Costo improves intralogistics between mezzanine and cold store warehouse at Zederik

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Smart solution for intralogistic challenge

Koelcentrum (‘cold store’) Zederik will build a new warehouse for their import fruited and the activities of subsidiary Zederik Verpakking (packaging) BV. The new building will consist of three parts: a cold store area for the storage of fruit, a sorting and packing area on a mezzanine floor and a storage area for cardboard boxes. Costo will facilitate the transport of pallets between the mezzanine floor and the cold store warehouse by supplying a number of pallet lifts.

Two triggers

Koelcentrum Zederik already owns two cold store warehouses: one in Tienhoven and one in Groot-Ammers. The company is known as a specialist for storing Dutch fruit in storage crates, but these days the storage and packaging of imported fruit has  becoming an increasingly important part of the daily work. Both activities have grown to such an extent that it was time for a dedicated building for the imported fruit.

In addition, a few years ago the company started developing its own line of cardboard (fruit) boxes to deliver to customers. At the moment, the cold store warehouse in Tienhoven is completely stuffed with erecting machines, folded and unfolded cardboard boxes. Besides for their own processes, several million boxes are now also produced every year for numerous customers. Because of this growth, it was decided to create a spot for Zederik Verpakking BV in the new warehouse.

Along the A15 highway

The new warehouse will find a spot at business park East II in Gorinchem and this facility will have between 10 and 15 employees, excluding a flexible layer for peak periods. The building will be no less than 17 meters high, with a floor surface of approximately 13,000 m2.

The new building will be divided into three sections: a cold store warehouse for the storage of fruit, a sorting and packing area and a storage area for the cardboard boxes. In the refrigerated warehouse there will be 9 large cold rooms with automated mobile rackings and a few rooms without rackings for ready-to-ship product. In total, they warehouse will have about 10,000 pallets places. All pallet movements are recorded by scanners.

Next to the cold store warehouse, a storage area will be created for the cardboard boxes. This hall will be used for the storage of both folded and unfolded boxes. In addition, the erecting machines will also be placed in this hall.

Above the hall for the boxes, there will be a mezzanine floor where a large space for sorting and packing space is set up. In this area, Zederik will process, among other things, boxes, crates, food containers and punnets. Some ripening cells for ripening fruit will also be on the first floor. The products that need to be packaged will have to be moved from the cold store warehouse to the packaging floor, while the packaged products have to travel the opposite way. In order to be able to manage these product flows efficiently, Costo will install two dedicated pallet lifts.

Because of their unfamiliarity with working at multiple levels, Zederik invited several companies for a series of meetings. After a few reference visits and an extensive study of the possibilities, the customer decided that the Costo solution was the best option.  Mark de Hoop from Koelcentrum Zederik explains: "During the orientation process, we became increasingly convinced that the solution which Costo offered would function well in our processes. To put it simply, it was just a great solution that we had confidence in."

Old versus new

Mark de Hoop continues: "In principle, the activities at the new location will largely remain the same, although there will be more and faster stock movements and we also expect more fragmentation of work in the imported fruit section."

The most important changes in the business processes:

  • All stock movements are fully processed with pallet scanners.
  • Almost all pallets can be reached individually due to the mobile racking
  • Zederik will work with reach trucks in the cells with mobile rackings. Currently, Zederik only works with ride-on powered pallet trucks and forklift trucks.
  • The supply towards the mezzanine floor and the transport back to the cold store  warehouse, facilitated by the lifts from Costo, is a complete new process.
  • In addition to packing in boxes and crates, the company will also automatically process consumer packaging (trays, punnets, etc.).
  • The sorting lines will largely be automated.

The new building will be built in a number of phases, with the cold store warehouse being the first to be operational. The entire building will be operational by mid-2019.

Costo realizes both turn-key projects and partial solutions for an intralogistics challenge. In the case of Koelcentrum Zederik, the extensive experience with bridging levels in a warehouse process was crucial for the overall solution.

 

 

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