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Meyer Material Handling Helps Customers Achieve New Levels of Efficiency

About Us : Case Studies

Meyer Partners with Omni Metalcraft

Faced with the need to expand production capacity and subsequent storage capacity into a new building, a local beverage manufacturer was forced to analyze the most cost effective solution for handling product between two facilities. The growth alternatives would not allow for onsite expansion due to land constraints. The resulting expansion was across a road. We analyzed the costs associated with AGV's, shuttling with trucks, relocation of palletizing equipment and the use of pallet conveyor to shuttle finished pallets.

The final analysis resulted in the implementation of a side by side conveyor system capable of handling 4 pallets per minute per side being installed into a bridge built between the facilities. The forklift loaded system was designed to handle 2,500 pound pallets of finished product in a 24/7 operation. The side by side system allowed for redundancy to support the current operation and excess capacity for future growth.

Meyer was contracted to complete the project and partnered with Omni Metalcraft for the design engineering and the system's component manufacturing. The system includes four large continuous vertical conveyors, two units lift up and two unit lower down, which are in the system to account for the elevation changes from site to site as well as the clearance across the road. Thousands of feet of chain driven live roller conveyor were installed to complete the length between sites, zero pressure accumulation conveyor to control critical zoned areas, pop up chain transfers for cross line access, and a very simple set of electrical controls were included for system overview, access, troubleshooting, and operations.

Push Back Rack Team Solutions

Three MHEDA member companies banded together to complete a series of warehouse storage system projects ranging from 100,000 sq. ft. to over 350,000 sq. ft. in nine distribution facilities across the United States. Meyer Material Handling Products (Indianapolis, IN), Advance Storage Products (Carson, CA) and Steel King Industries (Stevens Point, WI) developed both static and active storage solutions to meet the layout requirements of Southwire Company, a copper wire manufacturing firm. Handling and supporting the shipping pallet which was being stored on the rack systems, coupled with the fact that loads were in excess of 3200 lb. presented a challenge. Field testing, coupled with many runs on a standard trial lane, provided information to Meyer's representatives. Subtle modifications to the standard product were then created. Prior to determining the final design, the engineers from Advance and Steel King Industries discussed many possible alternatives. The result of this team effort and partnership was a cost effective and efficient design which successfully met the customer's requirements and secured future business for all three companies.

High Density Pallet Storage

The facility was designed to provide for ever increasing inventory levels and eliminate the need for outside warehousing. The costs associated with these requirements were skyrocketing as the business grew and filled the distributions facilities. The systems that have been implemented in the facility combine three very different styles of storage to address the various requirements within the facility.

The majority of storage within the facility focuses on density and efficiency for full pallet loads. This is the core of the business and the storage layout was designed to provide for high density and picking efficiency for full pallet loads. The layout includes thousands of pallet positions of high density push back storage systems ranging from four to five deep. Product mix was analyzed and a plan for slotting the system was developed prior to the completion of the installation so that systems could be set up prior to implementation. This mix was designed to allow for the greatest utilization within the racking systems as well as to fit the internal structure of the facility. The push back storage systems are combined with floor storage areas designed for handling and throughput efficiency of pallet loads that are virtually cross docked through the building.

There are two areas designed to handle the non-pallet load picking operations in the facility. The facility utilizes selective rack end caps to provide for case picking flexibility throughout the warehouse. There are also three pick modules designed for manual picking from two deep storage with replenishment from two deep push back above. These modules will provide for the ever increasing demands for individual case picking within the facility.

The Manufacturer's team combined efforts with the Meyer Material Handling team to develop the internal solutions for the storage and handling systems in the facility. Meyer utilized the services of Steel King Industries and Advance Storage Products as primary participants and their input and assistance were contributing factors to the success of the project. The project was successfully completed on schedule; a credit to all parties involved.

Pallet Conveyor with Bridge and Vertical Lift Elevators

Faced with the need to expand production capacity and subsequent storage capacity into a new building, a local beverage manufacturer was forced to analyze the most cost effective solution for handling product between two facilities. The growth alternatives would not allow for onsite expansion due to land constraints. The resulting expansion was across a road. We analyzed the costs associated with AGV's, shuttling with trucks, relocation of palletizing equipment and the use of pallet conveyor to shuttle finished pallets.

The final analysis resulted in the implementation of a side by side conveyor system capable of handling 4 pallets per minute per side being installed into a bridge built between the facilities. The forklift loaded system was designed to handle 2,500 pound pallets of finished product in a 24/7 operation. The side by side system allowed for redundancy to support the current operation and excess capacity for future growth.

Meyer was contracted to complete the project and partnered with Omni Metalcraft for the design engineering and the system's component manufacturing. The system includes four large continuous vertical conveyors, two units lift up and two unit lower down, which are in the system to account for the elevation changes from site to site as well as the clearance across the road.

Thousands of feet of chain driven live roller conveyor were installed to complete the length between sites, zero pressure accumulation conveyor to control critical zoned areas, pop up chain transfers for cross line access, and a very simple set of electrical controls were included for system overview, access, troubleshooting, and operations.

High Density Bulk Carton Storage

The challenges at Duckhead apparel were to provide for a large volume of bulk carton storage with many different SKU's and a diverse case pick area that allowed for growth and expansion. The solution that we developed and implemented for the warehouse in Winder, GA was a combination of very narrow aisle, high bay selective rack and a three level pick module with carton flow shelves throughout. The design allows for cartons to be stored two deep. The system allows the bays to house multiple SKU's across the picking face. The high bay storage area acts as both a primary pick location for full case picks, as well as a replenishment location for the broken case pick module. Steel King's tabular roll formed product was combined with wire decking panels and selected as the solution for the VNA application.

The pick module was designed to support broken case picking operations in three distinct areas. High volume products were slotted in very deep carton flow rack and placed in the front of the system and are picked to belt for packaging and release to shipping. Medium volume products are slotted in more traditional flow rack and are picked to order via a cart and delivered to packaging stations for preparation. Slower moving products and seasonal products were allowed for in the upper level so that changeover of the inventory could be accomplished simultaneously during common seasons.

The storage systems are supported by a WMS directed conveyor system that includes inbound and outbound sortation systems.

Increase Space - Mezzanines

Increased Storage Space with a shelf system supported mezzanine. A large manufacturer and distributor of hydraulic cylinders and values required additional record storage space and additional office space for their growing number of engineers. Floor space was at a premium, however the ability to go vertical provided an option to solve their problems. Meyer Material Handling Products, Inc. presented a shelf supported record archive mezzanine structure as a solution. Storage space was tripled. Spaced was made available for growing engineering staff. Meyer also provided a solution to secure sensitive documents with wire mesh partition security fencing within this system.

Meyer Can Help You With Your Mezzanine Project

Recently one of our customers was in the process of investigating how to best utilize the space in their building, and they asked us for solutions to the problem. The discussions resulted in the installation of a very heavy duty mezzanine to elevate large containers of their raw materials storage above the mixing operation. The structural mezzanine was designed to hold 2,000 plus gallon containers of materials. The resulting space savings allowed for the mixing area to be moved under the platform and the space to be utilized for staging of finished product.

Meyer has the ability to work with you on any Mezzanine application or situation.

We can help you with all types of Mezzanine projects

  • Free Standing
  • Rack Supported
  • Shelf Supported
  • Mezzanine Design
  • Mezzanine Install

We also can provide you all the accessories you require.

  • Decking
  • Hand Railings
  • Stair Units
  • Platforms
  • Gates
  • Ladders
  • Catwalks
  • Cross-overs

Besides these items, Meyer also can provide all the operational support equipment necessary for your operation.

  • Racks
  • Shelving
  • In-Plant Offices
  • Partitions
  • Carts
  • lifts
  • Trucks

And any other Material Handling Equipment that you require.

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