Preferred Freezer Services system walk-through

Preferred Freezer Services’s new facility maximizes throughput while minimizing labor and energy consumption.

By ·

Preferred Freezer Services; Elizabeth, N.J.
Size: 170,000 square feet, including 140,000 square feet of AS/RS
Products handled: frozen food products
Stock keeping units: 2,000 across multiple clients
Throughput: 1,020 pallets per day in and out of the facility
Employees: 30
Shifts/Days: 3 shifts/5.5 days

Receiving: When trailers are backed into a loading dock (1), the back portion of the trailer extends into the facility. This allows PFS to open the trailer doors inside the warehouse, minimizing the exchange of air with the outside. Trailers are unloaded by lift trucks or pallet jacks and staged in the receiving and shipping area (2). Pallets receive a license plate bar code that identifies the product and the customer. The bar code is then wirelessly scanned and the pallet is staged for induction into the automated storage and retrieval system (AS/RS).

Putaway: The automated system operates without conveyor. Instead, cranes can reach pick up and drop off staging and palletizing locations (3) near the freezer entrance. The system is a dual-cycle system. That means that the crane retrieves a pallet for picking each time it exits the freezer to pick up a pallet for storage. When pallets are ready for putaway, the warehouse control system sends a signal that opens a high-speed door and directs a crane to a pick up location. The crane drops off pallets (3) retrieved from storage, and picks up two pallets for putaway. The pallets are dropped off at one of several hundred freezer buffer locations (4) inside the 140,000-square-foot freezer AS/RS (5). Later, the crane will pick up a pallet from a buffer location and deliver it to a storage location inside the freezer AS/RS (5) based on throughput metrics for that stock keeping unit (SKU) and the customer. Pallets are now available for orders.

Picking and shipping: Order fulfillment takes place in the receiving and shipping area (2) on the dock. Full pallets are delivered from the drop off location directly to a trailer (1) for delivery. Mixed pallets are manually palletized in the receiving and shipping area (2). When the picks from a pallet are completed, the crane will remove the partial pallet and return it to the freezer buffer area (4) for putaway (5) later. The completed pallet is stretch-wrapped and loaded into a trailer (1) for delivery.

System suppliers
AS/RS cranes: LTW Intralogistics
WMS: Accellos
Warehouse control system: Preferred Freezer Services
Pallet rack: Frazier
Lift trucks: Crown
High-speed doors: Rytec
Insulated panels: Metl-Span
Dock equipment: Kelley (4Front Engineered Solutions)
Bar code scanning: LXE/Honeywell
Stretch wrapping: Lantech

image

click here to download the PDF article
click here to download PDF article

 


About the Author

Bob Trebilcock
Bob Trebilcock, editorial director, has covered materials handling, technology, logistics and supply chain topics for nearly 30 years. In addition to Supply Chain Management Review, he is also Executive Editor of Modern Materials Handling. A graduate of Bowling Green State University, Trebilcock lives in Keene, NH. He can be reached at 603-357-0484.

Subscribe to Logistics Management Magazine!

Subscribe today. It's FREE!
Get timely insider information that you can use to better manage your entire logistics operation.
Start your FREE subscription today!

Article Topics

All Topics
Latest Whitepaper
The Internet of Things and the Modern Supply Chain
Learn today how the internet of things is transforming supply chain operations.
Download Today!
From the February 2017 Issue
As the new administration sends waves of uncertainly through the global trade community, this could be the best time ever for shippers to build an investment case for GTM. Here are five trends you need to watch if you’re about to put these savvy systems to work
Carrier Consolidation Keeps Shippers Guessing
Getting Value from the Cloud
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
Advance your career with the fastest growing logistics certification – APICS CLTD
During this webcast presenters will give an overview of APICS and the new Certified in Logistics, Transportation and Distribution (CLTD) designation. Learn how the CLTD program can help you stay on top of current trends and advance your career.
Register Today!
EDITORS' PICKS
ASEAN Logistics: Building Collectively
While most of the world withdraws inward, Southeast Asia is practicing effective cooperation between...
2017 Rate Outlook: Will the pieces fall into place?
Trade and transport analysts see a turnaround in last year’s negative market outlook, but as...

Logistics Management’s Top Logistics News Stories 2016
From mergers and acquisitions to regulation changes, Logistics Management has compiled the most...
Making the TMS Decision: Ariens Finds Just the Right Fit
The third time is the charm for this U.S. manufacturer on the hunt for a third-party logistics (3PL)...