Food Logistics serves the entire food supply chain industry with targeted content for manufacturers, retailers, and distributors.
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S P E C I A L E D I T I O N 20 J U LY 2014 ❯❯ FO O D LO G I S T I C S W W W . F O O D L O G I S T I C S . C O M John B. Sanfilippo & Son, Inc., the Elgin, Ill.-based manufacturer of Fisher Nuts, with plants in five states, well understands the challenges of today's warehouse technol- ogy. The company uses robotic packaging equipment in its manufacturing operation, notes Tom Kirkham, director of business applications. The company chose not to pursue the use of conveyors and case pick modules for its ware- house operations as the current balance between case and pallet picks does not support the investment. John B. Sanfilippo & Son Inc. relies on its High Jump WMS soft- ware for labor management, Kirkham says. Since installing the WMS in 2006, the software has helped the company increase inventory accuracy as well as maintain allergen segregation to increase food safety. The software contin- ues to come in handy as they increase their export trade, since many countries require certificates of analysis (COA). "They (High Jump) have enabled us to segregate the COA product and prevent it from being picked with non-COA product," Kirkham says. "It is a very critical system to us." Minghini of Kenco notes that many food and beverage makers are finding new markets overseas, which requires them to expand their SKUs. "The taste in the American market is sometimes vastly different than the European or Asian market," he says. "The more globalization happens, the larger your SKU proliferation." A burgeoning foodservice market also affects food SKU counts, Minghini notes. In the last decade, away- from-home food outlets (restaurants, institutions and convenience stores) have grabbed "share of stomach" dollars from food retailers, forcing product manufactur- ers to adjust their offerings if they want to be where the growth is. (Who cooks at home anymore?) Repackaging is the least that is called for when a foodmaker that is used to selling to supermarkets decides to tackle the restaurant trade. For such manufacturers, Minghini observes that expansion into foodservice results in more private label SKUs. But SKU proliferation is only one challenge facing food and beverage warehouse manag- ers. Different retail channels usually require different case loads. Picking systems have to be more flexible to pick to order different case loads. All of which requires more dynamic WMS systems, a chal- lenge that Minghini claims the technology players have met head on. "If you don't have a really good WMS, you're going to struggle over the long term," he says. Real-time data will make labor more efficient, notes Jim Chamberlain, senior director of industrial engineering and continual improvement at DSC Logistics, a 3PL based in Des Plaines, Ill. This will be especially beneficial to food General Mills Optimizes Pallet Flow And Pushback Rack Storage F ood manufacturers can improve warehouse effciency by expanding package sizes where possible. In order to accommodate larger packages, General Mills Inc. reconfgured its warehouse in Cedar Rapids, Iowa, a project that required the assistance of a material handling equipment distributor and a pallet rack manufacturer. By switching from 50-lbs bags of ingredients to 2,500-pound bulk super sacks, the company enhanced efficiency and minimized material handling, according to Scott Ladwig, an inventory analyst at the plant. Ladwig turned to RMH Systems, a Bellevue, Neb.-based material handling equipment distributor, and Steel King, a flow storage system and pallet rack manufacturer in Stevens Point, Wis. After consultation with General Mills and Steel King engineers, RMH Systems sales engineer Marty Frangenberg recommended an integrated SK 3400 flow storage and SK 3600 pushback rack system. In a flow storage system, dynamic flow rails are inclined in a static rack structure, allowing loads placed on one end to move by gravity on rollers to the unloading end, with speed controllers acting as gentle brakes. As a load is removed, the loads behind it move forward automatically. Once loaded, first-in/first-out product rotation is automatic and the rack eliminates labor and fork truck operation to arrange loads. Forklifts are required only for the initial and final unloading. Since only two aisles are necessary, aisle space can be reduced by 75 percent and up to 100 percent more product can be stored than with traditional selective pallet racking. Unlike static, single-pallet deep selective racks, a dynamic pushback rack system allows storing pallets two to five deep while providing access to a variety of different SKUs. Pallets are stored behind each other in a series of nested carts and are loaded from the same side of the system, eliminating separate aisles for each function. Composed of a stable rack along with a series of inclined carts and rails, when one pallet is pulled, the one behind it rolls forward. To enhance rack longevity, General Mills chose SK3400 and SK3600 rack systems by Steel King; both feature a bolted-beam connection to structural channel columns. "With our new integrated pallet flow and pushback rack system, our Gen- eral Mills plant is operating more safely and efficiently than ever," says Lad- wig. "We're ready for continued growth for the next 15 years and beyond." The General Mills plant switched from 25-pound bags of ingredients to 2,500- pound bulk super sacks to enhance efficiency and minimize material handling. " If you don't have a really good WMS, you're going to struggle over the long term."