Finished products HBWH and manual picking for food distributor

The company
Grupo Herdez is one of the leading companies in the food
industry in Mexico, with a major international presence in
the USA and Canada.
Today Herdez enjoys great national and international
prestige due to the high quality of its products combined
with the experience that comes from over 90 years in the
Grupo Herdez produces and markets more than 600
products under different brand names with high visibility
in the markets in which it operates. Among the most
important brands in the portfolio of Grupo Herdez, the
following are among the most well-known: Herdez, Del
Fuerte, McCormick, Barilla, Yemina, Vesta, Nair, Embasa, La
Victoria, Buffalo, La Gloria, Charlotte, Crest, and Hormel.

Problems and objectives
Herdez’s main requirement was to create a modern and
technologically advanced logistics site to serve Mexico City
and the neighboring states.
They therefore decided to equip the new production site
with a storage warehouse that would ensure high storage
capacity and efficient management. Grupo Herdez chose
to partner with System Logistics because its picking systems
perfectly suit the Herdez SKU profile with an easy and
balanced solution.

The solution and the results
The warehouse designed by System Logistics is dedicated to
finished product storage in an automatic vertical warehouse
with a capacity of 37,440 pallet slots. The loading units are
39 x 47 in CHEP pallets. The Automatic Vertical Warehouse
is composed of four 112 ft high bi-pallet two-column stacker
cranes that slide along an aisle 590 ft long. Maximum
capacity is 2,645 lbs per loading unit.
The products coming from the outside and directly from
production enter the warehouse through 4 bays. The
products exit the warehouse through 7 pairs of bays served
by 10 SVL (System Vehicle Loop) shuttle vehicles.
The total flows in this configuration are 90 incoming and
150 outgoing pallets an hour. As well as storing the finished
product for the shipment of entire pallets, the warehouse is
used to restock the adjacent picking area by means of the
SVL system.
The picking concept applied to this system is the Pick to
Pallet System (PPS). The area dedicated to the PPS consists
of a pallet warehouse with a capacity of 1,100 loading units
and two single-depth aisles. The picking warehouse is served
by two 33 ft high stacker cranes, model NV. The warehouse
is connected to the main SVL by means of an elevator. The
picking warehouse is situated within an SVL with 8 shuttles
that deposit the source pallets on idle roller conveyors to
perform the picking activities in the 5 pairs of bays. The 180
Class A references are handled to the sides of the picking
area, deposited on gravity roller conveyors with two pallet
slots and fed by rectilinear shuttles. The 90 Class B and 450
Class C references are handled in the picking warehouse
and can always count on the presence of one entire pallet in
the warehouse and one pallet picked up and placed on the
idle roller conveyors. For the Class B references, the pallet
that is picked up is stored in non-motorized stalls on the first
shelving level. This way, the picking operations for Class B
references involve only the SVL, thus reducing the work of
the stacker cranes. The operator carries out the picking activities using a commissioning trolley on which he prepares the pallets guided by a radio frequency system. After completing the pallet using the main SVL, it is sent to the main warehouse which acts as
a meeting point pending shipment. The system designed and
constructed by System Logistics is capable of handling a flow
of more than 4000 crates an hour for a peak of 65,000 crates
a day and requires a workforce of only 15-20 people.
This simple and low-cost solution allows the low, medium
and high movement references to be concentrated in one
area, thus merging the advantages of “man to goods” with
“goods to man” solutions.