ASRS,
ACTIV, ACCESS Application Case Studies
View Retrotech’s case study library
to learn how various clients facilities in North America
solved their logistics automation problems and improved ROI.
Our expertise incorporates many different material handling
technologies and incorporates products and services such
as Automated Guided vehicles, (AGVs), Warehouse Management
Systems( wms) , Automated Storage and Retrieval Systems (asrs)
and conveyor systems. |
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Our
Clients and our History of Excellence |
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Automated Material Handling Case Studies |
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Fortune
50 company benefits from Automation, published
in The Lima News, June 2007 |
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Pratt and Whitney Article published in MRO Magazine, February 2006 |
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White Papers : ASRS, Activ, WMS, AGV |
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Retrotech Newsletter Winter 2005/2006 |
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Retrotech
Newsletter Summer/Spring 2006 |
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Automated Storage Retrieval
Case Studies ( =
PDF Download) |
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ACTIV Systems - |
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3PL Blast Freezer – ACTIV Systems have been used by a number of Fortune 500 food and consumer goods companies to support high turn distribution, however
this system is the first high turn blast freezer built in the USA using a modified ACTIV System design
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Activ
Distribution Center - ACTIV System – ACTIV
acts as a storage buffer for the manufactured product. Full
pallet unit loads are buffered
and continually flow through to staging lanes at the dock end
of the system. |
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ACTIV
Paper Roll Handling -
The North American pulp and paper industry competes with
foreign companies that use more advanced material handling
systems. Retrotech offers a proven automated material handling
system that will reduce costs from labor and prevent roll
damage. |
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ACTIV
P - Cat Systems - RETROTECH Incorporated,
manufacturer of ACTIV Systems for North America, recently
developed and installed a modification
to ACTIV’s standard CAT (cross aisle transfer) design. |
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ACTIV
Picking - Automated Picking Systems - ACTIV
can incorporate the basic elements of its single axis pallet
carts (DLTs), pallet lifts (VTLs), and cross aisle transfer
devices (CATs) to design pick slots and automated replenishment
into the dense, high turn storage envelope when a distribution
application demands it. |
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Beer & Beverage -
Large Volume Beverage Distribution Center Calanda Haldengut
Brauerein is a major distributor of beverages in Switzerland.
Their Calanda Bräu Distribution Center was a new build
facility designed to include maximum storage in a limited
footprint. This application showcases the modularity and
flexibility of ACTIV’s continuous
flow technology. |
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bo*frost
Freezer - The ACTIV System in this facility operates
16 hours/day. It is divided into three storage areas —
a full pallet cold store (VP), an order picking store (AP), and
an order picked/mixed pallet store (MP). |
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Frito
Lay - ACTIV System—Staging takes place within
the ACTIV footprint. Orders are arranged in reverse trailer
order in a “ staging slot.” For this application,
the staging slots consist of three staging lanes arranged
vertically. |
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ICA
Cross Docking - Partihandel, is a huge player in grocery
industry – a division of Ahold, with full service
stores as well as convenience style shops. To support the
servicing of stores with high frequency, ICA looks for
manufacturers to deliver store orders for a region in layer
quantities, on pallets, to their automated cross docking
facility, where many manufacturers “to store” order
pallets are merged onto ICA trucks. |
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Kraft
Foods Buffer - This ACTIV application is installed
in a new warehouse facility. With 25,000+ positions, it
is the world’s largest ACTIV System. A corporate
Warehouse Management System (WMS) manages the entire operating
warehouse environment. |
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Kraft
Refrigerated Mixing - The Mixed Pallet Picking area
is also located within the ACTIV footprint. Here, under
direction of the WMS, full and partial pallets are converted
into mixed pallets. |
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Li
Destri Distribution Warehouse - LiDestri Foods of Fairport,
NY manufactures LiDestri and Francesco Rinaldi spaghetti
sauces, Newman’ s Own salsa and pasta sauces, as well
as a number of major national and store branded products. |
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Procter
ACTIV System - Storage Buffer for Full-Pallet Unit
Loads - The manufacturing facility identified in this case
study shows a two-module system. The levels are 3 and 4
high, respectively, with the 3-level high system being
installed in an existing building. |
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Stora
Enso - The ACTIV input points consist of a short
input conveyor, a roll sizing station, and a bar code reader.
The ACTIV receives directly from in-floor on-the-bilge roll
conveyors. As the rolls move toward ACTIV’s vertical
transfer lift (VTL), they are scanned and size-checked to
validate the roll dimensions and reconcile the roll with
the host as a valid input. |
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Truck
Stage ACTIV System - Supply chain integration depends
on a continuous stream of products and information starting
with the raw materials supplier through the manufacturer,
distributor, carrier, retailer, and ultimately, the end user. |
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ACCESS Sytems - |
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Inter
Forum Publishing - Inter Forum, a division of Vivendi
Universal, is the number-two company in book distribution
within Europe. This mega-distribution center was created
when five smaller distribution centers were combined. |
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Lutosa
Access System - Van den Broeke-Lutosa - one of Europe’s
leading food processors and Belgium’s largest potato
processor - delivers over 300,000 tons of product annually. |
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Salvesen
Distribution - Christian Salvesen operates as a 3rd
party logistics (3PL) refrigerated/frozen food Distribution
Center serving Northern Europe. The ACCESS technology in
this application is a single rack-supported system that
was installed in 1997. |
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Unifrost
Access System - This design, when combined with a multi-deep
lane capability, gives this facility high density with
tremendous flexibility for throughput and future growth.
This facility allows Unifrost/Dujardin to control shipping
and eliminates a large outside storage and logistics cost. |
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Customer Support - |
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Customer
Service Brochure - View the extensive capability and
experience of the Retrotech organization. |
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New System Integration - |
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Cargill
Meat Solutions ASRS - Excel Corporation, a division
of Cargill, Inc., specializes in beef processing for the
consumer market and provides various grades of boxed beef
products to wholesale/retail distributors and high-volume
users. |
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Cargill Meat Solutions (Friona) ASRS - Cargill Meat Solutions, specializes in beef processing for the consumer market. A global leader in the beef processing industry, they provide various
grades of boxed beef products to both wholesale and retail distributors as well as to high volume end users. |
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Navy
Stacker System - This application discusses the ASKARS
project, which involved the modernization of two Naval
Aviation Depot sites—Cherry Point, NC and Jacksonville,
FL. RETROTECH Solution—Cherry Point - Replace existing
Supreme mini-load stackers with new Munck Autech mini-load
stackers. |
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Wegmans Food Markets, Inc. - Wegmans Food Markets, a top 10 grocery chain located in Rochester, NY, operates 70 stores and needed a facility to service their expanded Mid Atlantic region.
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Retrofits / Modernizations - |
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Burlington
ASRS - The Burlington Industries Distribution Center
(BIDC), with a capacity of 129,836 rolled fabric units,
serves as a storage and distribution facility for multiple
divisions within the company and throughout the day, BIDC
receives orders from the different divisions that have
stored units in the high-rise. |
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Cargill
Meat Solutions ASRS Crane - The warehouse operations
use an elaborate series of box and unit load conveyors
to move Vintage 5-aisle Demag unit load AS/RS had proprietary
control system with limited support capabilities and no
flexibility. Drive systems were obsolete and system performance
needed to be improved. |
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Georgia
Pacific - Georgia-Pacific’s existing system handled
storage of finished paper products for the corporation,
and served as a buffer between production and shipping.
Retrieved loads were placed by a onto stacker cranes. |
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Karmax -Karmax heavy stamping is one of the world’s most diversified automotive supplier.RETROTCH provided Karmax with a state of the art, non-proprietary ASRS equipment upgrade. The replacement equipment will provide improved reliability and supportability of the ASRS due to new technologies and improved industry practices to support future business needs. |
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IBM
ASRS - Efficiency of the Eaton-Kenway mini-load operation
had deteriorated due to equipment obsolescence and limited
OEM support. Notably, the stackers had obsolete horizontal
and vertical positioning systems, horizontal DC drives
and motors. between on-board controls and the off-board
computer. |
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Monfort
ASRS - Monfort Beef, a division of ConAgra, specializes
in the processing of meat. This facility provides an assortment
of grades of boxed beef for the consumer market, and ships
it to wholesale, retail distributors, and high-volume end
users. |
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Plainview - Retrotech has provided Cargill with another ASRS software replacement solution that exceeded the plant goal, provided cost reductions, and exceeded the plant's expectations.
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Pratt& Whitney - Making (ASRS) automated systems running better than ever. How as jet engine plant upgraded three automated machines (ASRS) Originally published in MRO Magazine, Toronto, February 2006.
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Ross Abbott Labs - One of the world's top health care companies substantially lowered maintenance costs and improved uptime service and product availability.
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Schering
ASRS Software - This case study represents an AS/RS
multi-project, multi-year effort resulting in a complete
facility modernization and resolving a variety of business
issues, including performance, reliability, and space. |
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Wendt's
Woodson ASRS - The bottom two levels of the AS/RS are
pick mezzanines with gravity pick slots that feed facings
that are adjacent to dairy chains. Here the pickers can
slide a case or a stack onto the adjacent chain with minimal
effort. |
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