Durham Box improves operational efficiencies with mobile pallet racking

A Whittan Group Company

Founded in 1989 and based in Bishop Auckland, Co Durham, Durham Box supply corrugated packaging solutions to an extensive customer base of over 450 firms.

One of the UK’s leading independent corrugated manufacturers, the family business occupies a 90,000 sq ft site, making in excess of 35 million products per year and employing over 70 people. Having made substantial investments in plant and machinery in recent years, the firm is on track to achieve its target of 10% growth year on year for the next 5 years.

Supplying a wide range of manufacturing sectors, with an increasing presence in the food, drink & retail sectors as well as automotive, Durham Box has over 28 years experience in packaging manufacture. Their expertise ensures that, whether it’s printed shelf ready packaging, industrial or protective packaging, their finished products are best suited to their customers’ supply chain, whilst enhancing the brands’ reputation.

The Brief

A key part of Durham Box’s offering, is their ability to hold finished goods stock for their customers. This enables customers to create efficiencies in their own supply chain, allowing them to ’call-off’ stock, as-and-when required, or to access stock in emergencies, i.e. at peak times or as a contingency. In accommodating this stock, Durham Box used block-stacking methods, where pallets would be stacked on top of each other, wherever there was space to do so. Not only did this result in double-handling, it created damage to stock and had a negative effect on warehouse efficiencies. As a further complication, finished goods were also being held off site in local temporary storage, thereby creating additional cost and logistics issues. With space available to extend the existing premises a decision was made to build a warehouse extension and use it for finished goods storage, thereby eliminating the need for off-site storage. In order to enhance efficiency within this warehouse, Durham Box looked at the possibilities of using pallet racking. Following supplier research, Link was contacted and asked to provide a solution.

To allow for different pallet sizes to be stored

within each bay, wood slat decking was specified.

“Link’s response to our requirement was very comprehensive. We had good quality answers quickly, which helped move the project forward within our required timescales. I expected Link to provide us with a professional job and that’s exactly what they delivered.”Dan Morris, Commercial Manager, Durham Box Company Ltd

The Solution

Given the amount of storage required, together with the frequency of pallet access needed, Link recommended the use of a high density mobile pallet storage system.

The racking is mounted on electrical driven mobile bases, which move along rails installed in the floor screed. Movement of the mobile racks is controlled by a hand-held remote, or via buttons on the racking. A central control system monitors the status of the installation and the operation itself. The system also incorporates a host of useful features to aid efficiency, together with multiple systems to ensure operator safety.

To protect operators and products on the floor of any aisle being closed, each mobile chassis has a photoelectric sensor system operating at floor level along the edge of each aisle. The system is stopped if any of the sensors are activated.

Photoelectric sensors also scan the the entry face and will automatically stop all movement of the bases, should a person or truck attempt to enter an aisle whilst the system is operating.

The main advantage of using mobile racking is that it increases the warehouse capacity by up to 100%, whilst providing unrestricted access to every pallet. To assist in building Durham Box’s confidence in the mobile racking system, Link organised a visit to the British Geological Survey in Nottingham, to see a similar mass storage solution in situ.

Following site surveys, CAD drawings and subsequent revisions, the project progressed.

The final installation included 13 mobile bases (19m long) with static racking located at either end of the system, providing Durham Box with 2100 pallet locations. The frame heights differ along the length of the system, in order to match the eaves; which maximises storage capacity.

Benefits to Durham Box

l Increased supply chain and warehousing efficiencies

l Increased stock capacity

l Limited stock damage

l Improved stock taking

Mobile racks can be moved by either a hand held remote control, or

by the buttons situated on each of the racking bases.

Photoelectric sensors scan the

entry face and will automatically

stop all movement if triggered.

Email: Info@whittan-storage.com www.whittan-storage.com

Tel: 0800 169 5151

This publication shows general concepts only, and should not be used as a guide for specific design or assembly purposes. Whittan reserves the right to alter the specification on any of these products, in the customers interest, without prior notification.

STORAGE SOLUTIONS Whittan is the UK’s largest manufacturer and supplier of steel shelving, pallet racking and lockers. We are able to offer a comprehensive range of products and services, to meet the demand for rigorous and effective storage management; for all types of industries and requirements.

From turnkey complex solutions, through to more simple requirements; we are able to supply storage solutions using one of our industry leading branded products.

l Pallet Racking brands; Apex and Link

l Locker brands; Probe and Link

l Shelving brands; including Euro, Stormor, Stockrax, and Probe

l Longspan ranges; from Polypal, Apex and Link

Our vast product range caters for all storage requirements; from Pallet Racking for warehouse environments, to heavy duty, static and mobile shelving and small parts storage for offices or stock rooms, and lockers - Whittan has the solution.

The excellent quality of our UK based manufacturing processes and products, is matched by our commitment to providing a wide array of services and comprehensive support to all our customers.

A Whittan Group Company

PALLET RACKING SOLUTIONS

A Whittan Group Company