Bulk Carton Storage at Duckhead Apparel

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 change over 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.

Contact us to learn more.