Intermec solution brings Birds Eye Walls in from the cold
by Intermec
When Power Europe were appointed to develop Birds Eye Walls frozen foods national distribution centre, the issue of selecting a data collection system capable of operating effectively in sub-zero temperatures was paramount.
Covering 18,580 square metres, measuring 34 metres high, operating at minus 28 degrees centigrade and containing 42,000 pallets of Birds Eye Walls products in double deep racking, the Birmingham distribution centre is Britains largest freezer.
The technology demand of the distribution centre project was immense. With an entirely automated system, all the components had to be highly reliable and work seamlessly with one another 24 hours a day, 7 days a week. Importantly, the technology had to operate effectively and accurately at extreme temperatures.
When a pallet of goods enters the freezer from a refrigerated lorry it starts a life which lasts until it is despatched to a destination. All along the life cycle of the pallet, computers will track its every movement, alteration, storage location, destination, history and contents. The warehouse management system maintains all the collected data and translates it into an effective business operation.
The Need
It was decided to automate the picking of products in the warehouse which would be carried out by operators on powered pallet trucks with installed Radio Data Terminals, saving operator time travelling to and from the end of aisles to select picking orders. Screens were needed which would not mist or crack ensuring clear visibility for the operator. Additionally, the terminal keyboards needed to be user friendly in sub-zero conditions, allowing for the operators large gloves. Each terminal would be required to operate as normal in freezing conditions, exchanging radio signals in the freezer with well placed access points and be robust with solid casings to protect the terminals in conditions where shrinkage was a concern.
Alongside the need for terminals, another priority was to identify a solution that had extended bandwidth capabilities. With the complexity of the total operation, Power Europe did not want to have concerns about speed of data transmission. The uncompromising demand had to be for the highest performing system, which could transmit data in real time and have no black spots within the freezer or on the yard where radio signals could not penetrate.
The standard solution for a demanding situation
After a rigorous testing phase, Power Europe selected and installed 19 x Intermec T2455 Vehicle Mounted Terminals and 9 x 2100 Universal Access Points.
The Intermec T2455s were mounted on to the powered pallet trucks that move around the freezer bays, with one fixed terminal at goods in, one terminal on the shunter vehicle and one as a spare for maintenance. After a thorough requirements survey, the access points were located in the roofing construction and were linked to the office systems using refrigeration-proof cabling.
The terminals needed no modification in order to meet the standards of Power Europe. Originally designed to operate at very low temperatures, be robust and deliver real ease of use, the Intermec T2455 configuration made the most sense.
Mike Dolman, Systems Manager for Power Europe explains; We have total confidence in the Intermec solution. This facility would not be able to function without the Intermec Radio Data Terminals, the perpetual inventory checking requirements of our operation must be 100% accurate and manual pick lists for this would simply fail to satisfy the requirement successfully. Intermecs spread spectrum is outstanding, we have not encountered any black spots or complaints. The terminals are unaffected by the freezer environment and all operatives found the terminals easy to use, ensuring that performance is down to the individual and not dictated by the device.
The Immediate Benefits
The Intermec solution delivered the benefits of best inventory control, productivity and pick rate accuracy and together with its sub zero capabilities, plus the minimal amount of necessary access points, its benefits have been substantial. Operators have their terminals updated in real time and despite full automation, still retain some choice in their working decisions, choosing the order in which to complete available tasks.