RESERVED FOR Rey writer only

ROCESS Í N D U S T

integrated suppiy ciiain expertise wins iien's siiare fer Linfex Linfox is Lion's in-house logistics

provider, servicing a large

proportion of its transport and

operations needs, including

ambient and temperature-

controlled warehousing on the

east coast of Australia and line

haul transport nationally on

all major legs. Lion engaged

Linfox to manage the majority

of its Australian distribution

requirements. Uon's new national distribution centres were estabiished by Linfox.

H O S E A N D C O R D R E E L S

Hose reels

Food Processing

Appiications ReCoila's SE Series spring rewind stainless steel reels are sfrong, compact and perfect for hygienic food processing and nnanufacturing environments. Tine SE Series is avaiiable in a wide range of sizes to suit various hose sizes and pressures.

Need a reel for a different applicotion? We've got thousands to choose from - or we can design and manufacture o reel tor your specitic requirements.

Coll us for more info or visit us online at www.recoila.co.nz

P 9 441 0177 E [email protected]

www.recoila.co.nz

PROUDLY!

AUSTRAÍIANI

MADE! OWNEDI

Lion (formerly Lion Natban National Foods) is a leading beverage and food company witb a portfolio tbat includes many of Australia and New Zealand's favourite brands. Tbe Dairy & Drinks division (formerly National Foods) produces bousebold name brands of milk and dairy beverages, juice, dairy, cbeese and soy products. Tbe Dairy & Drinks footprint includes production facilities and sales offices in all Australian states, as well as New Zealand, Singapore, Malaysia and Indonesia.

In addition to consolidating line baul and transport operations for Lion, a key feature of tbe massive 3PL contract was the establisbment of two new national distribution centres (NDCs) in Sydney and Melbourne. Tbe Sydney N D C was up and running in January 2009, witb tbe new Melbourne N D C at Laverton now fuUy operational as of June 2011. Witb a storage capacity

of more tban 26,000 pallets, tbe new 28,600m^, temperature- controlled Laverton N D C is a bigb velocity operation, distributing over 100,000 cases per day.

Linfox's N D C Operations Manager Travis Small said "Many of tbe SKUs (stock keeping units) we distribute for Lion bave a limited sbelf life. Stock turns over very quickly. Storing and distributing sucb SKUs efficiently requires a smart D C layout and storage systems, and tbat's exactly wbat Dematic delivered.

"Tbe use of drive-in or double deep storage racks would bave improved tbe site's total storage capacity. But, given tbe bigb turnover of tbe products we are distributing, Linfox opted for single deep selective racking to provide safer, faster, unrestricted access to every product Hne," be said. "It also gives us total storage flexibility, witb just about every product capable of being slotted in every location."

ÎENGINEERING& 1 2 IMANUFACTURJÜG March 2012

Meeting demanding project

milestones

"Dematic didn't just meet our demanding project deadlines; they exceeded expectations at every phase of the project," added Linfox's Travis Small. "We basically took possession of a massive empty shed in October 2010 and had to bring the first phase of the N D C with over 20,000 pallet locations online before Christmas. Fitting out a D C with over 20,000 pallet locations in such a short timeframe is no small task, and installation of the storage system was very much on our critical path. Dematic's ability to complete the installation of more than 26,000 pallet storage locations ahead of time across all four implementation phases contributed greatly to our meeting critical project delivery mUestones."

Dematic's Project Engineer Joe Carmody said implementing the short two-month installation

schedule required all of Dematic's extensive project management experience. "It was essential we had all of the storage equipment in place prior to each phase going live, which meant working around the clock, seven days a week when necessary," he said. "The installation of such a large storage system in less than two months was only made possible through Dematic's ISO9001 Certified Quality System- accredited project management and implementation methodology," said Mr Carmody.

Initiatives included:

• Setting up a steering committee comprising senior Linfox and Dematic managers to facilitate open communications at a high level, and ensure any non-project related matters that may impact the project were assessed.

• Project planning and scheduling, including a detailed program of works covering all major implementation tasks

from site establishment and installation to commissioning and acceptance.

• Development and implementation of a structured risk management process. • Regular site meetings, detailed weekly progress and monthly reporting.

Flexible DC design and layout

The Laverton N D C is currently configured with two separate chambers - one

is providing storage for over 21,000 pallets, and the other for more than 5000. Splitting the N D C into separate chambers gives Linfox the flexibility to run different zones at different temperatures if required. The N D C and storage system layout make it easy for walls to be added to create flirther separate chambers if required.

About half of the NDC's orders are despatched as fiiU pallets. Split case orders are picked from

'YASKAWA' MOTOMAN, 'DAIHEN' O.T.C. ROBOT a n d WELDING SYSTEMS.

Carbines Engineering supplying

Motoman & OTC Daihen robots to

New Zealand Industry for over 25 years, gives "Adept" as an example of the

Motoman quality product. Picture shows 4x of the

Multiple 6 axis 6kg Motoman Robots

mounted and interfaced into Adept's "Toyo" Plastic injection

Moulding- Machines.

Since the first UP6 installation in October 2006 a further 12 Robots have been added to their family of tireless Machine tenders.

www.demm.co.nz 1 3

Joe Carmody (left), Dematic's Project Engineer, and Travis Small, Unfox's Operations Manager

Colby Cartonflo catrton live storage and packed into shippers and palletised for local direct-to- store delivery through Linfox s route trade distribution network. AH order picking is RF-directed, with both Linfox and Lion running SAP IT.

Through its Vision Zero program, Linfox is totally committed to ensuring occupational health and safety (OHÔcS). To that end, the N D C s storage systems incorporate a number of safety initiatives including Dematic's ColbyRACK Protect-a-Rack.

Dematic designed the 26,000 pallet capacity storage system to

suit Lion's requirements, which includes not storing products on the ground for hygiene reasons. A first storage beam level 300mm above ground keeps all pallets clear of contamination or pests, and provides sufficient access for regular cleaning. Pallets are typically stored six high with a top beam level of around 8m.

Optimising storage system safety

To help prevent rack damage during pallet put-away and retrieval, the storage system incorporates modified Colby Protect-a-Racks to suit the 300mm high first beam level on

all rack uprights, together with end-of-aisle protection. AH aisle- facing uprights have also been fitted 'with Colby Protect-a-Base.

T h e new baseplate protector is mounted to the base of front uprights providing protection at ground level against minor collisions with forklifts and pallets. It features an angled front face, which curves and wraps around the whole upright to eliminate any catch points when pallets are being placed or removed.

Colby Protect-a-Rack upright protectors interlock 'with the Protect-a-Base, forming a highly robust member. Protect-a-Rack

upright protectors not only defiect impacts away fi-om the upright, they also absorb them and transfer inertia to the strongest part of the rack - the bracing nodes. They also include a rear flange protector to ensure the entire upright is shielded firom direct impact damage from the rear.

"Safety is obviously our number one concern. Preventing storage systems from getting damaged in the first place not only provides a much safer workplace, it wUl also reduce operating costs over the life of the D C , " said Linfox's Operations Manager Travis Small.

Hygienic pressure switcii Wika has expanded its family of electronic pressure

switches with a ne'w product for sanitary applications. The new PSA-31 is fitted 'with hygienic process connections and is therefore recommended, among other things, for applications in filling and packaging machinery for the food and pharmaceutical industries. The instrument is extremely robust and the wetted parts are particularly easy to clean. The hygienic design of the pressure switch conforms to the 3-A standard 74-03. With its case that can be turned through 300 degrees, this electronic pressure s'witch can be easily adjusted to any indiiddual installation situation. The large, angled display, which is also rotatable, is easy to read from any position. For this concept, which is characteristic of the entire family of electronic switches, Wika has already been awarded the I F product design award for 2009. This was awarded on the market launch of the PSD-30. • Go to www.demm.co.nz/enquiry quote: D120314

GEA Refrigeration Technologies

GEA Freezing 356 Church St. Penrose. Auckland. New Zealand

PO Box 12479 Penrose. Auckland 1642

Phone: NZ +64 9 526 3344 • Fax +64 9 526 3345

Phone: AUS +61 3 9770 8832 • Fax +61 3 9770 8839

www.geafreezing.com

I—#

GEA Freezing Offers a wide range of energy efficient freezing and cooling

systems. The design of our Spirals, Tunnels and Carton Freezers has

evolved from more than 30 years' experience in the food processing

industry. Our food application, engineering and manufacturing teams

ensure the freezers or chillers fully meet your processing needs.

ÍENGINEERING& 1 4 ! MANUFACTURING March 2012

Copyright of DEMM: Engineering & Manufacturing is the property of Adrenalin Publishing Limited and its

content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's

express written permission. However, users may print, download, or email articles for individual use.