Warehouse shuttle system delivers high throughput in less space

SWISSLOG IS introducing its flexible new PowerStore high density shuttle system for retail, fast-moving consumer goods (FMCG), and pallet warehousing applications seeking to achieve high throughput and optimal space utilisation.

The modularity of the PowerStore pallet shuttle system – for which the first installation in the Southern Hemisphere is currently being completed in Australia – enables storage of up to 60 percent more pallets compared to manual systems, says the warehousing and logistics automation company.

Swisslog has more than 50 years of global experience in the design and implementation of pallet warehouses, and its PowerStore system complements a comprehensive range of highly customisable automation and Industry 4.0 solutions that Swisslog provides to retail, FMCG, food and beverage, logistics, transport, pharmaceutical and warehousing operations globally.

“In addition to highly customisable new installations, PowerStore’s adaptability opens up completely new possibilities for automation in existing warehouses, due to its naturally compact and space-saving grid-like layout,” says Paul

Stringleman, senior consultant, Swisslog Australia.

“PowerStore is ideal for manufacturing businesses, especially those in the FMCG and food and beverage industries where high throughput is essential to profitability. In addition to being proven in manufacturing environments for FMCG operations, interest is increasing in applying this technology as a high- density storage and high pick of A Class movers in a retail environment,” said Stringleman.

PowerStore can operate in a range of environments, from -30°C in frozen food storage up to 50°C, and can easily be retrofitted to warehouses with low ceilings or unusual shapes.

POWERSTORE FUNCTIONALITY

Central to the system is a fleet of Swisslog AisleCarrier and RowCarrier red shuttle robots rolling along narrow tracks picking up and dropping off pallets, which ride conveyors between levels.

“Essentially the AisleCarriers and RowCarriers each operate on a different axis on a 2D plane. For simplicity, let’s call them rows and columns. The RowCarriers travel across their row to retrieve pallets and deliver them to their destination – the transfer station. AisleCarriers move across each column, and can transport a RowCarrier – without a load – between the designated row and the vertical conveyor at the end,” explains Stringleman.

“At the end of the column is a vertical conveyor, which facilitates fast and effective movement of pallets between levels. The end result is a highly efficient grid- based automated warehouse system that fits in a compact space, and delivers pallets significantly faster than manual solutions.”

INTEGRATION WITH SYNQ SOFTWARE

PowerStore control software is fully integrated in Swisslog’s SynQ suite of warehouse management software and designed to work seamlessly with customers’ Warehouse Management Systems ( WMS) and host systems.

Swisslog’s SynQ materials handling software provides warehouse management, material flow, automation and 3D visualisation all from a single point of control. SynQ software, which is a combination of Synchronisation and Intelligence Quotient, has been designed for dynamic, data- driven supply chains.

“Through continuous monitoring and real-time data, warehouses can continuously operate at maximum efficiency to ultimately reduce operational costs. Furthermore, early-warning system for malfunctions reduce downtime of critical equipment and allow a business to create calculated risks,” said Stringleman.

GLOBAL INSTALLATION

A global supermarket giant has become one of the early adopters of Swisslog’s PowerStore system, which is currently in the testing phase in its 79,000 sq m distribution centre. The system is intended to increase the centre’s storage capacity and throughput, Swisslog said.

Shane Faulkner, Swisslog head of sales in the UK, said: “For this leading supermarket, the system is significantly improving throughput capacity, and compared to their traditional racking, is increasing storage density by up to 60 percent. It is designed to utilise virtually every square cube of space. The solution removes the dependence on replenishment to a pick face, as processes are now automatic.”