouse may consider

per day, that 4 percent error rate can

– again increasing efficiency and

making the transition from laser

mean hundreds or even thousands of

productivity. A matrix code, better

readers to image-based readers, it’s

lost dollars, depending on the amount

known as a 2-D barcode, is a two-

important to know that not all image-

of goods being moved. Image-based

dimensional representation of infor-

based readers are of the same caliber.

readers give supervisors and manag-

mation. 2-D codes are similar to 1-D

The most sophisticated image-based

ers the ability to analyze and adjust

barcodes but are capable of repre-

readers have algorithms that can

how products are loaded onto lines

senting a greater amount of data,

decode and search for a multitude

by taking an actual image of faulty or

Photocell

Decode Thread Laser Light Processor Reader

Reflected Light

Display Oscillating Mirror Lens

Figure 1: Illustration of a bar code scanner.

98 •interlakemecalux• NEWS

Figure 2: Illustration of an image-based ID reader.

bar code readers I

unread barcodes, highlighting present

industry

Notable Image Based Readers

problems and possibly saving a considerable sum in the long run.

SICK Lector 620

Archiving Image-based readers record both barcodes that have and have not been read successfully, which allows for troubleshooting and interpretation later of why a code wasn’t correctly read. This also helps keep inventory under control so parts that have been scanned, and those

Lector620/SICK, Inc.

that haven’t, can be kept separate.

•••

Decodes most popular 1D & 2D direct park markings

•

25mm-500mm reading distance

•

60 Hz scanning frequency

•

Reads 1-50 codes per interval

•

135 MB Internal image storage

This information is stored, so when a faulty barcode passes through later, the image-based reader can

DataMan 500

recognize parts of the label and reconstruct the rest, ensuring the movement of the product is uninterrupted and reaches its appropriate destination. Industries such as aerospace and automotive are using image archiving to ensure superior traceability among products during manufacturing.

Maintenance

DataMan 500 fixed-mount barcode reader/Cognex

•

Doesn’t have to be positioned optimally to

achieve high read rates

•

1,000 frames/sec Image acquisition speeds

•

90 codes per/sec read rate

•

Decodes the most challenging matrix codes

•

Powered via Ethernet cable

Less is more when it comes to needed repairs. Unlike laser scanners, which have motors and rotating mirrors that move the lasers across barcodes, image-based readers have no mov-

This lets the operator quickly and

needs, but attempting to see growth

ing parts, safeguarding themselves

efficiently analyze if there are any

in two to five years is vital as well.

against mechanical failure. These

problems in the system or why

Varying degrees of image-based

readers are also packaged in tough

a code isn’t scanning correctly.

readers allow upgrades from 1-D to

industrial casings, diminishing the

Changes can be made during this

2-D barcode reading, and some of

likelihood of cracking or breaking,

process through the online viewing

the more progressive models have

allowing for next to no maintenance

system, disregarding a need for an

firmware updates, which upgrade

and long-term reliability.

operator to find a manual for help.

the system to meet the latest de-

Image-based readers also allow the

Future-proofing is integral for busi-

image-based readers dropping and

operator to view the read rate sta-

ness when making any changes in a

the growing integration of 2-D bar-

tistics of codes and look at the im-

production line or business model.

coding, laser readers are rapidly be-

ages as the reader captures them.

It is important to gauge immediate

coming old technology.

coding methods. With the cost of

www.interlakemecalux.com•

99

industry I sales

A Turning Point Named Crisis Interlake Mecalux takes the challenges of the market crisis and turns them into opportunity for growth.

by Marta Jiménez-Lutter

T

100 •interlakemecalux• NEWS

he word crisis has become

mindset as a decisive moment to grow

globally ubiquitous. Terms like

and expand, to be a bigger and bet-

“financial crisis,” “oil crisis” and

ter rack manufacturer in the face of

“real estate market crisis” have

economic hardship. Since a company

permeated the news and captivated

is a compendium of all its parts (en-

our attention for at least the past

gineering, manufacturing, customer

four years. Etymologically, crisis

service, sales and marketing), synergy

comes from the Greek word “krisis”

and cooperation between each part

meaning a turning point for better

is the only way to succeed and get

or worse. Interlake Mecalux has

ahead in this market. In the face of

taken the global population’s crisis

adversity, only the skilled make it.

sales I

industry

sides the obvious new installations, are relocations to new areas and en-

Sales’ Biggest Buzz Words SIDEBAR

larging existing facilities. Kris Ross-

The sales industry is seeing surpris-

miller, Midwest account manager for

ing growth in certain regions of the

Interlake Mecalux, explained that,

country that have maintained a solid

“with the uncertain economic times

manufacturing presence, as is the

we are facing, customers are more

case in North Carolina, Minnesota

concerned about cost than ever.

and Wisconsin. Below are the five

Customers are becoming more ag-

most prevalent skills-based keywords

gressive shoppers and they get more

found in resume searches in these

quotes from suppliers prior to mak-

three states:

ing a purchase decision than they had in the past.” Now, more than

1. Outside Sales

ever, companies have to make better

2. Development

products, provide better service and

3. Leads

work harder to close deals.

4. Closing

Interlake Mecalux counts on its

5. Aggressiveness

sales force and distributors to keep its name in front of the customers, so when the time comes to outfit a

Source: http://www.rezScore.com

warehouse, the company’s rack will be among the first considered. But

Interlake Mecalux

that is only the first step in the pro-

has taken the global

no longer enough.

cess and having a foot in the door is

population’s crisis

Neil Camberg, President of Ware-

mindset as a decisive

house Rack, an Interlake Mecalux

moment to grow and

assessment of the challenges facing

distributor, agrees with Rossmiller’s the sales force throughout the in-

expand.

dustry. “A rack salesman will rarely

Top: Fotohunter/Shutterstock Bottom: Wrangler/Shutterstock

experience the same sales oppor-

John D. Rockefeller said, “The se-

ondly, most customers tend to buy

tunity twice,” Camberg explains.

cret of success is to do the common

rack that matches what they already

“Every time [a salesperson] visits

things uncommonly well.” Success,

have, so getting there first will help

a customer to identify his require-

in the material handling industry, is

future sales although it certainly

ments, [that salesperson] will have

measured in minute increments, with

won’t guarantee them. A company

a new, different set of challenges.

no margin for error. Since rack is not

with Interlake Mecalux in its ware-

A good rack salesman must be flex-

a consumable product, getting a foot

house will likely lean toward using

ible and a good problem-solver.”

in the door is crucial for two reasons:

that company again in the future,

Camberg also emphasizes the im-

first, once you fill a warehouse with

but one cannot assume that it will

portance of training. “We train our

rack, nothing is likely to change in

always work out that way. The big

sales force to offer CAD drawings

that space for up to a decade. Sec-

opportunities when selling rack, be-

and technical assistance in order to

www.interlakemecalux.com•

101

industry I sales

earn our customer’s trust and loyal-

ings or stairs. Installation coordina-

to make sure everyone is getting

ty.” All of this, of course, is saddled

tors select qualified contractors and

their piece of the puzzle positioned

on the backs of each salesperson’s

negotiate and control contractors’

correctly and on time. Completing

repoire

knowledge

extras. They make sure all site de-

projects promptly and of the high-

of product as well as its collec-

liveries are made on time and each

est quality required of Interlake Me-

tive technical and organizational

phase of the project is completed

calux is the main responsibility of the

skill set. Selling the rack is just one

on time.

Project Manager.

with

clients,

step of the process, and while price is definitely important, this business is all about execution. “Once you get an order, you have to manufacture it correctly and ship it on time, that creates happy customers,” Rossmiller explains. “If you become known as a

Facing fierce competition, Interlake Mecalux has increased its market share in North America from 20 percent in 2010 to 33

company that does these two things

percent in 2011.

well, customers will seek you out.”

Warehouse construction is a process

The driving force behind any in-

Warehouse installations are a com-

that has to be finely synchronized.

stallation is the Project Manager

bination of many moving elements.

The Interlake Mecalux installation

(PM). The PMs, highly qualified as-

Making those elements fit properly

team is in charge of acquiring every

sociates within the company, over-

creates a high quality, state-of-the-

component needed for the instal-

see the construction project from

art storage space that will provide

lation of the rack, arranging the

beginning to end and are studied

invaluable organization and pro-

procurement of permits and coor-

in specific clients or certain prod-

ductivity for any company for years

dinating coordinating inspections

ucts. They have to understand every

to come. Smooth seas do not make

prior to starting the construction.

facet of the warehouse building

skillful sailors, which is why any

That includes purchasing material

process. From rack components

good sales force prepares for crisis;

not manufactured by Interlake Me-

to lighting fixtures, floors to fire

sails unfurled, all hands on deck, so-

calux for turnkey delivery, like rail-

suppression systems, the PM has

lutions at the ready.

102 •interlakemecalux• NEWS

industry I slotting

The Well- Slotted Warehouse

By Marta Jimenez-Lutter

O

rder picking can be the most

pends on the facility’s products, traf-

labor-intensive and costly activ-

fic and storage properties.

ity in a warehouse. The average full-

How a highly

time warehouse worker spends be-

We do slotting in our lives all the

tween 50 and 60 percent of his time

time. Construction workers do not

organized storage

traveling to retrieve SKUs. Personnel

throw their tools loosely in a bag,

travel represents an obvious waste

they use a compartmentalized bag

facility can save

of time and money for any storage

to separate screwdrivers from ham-

facility. The best way to address this

mers and other gadgets, so they

money and time in a

issue is slotting references properly.

can easily access them. We slot our

Slotting consists of determining the

kitchens, placing everyday items in

difficult economy.

most appropriate storage location

the most accessible spots in our

for every product in a distribution

cabinets. Warehouse storage spaces

center. The goal is to create the most

are no different. With hundreds of

highly efficient system where items

SKUs, it is imperative to know where

are retrieved quickly, accurately and

everything is and have access to it in

safely. Each design configuration de-

a timely manner.

104 •interlakemecalux• NEWS

slotting I

industry

cantilever rack, with its extensive range of load capabilities and adjustable arms, offers the greatest versatility and will accommodate camping tents or skis. This way, the product will change seasonally, while the rack stays in place in the most convenient location.

Placement Rules A well-organized warehouse with the highest picked items in the most accessible areas, stored in the right rack system, will save money in labor, space utilization and inventory control. The economic benefits of a well-sorted warehouse have helped warehouse owners and facility managers recognize slotting as an often misunderstood and overlooked building block of warehouse optimization. It is indeed a very important component of storage design, and although there is not a one-size-fits-all method, there are some basic rules and considerations that make the process easier and more effective.

Some of the rules include placing fast moving items close to the shipping docks and storing items with slower turnover further away from the loading area and on higher levels. Taller and heavier cases The varied nature of products stored in

mine where to store each one in order

should be placed at the beginning of

warehouses makes slotting a complex

to access them easily during their high

the pick path in the picking areas, while

process. The dimensions of the items

seasons; spring and summer for camping

the faster moving cases would be better

stored and any special characteristics

and fall and winter for skiing. The differ-

stored at floor level. Again, everything is

(cold storage or hazardous materials for

ence in dimensions and configurations of

relative to a specific facility’s layout and

example) have to be taken into account.

these products will have to be considered

schedule, but patterns emerge that may

Weight and height also play a role in

when selecting the rack. In this case, a

be helpful to acknowledge when deter-

how and where items should be placed.

The configuration of the installed rack has a big role in the slotting process. If a warehouse is storing outdoor equipment, for example, such as skis and camping gear, they will need to deter-

With hundreds of SKUs, it is imperative to know where everything is and have access to it in a timely manner. www.interlakemecalux.com•

105

industry I slotting

The first step to completing a slotting project is determining traffic flow and allocation of SKUs. mining the effectiveness of a space’s slotting area (generally considered the space reserved for forward picking) and zoning (the area in which reserve inventory used to picked in full pallets or used to replenish forward pick area is held).

When storing items in carton flow rack, positioning the fastest products on the center level and balancing the workload among the flow rack units will prevent congestion during retrieval and speed up the picking process.

Slow moving items can be placed on standard rack, while the fastest ones can be closer to the conveyor belt. It is always important to balance the loads, with the heavier items on the center levels.

Step up the

(TOP) A typical example of the inefficient footpath a poorly slotted warehouse may cause.

(BOTTTOM) Vertical slotting is important, too. The higher turnover items should be placed in the green “sweetspot”.

mon practice is to place the “A” items

mined by the user. The program can also

Organization Process

in the center levels of the flow rack, also

generate reports suggesting changes in the

The first step to completing a slotting proj-

called the “golden” zone, which is situated

rotation of references and provide images

ect is determining traffic flow and alloca-

between chest and waist height, at an easy

of the warehouse with the exact location

tion of SKUs. A warehouse management

ergonomic level for the workers. This place-

of references.

system (WMS) can help with this task by

ment makes the retrieval of SKUs easier

defining what items are retrieved most fre-

and safer.

quently and establishing a ranking system.

A storage facility is an evolving organism and as such, it needs to be slotted and

An ABC classification is used by most dis-

Once the particulars of the items to be

reorganized periodically. A study by the

tribution centers, with “A” being the fastest

stored are sorted out, an implementation

Insight Group showed that slotting every

moving items and “C” being the slowest.

system has to be created. A well-developed

three to six months can increase efficiency

WMS, such as EasyWMS from Mecalux,

7 to 15 percent more than doing it once a

Once the hierarchy of products is estab-

can make the execution of the process

year or less. Logical times to do this during

lished, the next step is to puzzle out the

easier by performing calculations of the

the year would be at the beginning and

best location for those items. A com-

rotation of each item at intervals deter-

end of each season (understanding this as

106 •interlakemecalux• NEWS

slotting I

industry

summer, holidays, winter, etc.) or before

their cold storage units. A beverage dis-

ten have easy retrieval systems that

and after promotions, when inventory

tributor would benefit from keeping spar-

don’t require traveling time around

needs and quantities change and shift.

kling wine and champagne stocked in

the warehouse.

greater quantities in easy to pick areas for Since warehouses are as varied as the

a couple of months leading to New Year,

No matter the warehouse, slotting is

products they store, each facility will have

while that preferential space will be bet-

as much of a necessity as an organized

to adjust to its particular market fluctua-

ter utilized to store beer and soda in the

garage or a fridge with easy access to

tions. A food storage facility will experi-

summer months.

the beer. And much like the shelves in

ence more demand of turkeys or hams, for

the fridge or the pegboard hanging the

example, during Thanksgiving and Easter,

Smaller products that are rarely ordered

tools, the right warehouse system and

so they will stock up on those items and

in bulk, can be placed in the picking

WMS make slotting easier and maxi-

put them in the most accessible area of

area in vertical lift module, which of-

mizes any company’s resources.

www.interlakemecalux.com•

107

industry I cantilevers

Product Spotlight: Cantilevers From architecture to aviation, cantilevers are ideal for warehouse applications.

by Dave Batka

S

elective shelving can transform

for very long loads of unequal size.”

a warehouse’s efficiency and

Cantilevers function through a beam an-

adapt to nearly any floorplan layout,

chored at one ended, which carries the

but there are instances in which a

load to support the extended structure.

unique storage system is the most

This allows for overhang without exter-

appropriate. In instances of oddly-

nal bracing.

shaped goods in need of storage, structural cantilever shelving provides

The Mecalux Group’s roll formed and

a unique alternative to traditional

structural cantilevers offer economical

flat-bottom storage.

designs to suit numerous applications and are ideal when trying to maximize

While cantilevers have been most no-

the storage of non-palletized and sheet-

tably used in architectural structuring,

type items. Cantilever rack also provides

most famously in Frank Lloyd Wright’s

operators easy access to product SKUs

Fallingwater project and WWII fighter

through its efficient and sturdy arm

planes, their simple construction and

construction. Also, since there are no up-

practicality make them ideal for opti-

rights in the aisle, rack stability is greatly

mizing storage space when large or

increased since forklift operators cannot

bulky items are being handled. Inter-

knock into a main support.

lake Mecalux engineer Greg Hajdus said, “Cantilevers are best applied

The rack’s versatility truly makes them

everywhere where the storage of long

ideal. Mecalux cantilever arms are ad-

pieces are needed, such as timber,

justable in 4 inch (10.2 cm) increments

pipes and sheet metal. They are ideal

on structural models and 3 inch (7.6

108 •interlakemecalux• NEWS

cantilevers

I

industry

Offering the safest arm-to-upright connection in the industry in addition to unmatched storage versatility, the Mecalux Group’s cantilevers are perfect for the storage of unconventionally shaped and sized goods.

www.interlakemecalux.com•

109

industry I cantilevers

CANTILEVER BENEFITS • Large range of load capacities

• Unlimited horizontal space

• Unobstructed accessibility

• Economical

• Adjustable arms to accomodate a wide variety of products

• Adjustable arms

is the strongest and

aesthetic appearance will withstand the

safest

arm-locking

daily wear and tear of loading and un-

method in the indus-

loading, while also allowing them to be

try, drawing together

displayed in consumer settings. The pow-

under loads, creating

der Mecalux uses in its paint process is a

the most secure con-

mixture of finely ground particles of pig-

nection available and

ment and resin. Once pieces are coated,

cm) increments on rolled-form ones, allow-

maximizing total capacity. The locking sys-

they are heated, fusing the paint particles

ing for storage of almost any conceivable

tem engages immediately once an arm is

together in a uniform coating. This results

item. The accessories offered for cantilevers

seated within the slot of the upright post

in an extremely durable product. And since

further heighten their versatility and the

but also allows for easy release if adjust-

no solvents are used in the process, insig-

accessibility of stored products. Drop-in

ments need to be made. The Lok-Joint sys-

nificant amounts of VOCs are released into

steel decks can be added, and arm stops

tem’s design also makes it damage-proof

the atmosphere.

and saddles for deck supports can also be

and tamper-proof, preventing disengage-

installed, increasing the safety and protec-

ment during use.

Safety and reliability are two key requirements that should be considered when

tion of both the product and rack system by preventing products like timber and pipe

Interlake Mecalux roll-formed and structur-

designing a storage system, and Mecalux

from rolling off the arms. Cantilevers can

al cantilevers can also be utilized in storage

cantilevers are not to be undone. Offering

also be mounted on to mobile systems for

situations where seismic conditions need

the safest arm-to-upright connection in the

extra storage capacity without limiting di-

to be addressed.

industry in addition to unmatched storage versatility, the Mecalux Group’s cantilevers

rect access to each load stored.

The cantilever’s patented Lok-Joint system 110 •interlakemecalux• NEWS

For longevity, the Mecalux Group’s canti-

are perfect for the storage of unconven-

levers are powder coated to ensure their

tionally shaped and sized goods.

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