Push Back Rack + Pallet Flow Rack + Column Protection for Floral Distributor – A Case Study

Services Provided: Design, Project Management, Installation, Permitting Support

Products Provided: Push Back Rack, Pallet Flow Rack, Column Protectors
Location: Carlsbad, CA

Concern: Low Storage Density and Inefficient Operation

A California-based floral importer and distributor was storing pallets of floral arrangements on the floor. This setup drastically expanded their storage footprint. It limited their storage capacity and provided little space for packing and shipping products.

Additionally, the facility lacked a clear layout for the several stages of their operation to take place. This inadequate layout caused bottlenecks, increasing the time it took to pick, prepare, and ship the flower arrangements.

Solution: Defined Layout with Push Back Rack and Pallet Flow Rack

The company hired REB Storage Systems to assess their operation, design a new layout, and manage the implementation process to completion.

The company receives pallets of flowers. They then store them in a cooler based on what must ship together. This includes full pallets of a single SKU of flowers as well as pallets of individual flower arrangements that include multiple SKUs. These pallets are then sent to the shipping area for distribution. This process of receiving, storing, and distributing happens quickly and in bulk for the majority of SKUs. Other SKUs have longer lifespans and storage times and pallets are shipped out individually.

The company wanted to use their existing forklifts, so the system needed to maximize storage while allowing the forklifts to reach the top pallet positions. The company also wanted to utilize a gravity flow system.

The flowers that leave the facility in bulk shortly after they are received do not require a first-in, first-out (FIFO) gravity storage solution, such as pallet flow rack. Instead, a last-in, first-out (LIFO) push back rack system was ideal because push back offers higher density than pallet flow in their restricted cooler space due to only requiring one aisle for both loading and unloading, as opposed to two separate aisles as pallet flow requires.

Furthermore, push back rack is an effective solution for the storage and distribution of several pallets at once, since all pallets that ship together can be stored in the same row(s). The company can store pallets of the same SKU together in each row as well as pallets of multiple SKUs that will ship together.

A push back system with 978 total pallet positions that is comprised of 3-deep, 5-deep, and 6-deep push back rack was designed. The system includes a ground level with no push back carts for secure storage of the tallest pallets and two levels of push back rack above the ground level for storage of 60” and 80” pallets. Additionally, REB provided column protection on the front columns to reduce the possibility of equipment impacting the uprights.

Conversely, the pallets of flowers that ship individually require a first-in, first-out storage solution. The gravity storage solution of pallet flow was included for these pallets. This FIFO product rotation ensures that the flowers nearest to expiring are shipped prior to those that are newer.

Two pallet flow systems with a total of 747 pallet positions were designed. They were installed in two separate sections of their warehouse. One was an 11-deep system with a total of 495 pallet positions and the other was a 7-deep system with a total of 252 pallet positions.

Solution: Full Project Management Services to Accommodate Special Requirements

After the design received approval, the REB project manager managed the project from beginning to final walkthrough. The company has several points of the year in which they have high throughput. These include Valentine’s Day and Mother’s Day. The company wanted the material handling system to be installed by Mother’s Day, making it a tight timeframe. REB project managers worked around the floral industry’s peak seasons throughout the year and had the system completed and ready to use before Mother’s Day.

The project manager’s responsibilities included:

• Obtain commitments on lead times and set a firm project schedule including completion date.
• Order and transport all materials from multiple manufacturers.
• Acquire necessary building permits for the construction.
• Manage all subcontractors.
• Manage installation of the rack system within the 33ᴼF, 90% humidity environment of the cooler.

Outcome: Organized Storage and Distribution

The new material handling system has several positive effects on the company’s distribution operation. These include:

Higher density: Adding racking to the floor stacking area allows the company to store more pallets vertically than what is possible with floor stacking, therefore shrinking their storage footprint and allowing for growth.

Increased pick rates: Products that were previously stacked on the floor are now organized within designated push back and pallet flow lanes. This decreases the time it takes employees to locate pallets needed for each shipment. Additionally, the gravity flow characteristic of push back rack and pallet flow rack makes each pallet readily available in the front picking aisle of the system.

Higher throughput: The increase in pick rates and storage capacity allows the company to distribute more pallets.

Cost savings: Including floor storage at the bottom level as opposed to having push back carts saved the company money.

Do you Have Storage Requirements That Need to be Met?

At REB Storage Systems International, we look at each project as unique. While many have similarities for which we can leverage our experience and knowledge, each client has unique needs that must be met.

REB has the flexibility to integrate products from multiple manufacturers based on the requirements of your rack system including pricing and lead time. This combined with in-house design, planning, and permitting support expertise allows us to provide you with your specific storage solution.

To receive a storage solution that optimizes your unique requirements, fill in the contact form on this page or call (800) 252-5955.