Central deep-freeze distribution center

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Initial situation

Within the last few years, the freezer specialist has grown significantly and wants to expand its capacities in the Ruhr area by concentrating them at one site. The newly constructed building in Herne will become a central hub and supply customers from the entire region. The distribution center is designed for high picking capacity and quality as well as flexibility. Several thousand packaging units per hour can be processed in the DC in a largely automated process according to the requirements of the customer and then made available for shipping.

Solution & Materialflow

• Goods receipt and storage
  In the goods receipt area, non-mixed product lines are loaded and then either stored temporarily in the high-bay warehouse or transported directly to the depalletizing area. 
• High-bay warehouse for pallets
  Pallets that come directly from the goods receipt area are stored in the high-bay warehouse in a clad rack structure with 42,000 frozen storage positions. Picked and palletized customer orders can also be stored temporarily.
• Depalletizing and tray loading
  Depending on product characteristics, incoming goods are depalletized either by two Splitex depalletizing robots or at manual workstations, The depalletized products are temporarily stored on trays in the shuttle warehouse (approximately 66,000 storage locations) at -11° F. 
• Order picking and palletizing
  After the customer orders are received, they are retrieved and transported sequentially to the workstations where the customer pallets are set up. After picking, a complete pallet is automatically wrapped and either transported directly to the goods receipt area or temporarily stored in the high-bay warehouse. 
• Shipping
  Shipping labels are affixed to the pallets in the goods issue area and are made available for shipping on nine destination conveyor belts. 

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