Reduced manual handling between production lines and the dock, shorter delivery cycles and increased order accuracy has dramatically improved operating costs.

Delivers peak shipping rates of twice the average day and three times the average hour. Reduced the truck traffic on local roads by 50% - or 3 million miles. Innovative super high-density technology eliminated the need for offsite storage. Decreased wait time, between dock arrival and departure, to the time required to actually load the trailer.

Retrotech Inc. was commissioned by a Fortune 50 consumer goods manufacturer to develop one of the world’s largest automated distribution centers using state-of-the-art technology. Retrotech employed a unique super high-density dynamic storage technology that buffers, sorts and pre-stages palletized unit loads. This technology allows companies to automate their distribution centers with a modular rack concept that is flexible, reliable, efficient and cost effective. The new distribution center was developed to replace seven satellite facilities once leased by the company. The massive facility is 1.15 million square feet, or equal to the size of 19 football fields.

The system operates 24 hours per day and stages over 160 orders. Full pallet unit loads are buffered and continually flow through to staging lanes at the dock end of the system. The system manages 109,000 pallet positions in one warehouse, and only 45 additional employees were needed to facilitate the process.

Algorithms direct the system’s Vertical Transfer Lifts (VTLs), Cross-Aisle Transfers (CATs), and Deep Lane Transfers (DLTs) to position pallets within the system based on when and where they are required for output. When a trailer arrives at the dock, the forklift operator uses an RF terminal to sign onto the order. The sign-on signals the system to begin indexing pallets forward from the slot to the rack face position, with each level indexing independently. As each load is removed from a staging lane, system and WMS software are updated automatically. To assure accurate trailer loading, the forklift operator scans a bar code on the dock door. Trailer content information is then provided to the warehouse management system, speeding the bill of lading cycle.

is a proud member of AS/RS, a Product Section of the Material Handling Industry of America

P.O. Box 586
Fishers, NY 14453-0586
Phone: 1-866-915-ASRS
Fax: 585-924-6334
info@retrotech.com
www.retrotech.com