Multilevel Pick Module + Conveyor + VRCs for Home Decor Backroom Storage

Solution and a Glance

To meet the storage and fulfillment demands of a high-traffic retail store, REB designed a two-level pick module for the retailer’s backroom. This design provides high storage density and rapid tote delivery to the pickup counter, creating a highly efficient backroom.

• Products: Multilevel Pick Module, Selective Pallet Racking, Catwalk Racking System, Vertical Reciprocating Conveyor, Zero Pressure Accumulation Spiral Conveyor, Pallet Rack Protection, Lighting
• Services: Design, Permitting Support, Installation, Project Management
• Location: Wilmette, IL
• Number of Projects REB has Completed for Customer: 15

Concern: Backroom Storage Solution for a High-Traffic Retail Location

A national home goods retailer was preparing to open a flagship store in a high-traffic market. The retailer’s traditional backroom layouts could not provide the storage density, SKU accessibility, or throughput required to support the store’s high volume. This retail location would be the blueprint for future high-traffic locations opened by the retailer.

Due to the complexity of the storage system required, the retailer wanted to work with an experienced material handling systems integrator with proven experience designing and implementing multilevel, automated storage systems.

Solution: Innovative Storage System Design for Retail Backroom

Having partnered with REB Storage Systems International on numerous projects for the retailer, they knew they could rely on REB’s design and project management capabilities to assist with this project.

After analyzing the retailer’s large range of SKUs and available storage space, REB designers developed a layout unique for a retail backroom: a two-level catwalk rack system integrated with automation. This innovative backroom design provides the highest storage density and throughput possible in the confined backroom footprint.

Continue reading below to learn more about the backroom storage solution that REB provides to the customer.

Solution: Multi-level Pick Module with Integrated Automation for Retail Backroom

Catwalk Racking System

The pick module consists of a two-level catwalk system made up of 27 different selective pallet racking bay elevations, allowing items of all sizes to be stored. In total, the selective rackling provides the retailer with 38,268 cubic feet of storage capacity, utilizing nearly the full vertical cube of the backroom.

The two levels of the system are accessible by two staircases. The staircases are positioned on opposite sides of the system, allowing multiple employees to smoothly ascend and descend the catwalk level at once.

Vertical Reciprocating Conveyors

For transporting pallets or cartons to and from the upper levels the pick module, two vertical reciprocating conveyors (VRCs) are integrated. A VRC features a lift platform that moves up and down on a track, driven by hydraulic or mechanical systems. They are customized to product characteristics, such as weight and dimensions.

The VRCs make it easy to transport large items and pallets between levels, so more items can be moved simultaneously. This also allows the retailer to use their picking carts on the second level of the system, since each VRC can transport two carts and up to 2,000 lbs.

Zero Pressure Accumulation Spiral Conveyor

A spiral conveyor is integrated with the catwalk system to transport items from the second level of the system to the in-store pickup counter

When an in-store pickup order is placed, the picker loads a tote onto the conveyor, which transports it at 180 feet per minute over a total system length of 117 feet. Totes reach the pickup area in under a minute, supporting a throughput rate of approximately 41 totes per minute when considering operator load/unload time.

Zero pressure accumulation technology is included to ensure safe transport of the retailer’s fragile home decor items during transport.

Pallet Rack Protection

To safeguard the system, inventory, and most importantly employees, pallet rack protection is integrated, including:

• Row end protection is installed on the floor of high traffic areas to minimize damage if a forklift drives into the rack uprights.
• Guardrail is installed in high traffic areas on the ground level to provide a physical and visual barrier between work areas and forklift driving areas.
• Handrails are installed on stairs to assist employees.
• Kickplates are installed on the floor of each drop-off in the upper level of the system to prevent items from sliding off.
• Safety netting is installed in all locations on the rack system where items can fall off.

Solution: Full Project Management

REB served as the single point of contact throughout design, project management, permitting support, freight coordination, and installation.

As a systems integrator, REB utilizes an expansive network of trusted and verified manufacturers and installers to source and install the required items needed for every job.

Outcome: High-Efficiency Storage for Flagship Store

The pick module system delivered measurable benefits. These include:

High backroom storage density: The catwalk racking system utilizes all vertical space of the retailer’s backroom. This, combined with varying rack bay sizes, provides storage in the full cube of the backroom.

High throughput: Automated tote transport enables up to 41 totes per minute, shortening fulfillment times and supporting the store’s high-traffic environment.

High pick rates: The retailer stores each of its products in a designated location within the backroom. This makes it easy for employees to locate and pick products.

Reduced labor requirements: Automation decreases the requirement for employees to be involved in every step of the picking process.

Ontime store opening: REB managed schedules, coordinated with all vendors, and provided ongoing updates to ensure the backroom was completed in a timely manner so the store could open on time.

Standardization: Partnering with REB for all retail store openings allows consistent execution from store to store. Future high-traffic store locations will benefit from the system quality and design standards developed for this location.

How To Transform Your Backroom Storage for Efficiency

Do you need a unique backroom storage solution? REB can help.

Our team of material handling specialists will partner with you to develop a customized solution that optimizes your backroom space. We bring proven expertise in designing and project managing storage systems that address the unique challenges of retail backrooms.

We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill in the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.