BS Handling Systems has completed a multi-million pound project for the global online fashion retailer, ASOS. Due to continued success and rapid growth, ASOS needed to extend and maximise the storage capacity at its fulfilment centre in Barnsley.
The project has seen BS Handling Systems expand its previous work at the Barnsley site to include a three tier mezzanine above the goods-in area, with each floor totalling 6,000 sq. metres. In addition to this, BS Handling Systems installed long span shelving on all three floors of the mezzanine, enabling ASOS to store an extra 169,000 cartons on site. BS Handling Systems has also moved and extended the security cage for high value goods as well as fitting additional office space.
Expanding capacity for continued growth
Mike Kosciukiewicz, Head of Returns Operations, ASOS Supply Chain explains: “ASOS is continuing to expand and we constantly have to evolve to keep up with our increasing outbound volumes.
“We needed to increase the capacity of our Barnsley facility to match the growing product range and meet the demands of peak periods.”
In order to maximise the existing space at the Barnsley facility without extending its footprint, BS Handling Systems designed and built the mezzanine floors over the current operational area.
To avoid compromising on floor space, they devised a design to minimise the amount of visible upright steel columns used to support the new mezzanine.
On the ground floor, the design skillfully allowed for wide aisles whilst concealing columns within the shelving on the mezzanine floors. This was important for health and safety to ensure the ease of movement for both forklift trucks and workers within the busy facility. It was also essential that the mezzanine floor columns did not block the dock doors for delivery and dispatch access.
In addition to the three tier mezzanine floor installation, BS Handling Systems also fitted almost 59 linear kilometres of shelf space with 2,400 shelving bays over the three mezzanine levels. The design has enabled ASOS to store an additional 169,000 cartons at the Barnsley site.
All the bays were designed to hide the mezzanine floor columns whilst maintaining a wide aisle design for the ease of trolley movement.
BS Handling Systems also completed extra work on the Barnsley site including the installation of office space, a control pod and meeting rooms. Additional works also saw the movement and expansion of an existing secure cage for valuable items and the supply of a spiral tote chute and conveyor system from the existing pick tower.
Overcoming challenges for a successful installation
Kosciukiewicz continues: “The expansion has significantly increased the storage capacity for the Barnsley site. Our product range is now so large, we need to ensure we have enough space to store sufficient levels of stock to supply order demand.
“It was a challenging project, not only because we had specific design elements, but also the installation had to be completed within a five month period whilst our operation was still live.
“We have worked with BS Handling Systems on several projects now and, throughout this process, they maintained the same very high standards we have come to expect,” concludes Kosciukiewic.