PALLET RACKING SOLUTIONS

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1 PALLET RACKING SOLUTIONS

2 DESIGN, MANUFACTURE, INSTALL Based in Milton Keynes, Apex has provided pallet racking solutions to a huge number of household name brands, across all sectors and industries. Our leading design and technical solutions provide our clients with the best in storage solutions. 2

3 CUSTOM DESIGN The best design for a business looking to implement a new storage solution, is the one that provides the ideal balance between capital cost, operational efficiencies (that improves ROI) and providing end user satisfaction. At Apex, we have been designing solutions with this in mind for more than over 75 years. We understand the importance of using the most appropriate storage equipment, utilising the cube to create maximum storage space, as well as minimising distances that products travel, increasing pick rates and improving pick accuracy. MANUFACTURED IN THE UK Maintaining in-house manufacturing and quality control, allows our clients to benefit from our extensive experience in steel forming and fabrication techniques; creating bespoke-designed storage solutions using standard or custom components. Our pallet racking are made in Milton Keynes, at one of the largest manufacturing operations in the storage equipment industry. The central location of the factory, ensures effective delivery and helps minimise our carbon footprint. THE UK S LARGEST INDIVIDUAL SUPPLIER OF PALLET RACKING We are a member of Whittan, the largest manufacturer in the United Kingdom of steel storage products. Operating through a number of market leading brands; we design, manufacture and install storage solutions for commercial and industrial environments. 3

4 QUALITY ASSURED Apex maintains rigorous management processes in order to comply with a wide of policies, covering health & safety, environmental and quality. We operate quality systems in accordance with the latest ISO standards. Over the years SEMA has developed a series of relevant Codes of Practice, which are the Industry standards. As SEMA Members, we are required to conform to these standards. ISO 9001:2008 Certification of quality management system for all areas of the business. ISO The globally recognised standard for environmental management. BS OHSAS The international standard for occupational health and safety management. PROJECT MANAGEMENT YOU CAN RELY ON Large or small, your project will require careful project management, in order to ensure delivery of the parts, the consumables, labour and transport are all synchronised; and that the work takes place in a safe and efficient manner. Some of these components can often form part of a large project, such as a new-build warehouse, where delays or non-compliance can lead to delays in the larger programme. We can offer a range of services that complies with The Construction (Design and Management) Regulations 2015 and all relevant industry & building control standards. From the initial briefings and site surveys, to detailed design proposals, manufacturing, installation and final commissioning; our storage experts take project planning seriously, so you know your project is in good hands. 4

5 SAFETY FIRST Whittan is committed to Safety, Health, Environment and Quality Assurance. SHEQ is at the forefront of our business. We are fully aware of the responsibilities that come with working in a high risk industry, and as such, we constantly strive to continually improve our solutions that safeguard our staff, our customers, our supply chain and our planet. Our overall approach to efficiency, means that both customers and colleagues are able to make the safe choice. Our Safety, Health, Environment and Quality statements, along with our wider policies and procedures, allow us to maintain the highest standards of efficiency. SHEQ is constantly reviewed to promote a zero harm culture across Whittan. As a member of the British Safety Council, we are committed to keeping people safe and healthy at work. Working in compliance with the SEMA codes, provides recognised quality assurance to our customers, who can have full confidence in our abilities as a premier storage equipment supplier. We ensure that we conform to all applicable industry standards; covering storage installation, (including correct health and safety practices). All of our method statements and procedures are based on published SEMA guidelines. Additionally, our quality assurance systems, assessed to ISO 9001, cover not only manufacturing, but also installation; ensuring that all processes are formalised and regularly audited. We want you to experience the peace of mind you get from a professionally designed and installed storage solution. 5

6 STORAGE CAPACITY These charts give an indication of the number of pallet positions available in a given space, depending on the type of pallet racking storage system used. This is based on the 2 most popular pallet sizes; 1200 entry x 1000 and 1200 x 800 entry pallet. HOW DOES IT WORK? Example For 1200 entry x 1000 pallets in a 3,000m 2 warehouse (using Wide Aisle Pallet Racking). PALLET SIZE 1200 x 1000mm 2000 Find 3,000 on the bottom of each chart, then follow the vertical line up to the point where it meets the diagonal line, for Standard Aisle Pallet Racking. At this point follow the horizontal line back to the left hand side; this will be the number of pallets per level. So, for Wide Aisle Pallet Racking in a 3,000m 2 warehouse, there will be 750 pallet positions per level. Further guidance How many levels will there be? The following details will help determine the number of pallet levels: l The height of the pallet l The height of the building l The lift height/capability of the fork lift truck NUMBER OF PALLETS STORED PER LEVEL Note This chart includes an allowance for pedestrian access areas & cross-aisles, and are based upon typical Reach Truck Operation. The use of different trucks may alter the number of pallets stored. PALLET LIVE RACKING DRIVE-IN RACKING PUSH BACK RACKING NARROW AISLE RACKING STANDARD AISLE RACKING FLOOR AREA OF THE WAREHOUSE IN SQUARE METRES 6

7 PALLET SIZE 1200 x 800mm HOW WILL THE WAREHOUSE OPERATE? NUMBER OF PALLETS STORED PER LEVEL Note This chart includes an allowance for pedestrian access areas & cross-aisles, and are based upon typical Reach Truck Operation. The use of different trucks may alter the number of pallets stored. DRIVE-IN RACKING PALLET LIVE RACKING PUSH BACK RACKING NARROW AISLE RACKING STANDARD AISLE RACKING The throughput of the pallets should also be considered. For example, some of the higher density systems may limit access to stored pallets. General guide Mechanically Handled: Wide Aisle Pallet Racking - 100% access to every pallet Narrow Aisle Pallet Racking - 100% access to every pallet Drive In - FILO (First In Last Out) Push Back - FILO (First In Last Out) Pallet Live - FIFO (First In First Out) Manually Handled: Carton Live - FIFO (First In First Out) Pick Towers - 100% access to all pallets & SKU s For larger schemes, a combination of pallet racking systems will offer the optimum solution. The charts are for general initial guidance only FLOOR AREA OF THE WAREHOUSE IN SQUARE METRES 7

8 WIDE AISLE The simplest of racking systems, wide aisle pallet racking allows direct access to every pallet and is easily adjustable, subject to manufacturers approval, to cater for different sizes and shapes of goods. Wide aisle (with a minimum of 2.5 metres wide aisles) requires no specialised handling equipment. A standard counter balance truck can be used in aisles 3.5 to 4 metres wide, whilst reach trucks can work in aisles only 2.5 metres wide. A limitation of using standard lift trucks, is that the racking systems height is restricted to the maximum lift height of the trucks. With fast and easy loading and unloading, this type of racking is extremely popular, but may only utilise 40% of the available floor space, the rest being aisles. 8

9 NARROW AISLE Narrow Aisle Racking significantly increases storage capacity compared, to Wide Aisle solutions, by reducing the aisle widths by up to 50% and increasing rack heights. This makes excellent use of the floor space and ensures maximum use of the available headroom, whilst still allowing individual access to all pallets stored. Specialist Narrow Aisle lift trucks are required in either man-down or man-up variants, allow movement in the narrow aisles. To reduce the risk of accidental damage from user error and to improve safety within the system, rails or wire guidance is installed at floor level to guide trucks precisely into position between racks. NEW APEX SITE IMAGE REQUIRED ASRS With working aisles reduced to the absolute minimum to save floor space ASRS allows rack heights to up to 30m. Specialist automated or semi-automated cranes are used with floor and top guidance. These providing fast throughput and high accuracy in storage and retrieval. 9

10 DYNAMIC STORAGE Our range of Dynamic Storage solutions can save up to 50% space and reduce travel distances by up to 80%. Pallet Live, Carton Live and Push-back Racking offer, maximum flexibility and efficiency in storing high turnover stock, with accurate FIFO or FILO flow of products. DRIVE-IN Drive-in Racking is the ideal solution when space is at a premium, or high-density storage is required. By eliminating aisles, it is possible to maximise cubic space, enabling more pallets to be stored per cubic metre. Pallets are stored on guide rails, so forklift trucks can enter storage lanes, in order to deposit and retrieve loads. A safe and efficient solution for fragile loads compared with block stacking, as loads are stacked individually, rather than on top of each other. Access can be from one end (the true drive-in configuration) which necessitates a first in, last out principle (FILO) or from both ends ( drive- through, for improved stock rotation). It is ideal for storing large quantities of similar or identical goods. The system is popular in cold stores (for both refrigerated and frozen goods), since it makes maximum use of space and therefore minimises costs in a temperature-controlled environment. Pallet Live Racking - First In - First Out (FIFO) Working on a first in, first out basis, Pallet Live storage provides automatic stock rotation, ideal for storing perishable goods with high rotation, as well as high consumption goods with a continuous flow. Pallets are loaded onto dedicated lanes of inclined gravity rollers, when a load is taken from the picking face, the next pallet rolls into position. This requires two fork truck aisles; one for loading and one for picking. Integrated speed controllers ensures each pallet rolls at controlled speeds to the picking face. 10

11 Push-Back Racking - First In - Last Out (FILO) Pallets are loaded and unloaded from the same aisle, reducing truck travel distances and improves workplace efficiency. Pallets are loaded in sequence onto roller beds or wheeled carriers and are pushed back along inclines to utilise the full depth of the racking. When a load is retrieved, the remaining pallets roll forward into position at the loading/unloading face. Ideal for utilising space against walls and for marshalling areas. Carton Live Storage - First In - First Out (FIFO) Working on the same principle as Pallet Live, Carton Live offers first-in, first-out storage for hand loaded items. Inclined trays of roller tracks are installed within pallet racking bays, allowing goods to roll down dedicated lanes within the trays, from the loading to the picking face. 11

12 MULTI TIER PALLET RACKING STRUCTURES Installing a multi tier pallet racking structure maximises your buildings storage capacity, without the need to extend or relocate. Multi-tiers are most effective for online retailers and e-commerce operations where picking and packing are combined with a high SKU (Stock Keeping Unit) turnover. The system is extremely cost-effective, as the racking structure supports the walkways - saving on construction costs. It improves the pick efficiency of the warehouse operation, making all products accessible for picking. The modular design of our pick towers allows us to easily accommodate other services and utilities into the structures, working closely with other trades to ensure smooth project. l Allows order picking on multiple levels l Most efficient use of the building, maximising floor area against height l Can combine pallet, box, garment hanging and small goods storage l Can be integrated with a mezzanine floor l Sprinkler, lighting and environmental systems can be incorporated l Lighting and heating cost efficiencies l Lifts, conveyors, hoists and pallet gates can be included to help access each level 12

13 Open or protected stairways are incorporated into the structure to comply with building regulations. Aisles can be designed to various widths dependant on the traffic flow for operatives, trolleys and hand trucks. Garment rails can be fitted within pallet racking bays. They are easily adjusted to meet changing stock needs. Hand rails can be fitted with netting or mesh to protect operatives and to stop falling items. Conveyors can be integrated onto each level, delivering stock in and picked items out to the packing areas. Goods lifts allow for pallets to be safely moved onto or between different floor levels. 13

14 MEZZANINE FLOORS Mezzanine floors are being used more and more in warehouse and distribution centres, in order to make the most of valuable unused space for general storage, and to support automated material handling equipment. It creates invaluable extra floor space; increasing the amount of space available. It can be as small or as large as you like, be one, two or three tiers high, have standard or special staircases, lifts or access gates, handrails or partitioning barriers, wood or steel decking, be totally encased, fitted with lighting and sprinklers. This vast array of options ensures we deliver a solution to meet your exact needs, whether it be a stand alone or integrated requirement. 14

15 SPECIALISED RACKING Apex s versatile racking and storage equipment can store large, bulky or awkward items, utilising space efficient methods. With standard components used in a novel way, or by utilising specialised bespoke accessories, (specified and manufactured to a customers particular requirement), our expertise in creative storage design, means there is always a cost and space-effective solution to what can appear to be the most awkward of storage problems

16 ON-SITE AWARENESS TRAINING SEMINARS FOR YOUR STAFF Our racking safety training seminar, is a half day course that teaches your staff everything they need to know about how to properly maintain their warehouse pallet racking system, for safer usage and a longer lifespan. We understand the demands on staff time involved in any busy work place, and that s why we come to your site to carry out our racking safety seminars for groups of around 4-10 people. The seminars consists of classroom based learning techniques; which involves presentations, question and answer sessions with one of our SARI (SEMA Approved Racking Inspectors), and hands on instructions. Our racking expert will tour your warehouse to examine your racking and highlight real issues to watch out for that, are specific to your business. PALLET RACKING INSPECTION SERVICE Racking systems deal with heavy duty load requirements on a daily basis. Damage can take its toll on even the most robust and reliable racking solution, and failure to maintain racking properly can lead to extensive problems, costly repairs, disruption to work, loss of stock or even worse staff injury or fatality. Keep on top of your pallet racking maintenance with annual safety inspections carried out by our SEMA approved storage inspectors. Our storage experts come to your premises and systematically review every component in your pallet racking system, in order to: l Provide a full colour coded report indicating where damage has occurred and its severity. l Recommend repair work required. l Offer a quote to fix existing issues. l Suggest preventative measures to protect your racking from future damage. Garamonde Drive, Wymbush, Milton Keynes MK8 8ND Tel: This publication shows general concepts only, and should not be used as a guide for specific design or assembly purposes. Apex reserves the right to alter the specification on any of these products, in the customers interest, without prior notification.