Due to continued investment and growth, Whitefurze Limited had the requirement to increase storage capacity across its existing warehouse facilities in Coventry. A double deep racking installation has not only enabled a significant increase in pallet capacity but product selectivity and operational efficiency.
Whitefurze is one of the UK’s leading manufacturers of plastic consumer products. Since the company’s inception in 1978, the privately owned company has grown into a successful and dynamic business with a comprehensive product range across Food Storage, Storage, Housewares and Garden categories. An extensive range combined with ongoing new product development has highlighted the need for a flexible storage facility to accommodate a variety of product types.
With a state of the art manufacturing facility in Nuneaton, the company currently has a 17,000 pallet capacity warehouse in Coventry. Recent product additions and increased growth provided opportunity for Whitefurze to take on additional storage capacity within the locale of Coventry.
Whilst the existing very narrow aisle storage facility achieves a high level of pallet capacity it doesn’t offer the company the level of operational flexibility it requires due to seasonality changes and associated stock levels. It therefore approached SEC Storage to help determine the optimum storage solution at its new Coventry warehouse, from both a capacity and operational basis.
The first storage solution conceptualised was a dense drive-in storage system. Due to the non-perishable nature and high stock volumes stored, this appeared to be the best solution to maximise pallet capacity. However it would have meant combining multiple Stock Keeping Units (SKU’s) in each drive-in aisle to optimise space utilisation of the system. However this would prove problematic for product selectivity based on mixed SKU’s in each aisle.
Another consideration was an articulated narrow aisle configuration. Similar to the existing very narrow aisle system in Coventry but it would offer greater flexibility in the use of the materials handling equipment, as it could be used for other functions within the warehouse. Unfortunately desired pallet capacity could not be achieved.
The final solution, following systematic space planning and analysis of space utilisation, was a double deep pallet racking configuration using a reach truck forklift. On a number of facets this proved to be the optimum solution including greater volume at the pick face, greater selectivity of product and an increase pallet count over the articulated truck configuration.
Almost replicating dense storage pallet capacity, it would provide the flexibility to store high volumes of the same SKU’s and easily accessible from the pick face due to the wide aisle configuration. Space utilisation is expected to be at 97% and is not affected by seasonality changes.
Whitefurze is now able to store a total of 6,203 pallets. The initial pallet count was 5,693 however SEC Storage suggested by incorporating “half pallets” into the operation, an additional 510 pallets could be stored maximising the height of the building.
Other aspects of the installation were considered included anti-collapse steel mesh on the rear of a single entry pallet racking run to act as a safety screen in front of the loading bay area. Whitefurze also requested that a number of the pallet spaces have timber decking installed as a safety measure for the more inaccessible pallet locations at the top and rear of each bay.
Providing more than just racking SEC Storage also designed and installed a low bay lighting system for the installation. It was soon realised that the double deep installation would provide the most economical lighting configuration over the dense storage systems considered, adding further benefits to the configuration.
Furthermore, with Whitefurze’s desire to limit the environmental impact of its second warehouse, SEC Storage specified the use of LED lighting coupled with PIR sensors. Not only do LED lights offer running cost savings of up to 60%, the PIR sensors installed will only activate the lighting when motion is detected, meaning running costs are further reduced. This will also significantly lower the impact of emissions produced by the facility.
“We are very pleased with the outcome of this project and the work carried out by SEC. They understood our requirements, controlled the project well from start to finish and delivered the end result on time”, commented Stuart Draper, Production Director.
With a 36% increase in storage across its two facilities, Whitefurze Limited are now able to accommodate future growth and innovation of its product range, with the flexibility and operational efficiency the company requires.
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