FILO Gravity Racking System with Push Back Flow Beds

A privately owned Midlands based company approached Teccon for guidance on how they could streamline their warehouse operation and hold more stock utilising empty space above their existing pallet racking system.

Challenge

Fast and slow moving stock lines were mixed in the racking system. With the existing standard high bay pallet racking and 6ft high shelving used for picking, a lot of overhead space was being wasted in certain areas.

In addition, the operational efficiency of the warehouse needed to be maintained meaning all works had to be completed at night to keep disruption to a minimum.

Solution

Teccon’s consultation phase identified the bulk pallets from the racking system with no or little shelf life and proposed to move them to an area of the warehouse in a FILO gravity system (First in, last out)

To compliment this two separate push back systems were proposed to hold the fast pace bulk pallets, located near the goods in and out areas that also improved efficiency. Creating these 2 systems, freed up a number of pallet positions in the existing racking area.

By stripping down the 6ft high shelving, where the overhead space wasn’t utilised, low level push back flow beds to ground level on 18no bays of racking were installed.

The flow beds were designed to take the weight and size of the existing boxes meaning it was a straight forward transfer from the shelving, also this did increase the number of box positions for the customer.

A carefully scheduled rollout plan saw both the 2 new FILO systems and the flow beds built during night hours to minimise disruption.

In addition Teccon also installed a brand new double skin warehouse office designed for 3 personnel, together with lighting, electrics & data, flooring and heating.

The customer also asked to us to make some racking alterations to the existing system, including new beam levels to gain more capacity.