Case Studies
FAGE USA Dairy expands into the US, its 28th country
Overview
Automation & Control - Automation & Process Control Systems Functional Applications - Remote Monitoring & Control Systems Functional Applications - Warehouse Management Systems (WMS) | |
Consumer Goods Food & Beverage | |
Logistics & Transportation Warehouse & Inventory Management | |
Inventory Management Predictive Maintenance Warehouse Automation | |
Software Design & Engineering Services System Integration | |
Operational Impact
Westfalia’s high-density technology enables flexible AS/RS designs, and a key feature of this system is its ability to accommodate growth. FAGE’s growth has been managed through extending the crane aisle for more storage lanes, and the depth of those storage lanes. The expansion area’s cubic space above the new pick lanes has been extended to 11 deep on levels 2 and up, thereby providing an additional 509 pallet storage locations (26% more storage) in addition to the 1,960 from the crane aisle extension. If not for Westfalia’s ability to program the Satellite to extend 11-deep into the racks, these 509 places would have required a 25% larger building expansion. | |
Westfalia’s modular Warehouse Management System (WMS) Savanna.NET® controls the movement and storage of all pallets within the facility. It initiates control of yogurt products at the shuttle car interface from the cooling tunnels, and for the cheese products as they enter from the dock side. To track each pallet load, a bar code reader, which interfaces with the WMS, is positioned at the infeed conveyors from the cooling tunnels and the dock area. Pallets moving both into and out of the AS/RS utilize an accumulation conveyor system which includes a profile checking station and a load squaring station. The accumulation conveyors smooth throughput surges and ensure a more streamlined flow of material between the AS/RS and order processing. Savanna controls the order picking systems, interfacing with portable RF equipment carried by the pickers in hip holsters. As the pallet loads leave the AS/RS area, a print and apply bar code device prints and automatically places labels on the outside of stretch wrapped loads. | |
Quantitative Benefit
Storage for 1600 pallets originally, later expanded to 4100 pallet positions | |
40% increase in storage capacity with a high-density AS/RS | |
30% reduction in energy costs due to efficiencies of AS/RS systems -- reduced lighting, regenerative SRM braking, smaller area to cool/freeze, etc. | |