Stacking Up Positive Results for Beverage Distribution
Beverage distribution has seen its share of changes over the decades but none more challenging than the supply chain demand of today; from the SKU explosion of craft beers, bottled waters, and health drinks to the conundrum of smaller, more specialized order fulfillment, and, let’s top it all off with a worker shortage. Success today demands a new approach to “beverage distribution as usual”.
While a strategically designed warehouse storage solution can’t alone solve all your challenges, it can give you the tools you need to succeed. Let’s talk strategy…
Pallet Racking for Today’s Beverage Distribution
Pallet storage solutions serve as:
- Reserve for case pick order fulfillment
- Full pallet orders of faster-moving SKUs
While it’s been common to floor stack fast-moving full pallets in the past, those days are largely over due to fulfillment challenges, space constraints, safety concerns, and the availability of more efficient storage and handling alternatives.
Pallet Rack Storage for Optimized Beverage Distribution
Selective Pallet Rack
Selective rack is the most commonly used pallet rack solution. It’s quick to load and unload with 100% SKU accessibility. It is constructed as a single bay deep or can be designed double-deep if volume requires, however, a special deep-reach fork truck is then required.
Pallet Flow Rack
Pallet Flow is an ideal option for storing high-volume, moderate to fast-moving SKUs. It’s a dynamic system using slightly inclined wheeled tracks to store multiple deep pallets in a condensed space. Pallets are loaded on one side and slowly flow toward the opposite aisle for retrieval using first-in/first-out (FIFO) inventory rotation. Systems can range from 2 to 10 pallets deep depending on the application.
Pallet flow can also be configured as a push-back system using a single aisle for load and pick to support (last-in/first-out) LIFO inventory rotation if space is tight. One benefit over regular push-back is the flexibility to store non-standard-sized pallets.
Pallet flow is low maintenance and can be designed to work with nearly any pallet size or style.
Push-Back Rack
Push-back is another dynamic, dense storage option. It is loaded and picked from a single aisle, therefore supporting LIFO inventory rotation. Pallets are loaded onto nested carts one at a time. As a new pallet is loaded the top cart is pushed back to reveal a waiting cart. As pallets are withdrawn from the system, the rear cart flows forward to fill the pick face. Typically, push-back systems go up to 3-4 pallets deep.
Layer Picking
Layer picking is a method of order selection used in high-volume staging or mixing centers that allows for full layers of cases to be picked in one single pick from a pallet using a clamp or suction attachment affixed to the forklift. Layer picking has steadily gained in popularity as the need for high-volume, case-picking increases to meet demand within an ever-expanding SKU universe. Layer picking produces an exponential rise in pick rates vs. manual case selection.
ASRS
Automated storage and retrieval systems are incredibly beneficial for the right beverage distribution operation. ASRS takes advantage of vertical space and operational efficiencies found in a high-volume fulfillment operation. ASRS automation can run 24/7/365 increasing throughput without overtime pay or worker injury. It also improves inventory accuracy and response times, while managing seasonality and changing consumer preferences more efficiently. ASRS has come a long way in just the past decade from semi-automated to fully automated and fully-integrated. Customizing the system to your specific needs has never been easier.
Carton, Case, Bottle, Keg Storage
Carton Flow (Case Flow)
Carton flow is a perfect dynamic solution for full or split case picking of slower movers (vs case pick from pallet for fast movers). Store ready-reserve inventory in designated SKU lanes for faster, more accurate load and pick. With separate load and pick aisles, carton flow supports FIFO inventory rotation. The downward slope of the carton flow design ensures the pick face is automatically replenished with reserve stock as soon as the front item is picked. The systems can be equipped with tilt trays to improve the ergonomic positioning of the product to benefit your pickers and improve speed and accuracy.
Keg Flow
Keg flow rack is ideally suited for keg rooms. It’s constructed with durable rollers that gently move the kegs toward the pick aisle while keeping them upright and orderly in designated SKU lanes. Keg flow accommodates all sizes and shapes (full and partial kegs — 1/2, 1/4, and 1/6), and speeds accurate picking & loading to reduce the number of workers needed and the length of time they spend in the cooler. Dynamic design can be set up for LIFO (push-back) or FIFO (separate load and pick aisles) inventory rotation.
Bottle Flow Rack
Bottle flow is an option for slower-moving individual bottles. It keeps SKUs separate and consolidates inventory to free-up valuable storage rack space. Individual bottle troughs drop into standard pallet rack for a fully custom solution without the custom price.
Each pallet racking system has a sweet spot concerning the type of inventory that optimizes its use… as such, we often use multiple systems in combination to ensure maximized warehouse performance.
Common Storage Rack Combos for Beverage Operations:
Pick Modules
A pick module is a multi-level order fulfillment solution that integrates several storage mediums, including carton flow, pallet flow, push-back, or shelving with conveyor systems to create a highly productive picking system. By consolidating picking activity and reducing travel time, pick modules save space while improving pick rates and lowering labor costs. Pick modules are frequently seen in high-volume beverage distribution centers effectively managing thousands of SKUs and orders per day.
Ultimately the best configuration of storage systems and applications lies with you, your facility, employees, and processing demands. The Apex Warehouse Systems team is here to help you sort through the options and deliver the full-service solution that meets your operational goals. Call today and speak with our material handling systems, automation, and equipment experts.
