Preferred Freezer Services system walk-through
Preferred Freezer Services’s new facility maximizes throughput while minimizing labor and energy consumption.
Latest NewsSTB reschedules listening session for CSX service issues AAR reports mixed volumes for week ending September 16 Maersk makes bold bid at differentiation by teaming with CRM giant Federal Maritime Commission to take closer look at “Fair Port Practices” CEMA reports unexpectedly strong gains in 2017 More News
Latest ResourceeBook: Why Multi-Tier Supplier Collaboration is More Important Now Explore the benefits of supplier collaboration including sharing demand forecasts, faster reactions to demand or capacity changes and well-coordinated product launches.
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
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.
AS/RS cranes: LTW Intralogistics
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
About the AuthorBob 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!
Improving 3PL Management: Glanbia Adds Muscle to Logistics Why Retail Supply Chain Transformations Fail - and how to get it right View More From this Issue