Cold Storage System Case Study

Rochelle, IL

Coffee Manufacturing

System Hardware/Software

  • KPI-S WES Software and Control System
  • 9 High bay cranes
  • High bay pallet shuttle system:  3 lifts, 3 aisle carts, and 3 row carts
  • Layer picking:  2 gantry
  • 2 Case picking cranes
  • Goods-to-person
  • 2 High-speed stretch wrappers
  • 4 Pallet support board inserters
  • 4 Print & Apply machines
  • 28 Scanners
  • 329 Pallet conveyors
  • High-speed monorail:  50 carts
Cold Storage System

The Details

Facility Size
116,424 Square Feet
14M Cubic Feet
High bay 120’h
Low bay 33,880 square feet

Project Value
$90 M

Products Handled
Frozen Foods – Pallets, Layers, Cases

Throughput/Capacity
53,000 Pallet positions
Annual volume (pounds) 1 billion
Turns per year – 14 average
Pallet pick – 63% of volume
Half pallet pick – 14% of volume
Layer pick – 22% of volume
Case pick – 1% of volume

People/Shifts
Operations are 6 days per week and 3 shifts per day

SKUs
2,000

Cold Storage System