Storage/Staging: Pick modules boost retailer’s shipping capacity

Retailer Crate&Barrel wanted to increase their distribution shipping capacity by 40% to meet high demand and ensure fast turnaround for home furnishing deliveries. The company achieved its goal by installing a new integrated picking and packing system.

The company’s Cranbury, N.J., distribution center is a 700,000-square-foot facility that processes 15,000 shipments a day and has more than 18,000 stock keeping units (SKUs) in inventory. The systems integrator for the project decided to use one of the largest storage rack manufacturers in North America to meet the facility’s requirements by installing pick modules and selective pallet rack systems.

Four multi-level pick modules were built with 10,000 pick locations, in addition to pallet and carton flow racking with approximately 15,000 selective pallet locations. A lift truck aisle is on the outside of the system while the interior has an order-picking area. Pallets, cartons and products are loaded into the system from the truck aisle. Once loaded, products flow to the pick area where they are retrieved and placed on a powered conveyor system.

Following the installation, the company achieved the 40% increased shipping capacity with a 45-totes-per-minute peak picking and packing process.

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