The ColdHub is a new frozen food warehouse in Dordrecht that offers space for 32,000 pallet locations. In the fully automated warehouse, 9 pallet shuttles in cooperation with 8 pallet lifts ensure the inbound and outbound storage of goods. For order picking, a smart concept has been devised with 4 workstations and 8 autonomous mobile robots. The automation solution is realised by Reesink Logistic Solutions, using shuttles and robots from Movu.
During the Coldstore Knowledge & Networking Day of Isocab, manufacturer of insulation panels, the programme included a tour of The Coldhub. This automated freezer warehouse is part of the B&S Group, a consumer products distributor headquartered in Dordrecht. Event participants saw an innovative warehouse in its start-up phase, which has an area of 16,000 square metres and a height of 24 metres.
The racking in the high-bay warehouse accommodates 32,000 pallets. These are stored in channels with space for six to 12 pallets. Nine shuttles from Movu provide horizontal transport, while eight pallet lifts handle vertical transport. If growth requires it, storage capacity can easily be scaled up by deploying additional shuttles. The concept can accommodate 28 shuttles in total.
Four workstations
For order picking, a concrete mezzanine floor was created with space for four workstations. Each workstation accommodates one target pallet and two pallets of picking stock from the high bay warehouse. The ergonomic design of the workstations makes it easy to slide the right number of boxes onto the target pallet, so operators do not have to lift heavy boxes.
When a pallet layer is complete, the built-in lift lowers the pallet slightly until the top is at ergonomic working height again. When an order is complete, the pallet sinks completely through the floor towards the floor below. After wrapping the pallet with film, the lift places the goods on a roller conveyor that runs under the four workstations. A forklift picks up the pallets from the roller conveyor and sets them ready for transport.
Eight mobile robots
Eight autonomous mobile robots (AMRs) drive on the mezzanine floor to transport pallets of picking stock. These robots pick the pallets from the roller conveyor from the high-bay warehouse and place them ready at the four workstations. Once the right number of boxes have been picked, the pallets containing the remainder of the picking stock do not return to the high-bay warehouse. Instead, the robots place them at a temporary buffer location until it is their turn again.
Control takes place through the warehouse control system has implemented. As soon as an operator logs on to the screen of one of the four workstations, he immediately sees the order he needs to prepare. The system then automatically ensures that the AMRs pick up the right pallets and prepare them at the workstation. The screen shows how many boxes the operator needs to pick and place on the target pallet. Reesink Logistic Solutions signed up for the design and realisation of the logistics concept.
