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High-density storage with bluetooth technology saves time and doubles a brewery’s capacity in their cold storage warehouse.

High-density storage with bluetooth technology saves time and doubles a brewery’s capacity.

Improving Efficiency in a Cold Storage Warehouse

<h2>A Small Brewery that Thinks Big</h2>
<p>The Abnormal Beer Company has built a reputation around creative collaboration and new approaches to complex challenges. The business began as a small winery and is now a 10-barrel brew house with 440 barrels of fermentation capacity. The company does all production on site at its unique brewery / winery / restaurant facility while housing its barrels, kegs, and cans in a nearby warehouse.</p>
<p>The warehouse, which includes a 15,000-cubic-foot cold box, is a key component of the company’s growth strategy. Optimizing space in the cold box has allowed the company to operate more efficiently and rent cold storage space to other breweries.</p>

<p>This was a key aspect of the brewery’s growth strategy.</p>

Optimizing space in the cold box 

<p>After consulting with the local Spacesaver representative, Milton and the rest of the team decided an <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label=“heavy-duty mobile system product details”>ActivRAC® Mobilized Storage System</a> would be the best solution. Mounting movable racking on rails would allow them to double the cold storage area’s capacity, from roughly 2,000 kegs to close to 4,000, and it would save time by offering convenient access to every pallet.</p>



Warehouse Manager

<h2>Providing Fresh Inventory</h2>
<p>Supplying fresh product is crucial, so inventory control is always top of mind. The ActivRAC system allows staff to easily stock, rotate, and pick kegs and other products.</p>
<p>“We need to make sure that we’re taking first in, first out,” Milton said. “This system allows us to do that. Each pallet has its own position, and each set of kegs has a date, so I just look up in the racks. I can look at the date and go, ‘Boom. That’s the one that I need’ and pull it out. And I don’t have to move around 20 different pallets to get to it.”</p>


<h2>Minutes Add Up to Hours</h2>
<p>As any warehouse manager knows, even the smallest efficiency gains can really add up over time. Although Milton was using a remote control for the ActivRAC system, its range was limited and Milton usually had to wait a few seconds when he needed an aisle to open.</p>
<p><b>After installing Spacesaver’s bluetooth-enabled app to open the aisles from a distance</b>, Milton saw efficiency improvements right away. “Being able to be on the forklift and hop between aisles, utilizing my phone, made a big difference,” he said. “When I’m pulling out of my first aisle row, and I know that I need something from the second row, as I’m pulling it out of the cold box I can tell it to start moving. And while I’m loading our truck, the whole system’s already moving, so when I come back in I’m already on the row, ready to go.”</p>

<h2>Bluetooth Benefits:</h2>
<p>The ActivRAC system mounts pallet racking on rails to eliminate wasted space. Aisles can be opened with the press of a button, with remote control, or with the Spacesaver bluetooth-enabled app that offers:</p>
<ul>
<li>Compatibility with iOS and Android Devices</li>
<li>Easy Set-Up Process <span style="font-size: 0.6rem;">(IT support not required)</span></li>
<li>Native Security</li>
<li>Direct Connection between Smart Device and ActivRAC (independent of system network)</li>
<li>Ability to Restrict Access based on Device’s Unique ID</li>
<li>Ability to Request a Credential such as PIN, Swipe, or Fingerprint</li>
<li>Searchable “soft” Directory/Index that Mimics Physical Labels</li>
<li>Tested Maximum Range between 80-100 feet</li>
</ul>

<h2>New Revenue</h2>
<p>With the increased capacity and efficiencies gained with the ActivRAC system, Abnormal Beer has been able to rent out space to other breweries in the area, and even to its own distributor. This unexpected revenue stream is helping ensure the young firm’s financial stability while it continues to ramp up production.</p>
<h3>Pivoting Due to COVID</h3>
<p>Like many bars and restaurants, Abnormal Beer Co. was hit hard by the COVID crisis. Fortunately, its investment in Spacesaver mobile pallet racking allowed the brewery to quickly make changes. <a href="/blog/mobile-pallet-racking-brewery-cold-warehouse">Learn how flexible storage made it.</a></p>

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Spacesaver helped a Chicago-area beer distributorship optimize space in its cold storage warehouse, resulting in better selectivity, fewer write-offs, and a safer workflow.

Saving Space in a Cold Storage Warehouse

<h2>Providing Access to 2400 SKUs</h2>
<p>Managers of cold storage facilities all face the same challenge: they want to store the most stock in the least amount of space, while still maintaining safe and convenient access to every item.</p>
<p>One of those managers is Dave Tripicchio, head operations manager at the Louis Glunz Beer distributorship in Chicago. Founded in 1888, the Glunz distributorship deals in beers from hundreds of breweries around the world, maintaining access to 2400 SKUs at any given time. Effectively managing that many SKUs in a beer cooler demands a commitment to quality and an organizational system to match, and much of that responsibility rests with the operations department.</p>

<p>The distributorship owners were dissatisfied with their cooler storage situation. The cold storage warehouse had about 250 feet of static racking, four levels high, and extra kegs would often get set in front of the racks. In order to get a keg off any particular rack, staff would first need to clear a path through kegs stored in front of them. “We’d get the beer in and find a place for it to sit safely, and hopefully we’d rotate it in the proper order and no one would get hurt,” Tripicchio said. The system was inefficient, and they realized that something needed to change.</p>

Head Operations Manager 

<h2>Racking that Moves</h2>
<p>Substantially improving safety and organization would involve completely rethinking their keg storage, and one of the owners asked Tripicchio to look into the <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile sytem product details">ActivRAC® Mobilized Storage System</a>. Tripicchio called the local Spacesaver consultant, who visited the facility to conduct a free space assessment. He explained the ActivRAC system, conducted a space analysis to determine how many barrels could fit in the cooler, and provided a quote. Four large load-bearing columns are located in the middle of the cooler, and the Spacesaver consultant suggested locating the ActivRAC system inside the space enclosed by those columns.”</p>
<p>Since the business is family owned, the decision to go ahead was easy: Tripicchio said it took about 20 minutes for the siblings on the executive team to green-light the proposal. Installation went smoothly and staff were trained on the system’s operation. Then they loaded the slower-moving and specialty SKUs onto the ActivRAC system and moved faster-moving SKUs out of the middle of the cooler and placed them around the perimeter. Now the racking system accommodates between 1500-1800 half-barrels at any given time.</p>

<p>Do you need more space? See how Glunz Beer was able to work with Spacesaver to optimize space in its cold storage warehouse, resulting in better selectivity, fewer write-offs, and a safer workflow.</p>

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<h2>The Safety Aspect is Immeasurable</h2>
<p>Looking back, Tripicchio said the ActivRAC has eliminated potential safety hazards. “After we got the ActivRAC installed, it really became evident how much safer the cooler became,” he said, noting the system made it safer to walk around the cooler and drive the forklift, and more efficient to pick barrels. “The safety aspect is immeasurable.”</p>
<p>The end result is a safe system that keeps slow movers out of the way and allows for convenient picking and rotation. Every barrel has a location, which has made location integrity nearly perfect.</p>

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A composite manufacturer installed an ActivRAC® Mobilized Storage System to improve efficiency and reduce energy costs in a frozen warehouse storage area.

Frozen Warehouse Storage for a Composite Manufacturer

<p>Composite materials allow aerospace manufacturers to build aircraft that are lighter, stronger, and more&nbsp;fuel efficient than their counterparts made of metal. That’s because composites consist of strong carbon fibers embedded in resin-like material, making them more resistant to corrosion and fatigue-related failure. But processing composites is a tricky process: heat causes the unfinished material to degrade, so the material must be kept at extremely cold temperatures until it is formed and finished for assembly.</p>
<p>Web Industries, Inc. is the leader in formatting pre-impregnated composites for aerospace fabrication, and its Atlanta facility is the largest and most advanced composites formatting facility in the world. Web Atlanta specializes in producing spools of composite slit tape and ply kits. In order to create these products, the facility’s staff takes delivery of a particular composite material, stores it until it can be processed, and then either slits and spools the material into composite slit tape,&nbsp;or cuts and assembles the parts into ply kits. After formatting, the products are refrozen and stored until they can be shipped to the end user, where they are used to manufacture composite aircraft and engine parts.</p>
<p>When the composite materials aren’t being processed, they must be stored at -10 degrees Fahrenheit to prevent premature curing and extend shelf life.</p>

process engineer at Web Industries, Inc.

<p>Download this free case study&nbsp;to learn more about how Spacesaver can help you:</p>
<ul>
<li>Save space</li>
<li>Reduce energy costs</li>
<li>Improve productivity</li>
</ul>

Optimize Frozen Warehouse Storage Space

<h2>Cold Control</h2>
<p>Due to dramatically increasing demand for composite products in the aerospace industry, Web Atlanta was projecting a fivefold increase in inventory over the next decade. Not only was the sheer volume of material increasing, but so was the complexity of the entire operation. As the business accepted new contracts, staff needed to devise and implement new procedures to fulfill them. More freezer space was needed to ensure that materials could be kept accessible and organized as inventory increased.</p>

<h3>Analyzing Alternatives</h3>
<p>The executive team considered three options: they could build a new freezer with conventional push-back racking, rent storage space, or build a new freezer with movable racking similar to a system a Web Industries executive had seen in Europe. A thorough analysis determined that building a new freezer and installing Spacesaver’s ActivRAC system inside would be the most cost-effective option. That’s because the ActivRAC system allows the pallet racking to move on rails, eliminating empty aisle space and allowing more product to be stored in a smaller footprint. When staff need to retrieve items or place them in storage, they can open aisles at the point of need with the simple push of a button.</p>

<p>The team approached the local Spacesaver distributor to discuss purchasing an ActivRAC system, but at that time Spacesaver’s engineers weren’t sure it could operate at such cold temperatures. “We explained that this is a solution that’s not just ours,” said Bob Scott, Web Atlanta’s process engineer. “This is a solution that’s required for the whole industry. Anybody who uses thermoset prepreg composite material has the same problem of how to store it.”</p>

<h3>Creating a New Solution</h3>
<p>Spacesaver’s electrical engineering team quickly began working on a solution, creating a sophisticated new electronic control system to ensure that the ActivRAC would perform reliably in extreme cold. To test the new product, Spacesaver rented a freezer, installed an ActivRAC system inside, brought the internal temperature down to -20 degrees Fahrenheit, and tested the ActivRAC system through 50,000 cycles.</p>




<p>The research, development, and testing process took about a year. During that time, Scott and other Web Atlanta executives visited Spacesaver’s headquarters and manufacturing facility in Wisconsin. “Spacesaver took it upon themselves to do the research and development,” Scott said. “So when we started the discussions again, they had a tested solution that made us feel much more comfortable.”</p>

 Process Engineer at Web Industries, Inc.

<h2>A Model for the Industry</h2>
<p>Meanwhile, the local Spacesaver consultant worked with the Web Atlanta team to plan an ActivRAC system that would make the most of the facility’s new freezer space. The freezer measures 108’ by 37’ and has a volume of nearly 121,000 cubic feet — and although that’s certainly a large freezer, the space-saving ActivRAC allowed its footprint to take up half the space that had initially been considered. The Spacesaver consultant designed an ActivRAC system that had 11 aisles with 60 pallet positions per aisle, for a total of 660 pallet positions, twice as many as would be available in the same space with traditional stationary pallet racking.</p>
<p>The project was completed in July 2016. The freezer was brought down to temperature gradually to keep the concrete slab from cracking or buckling—first to 40 degrees and then down about 10 degrees per week.</p>
<p>Today, the ActivRAC system is functioning well, and the local Spacesaver distributor’s nearby location ensures prompt response to any service calls that might be required in the future. With a full staff of factory-certified installers and space planners at the ready, the local Spacesaver distributor is just a phone call away should Web Atlanta require routine maintenance, repairs, or an additional ActivRAC system to store the fast-growing company’s inventory.</p>

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Industrial mobile racking helped a Southern Car Manufacturing Facility avoid a costly plant expansion by gaining 54% more storage capacity.

Industrial Mobile Racking Assists Southern Car Manufacturing Facility with Consolidation

<h2>Winning With Hard Work And Innovation</h2>
<p>Southern Car Manufacturing Facility emphasizes innovation and a healthy dose of hard work.&nbsp;Southern Car Manufacturing Facility&nbsp;has redefined plant operations in the automobile industry, winning the J.D. Power and Associates Silver award for Assembly Plant Quality in its first year of production.</p>
<p>“With the ActivRAC system in place, we save as much as one hour a day—making it a much better situation for our team and the departments we serve.”</p>



<p>Industrial mobile racking can be used for parts and equipment storage at large automotive manufacturing plants as well as the service departments for their dealership counterparts. To learn more, download our ActivRAC brochure.</p>

Download our Mobilized Storage Systems Brochure

In 2008, the Southern Car Manufacturing Facility plant won the J.D. Power and Associates Silver award for Assembly Plant Quality—the first time a new plant had ever won the honor.

<h2>New plant, increased production, limited space</h2>
<p>When the Southern Car Manufacturing Facility broke ground at the new plant site in Fall 2003, it was to be a simple assembly plant—but the site quickly evolved into an automotive production site including several on-site suppliers that shipped directly to the factory. In addition, Southern Car Manufacturing Facility announced that production capacity would shift from the preliminary plan of 150,000 units per years to 200,000 units. The first pickups rolled off the line just over three years later in November 2006.</p>



<p>Two years later, the Southern Car Manufacturing Facility was facing a space shortage when it announced that all production of this particular vehicle line would be moved to the&nbsp;Southern Car Manufacturing Facility. In addition, all production of an additional vehicle line would be relocating to the Southern Car Manufacturing Facility as well. While the consolidation proved to be a fantastic move for Southern Car Manufacturing Facility, especially in the wake of the financial crisis, it created a challenge: how would the Southern Car Manufacturing Facility effectively store spare parts for production machinery in its General Stores area and avoid a facility expansion to a plant that was just two years old? Storage in General Stores was already maxed out, and all materials needed to be organized and 100% accessible at all times to maintain the Southern Car Manufacturing Facility’s legendary passion for efficiency.</p>

As a result of the ActivRAC system, the Southern Car Manufacturing Facility is able to store nearly 100% of the spare parts needed for production machines.

<h2>Rethinking Spare Parts Storage</h2>
<p>Southern Car Manufacturing Facility’s plant managers needed to rethink their existing pallet racking placement in order to make 5,000 square feet of storage space do way more than ever before—and after researching a multitude of options, they decided to utilize <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile system product details">ActivRAC industrial mobile racking</a>. Southwest Solutions Group, a Spacesaver authorized distributor, worked with the facility to implement the ActivRAC system while the plant was fully operational, determined not to let a switchover in storage impact any of Southern Car Manufacturing Facility’s day-to-day operations.</p>
<p>As a result of the ActivRAC system, the Southern Car Manufacturing Facility is able to store nearly 100% of the spare parts needed for production machines—and gained 54% more storage capacity in the same footprint. Parts include everything from tiny gaskets and motors to large pumps and transformers. The 16’ high industrial mobile racking system features four carriages, all equipped with the plant’s existing pallet racking. The system offers five levels of storage—all match to the dimensions of stored materials to conserve space.</p>

<p>We understand the diverse storage requirements within the manufacturing industry, and how efficient storage supports unified operations. Learn about all the solutions and benefits.</p>

Manufacturing Storage Guide

The Southern Car Manufacturing Facility is responsible for producing 200,000 of both vehicle lines per year.

<h2>Matching Storage to Fit Equipment Needs</h2>
<p>One of Southern Car Manufacturing Facility’s necessities was to be able to drive forklifts from one side of the General Stores past the industrial mobile racking and into the plant as needed. To accommodate this, the ActivRAC system was built into an L-shape, with two carriages 63’ in length and two 36’ in length. Stationary racks on both sides of the system house consumables and other frequently accessed items, and traffic can freely flow in, out, and around the General Stores area.</p>
<p>In addition to the easy flow between storage and plant, the ActivRAC system has allowed the Southern Car Manufacturing Facility’s General Stores to hum along at peak efficiency, producing over 200,000 vehicles per year. The team can quickly locate, access, and deliver items, even with the increase in parts due to the plant consolidation, and Assistant Manager says the team saves about an hour of work each day with the more organized system.</p>
<p>“Even before the consolidation, there was a lot of congestion in General Stores due to the lack of space. With the ActivRAC system in place, it makes for a much better situation for our team and the departments we serve,” Assistant Manager says.</p>

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Industrial Mobile Racking Assists Southern Car Manufacturing Facility With Consolidation

For one beer distributor, the craft beer boom meant finding a craft beer storage solution to handle double the SKUs.

Finding Space for Craft Beer Storage amid Changing Market

<p>“Craft beer is exploding.” This observation from an Operations Manager at a beer distribution company is great news for beer aficionados and beer distributors – but it’s not without its complications. Despite minimal growth in the mainstream beer market, the craft beer segment grew 17% in 2014. Although craft beer still only accounts for only 6.5% of the beer U.S. beer market, craft breweries account for 98% of the breweries.</p>

<p>Heavy-duty mobile shelving can help you increase the capacity and efficiency of your craft beer storage, and streamline your warehouse inventory management. In the golden age of craft beer, distributors have to be poised to accommodate more variety and volume than ever.</p>

Download Our Mobile Storage Brochure

<h2>More Kegs, More Problems</h2>
<p>For beer distributors, the proliferation of unique microbrews means more market opportunities, but also means more products, space, and capital needed to accommodate them. One Midwest beer distribution company was struggling with these facets of the changing beer landscape. Said the operations manager, “The business has changed. The SKUs have basically doubled over the past three years.” Unfortunately, the distributor had a fixed amount of cooler storage space, and it became increasingly difficult to handle the influx of new product at the warehouse.</p>
<p>With overcrowded coolers, retrieving kegs became a frustrating ordeal. The 1500 square foot storage cooler was lined with racks of static shelving. Kegs were stacked one on top of the other on the shelves and on pallets in the center of the floor. Employees had to unload the cooler each morning just to get into the cooler and access to the kegs for distribution that day. The accessibility issue slowed operations and created an inefficient process that could slow deliveries. Unstacking and restacking the 165 pound kegs was not only inefficient, but also posed a possibility for injury. The distributor considered adding additional warehouse space, but doing so was capital-intensive and would require additional employees.</p>

92% percent of breweries operating in the United States that are small to mid-sized craft breweries.

<h2>Tapping into a New Storage Solution</h2>
<p>The operations Manager reached out to Dave Poissant, a representative from McCormick Storage Solutions LLC, an authorized Spacesaver distributor in their area. When Dave pointed out to the manager that the storage problem would only be amplified in the coming years, the Operations Manager decided it was time to do something about their craft beer storage and expand the cooler. Dave recommended they install <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile sytem product details">ActivRAC 16P powered mobile racking</a>.</p>
<p>The ActivRAC system designed for the beer distributor used new and existing pallet racking and eliminated idle aisles to maximize space. The heavy duty carriages support up to 16,000 pounds to easily hold the weight of the half-barrels stored on the system. The ActivRAC shelves hold 700 kegs, 100% more than their old static racking, which meant the new cooler had double the capacity anticipated without purchasing new warehouse space.</p>

<p>With the improved craft beer storage system in place, the distribution center is ready to accommodate the variety of seasonal and craft beers needed to stay competitive. Employees can easily maneuver in and out of the room with a forklift or picker, and gone are the days of emptying the cooler at the start of the day. The increased efficiency and selectivity makes for faster turnover times and less risk of injury on the job. As a bonus, the old cooler has extra capacity for the company to store fine wines and prepare for future growth.</p>

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For a major gas and wind turbine manufacturing company, mobilizing an industrial storage system made the difference in easily accessing legacy parts.

An Industrial Storage System Goes Mobile for Wind Turbine Company

Wind Turbine Manufacturing Facility

<p>It’s an interesting feeling—the knowledge that even with a recently constructed facility, you’re still facing the issue of needing additional facilities and storage in the near future.</p>
<p>That’s how Mark, the Lead Test Specialist for a major gas and wind turbine company, felt when he was in the building of the facility used for engineering and testing components of the turbines. He knew there was very little chance of being able to expand the warehouse—and in order to solve the company’s budding storage challenge, they would need to improvise with the shelving and racking of their current industrial storage system.</p>

The number of wind-related manufacturing facilities producing a product for the United States wind energy industry, across 44 states.

<h3>Running Out of Space of Legacy Parts</h3>
<p>An unexpected email about a <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile system product details">heavy-duty mobile storage system</a> peaked Mark’s interest, and immediately, he took it to his managers. “I knew this was exactly the type of storage we needed to maintain our legacy parts inventory,” he says.</p>
<p>The legacy parts were not used on a regular basis—purchased by the company in bulk, the materials and parts are kept on hand in case they are needed to repair turbines in the future. In addition to the legacy materials, old parts that planned to be salvaged at some point where being stored in the same space, as well as a mix of other materials and tools. Mark’s managers were skeptical—but not wanting to pursue a facility expansion so soon after constructing a new space, they took his suggestion.</p>


<h4>An Industrial Storage System creates a Cost-Effective Solutions to Expansion</h4>
<p>Working with Bart Lassiter from Advanced Equipment Company, a Spacesaver-authorized distributor, a specific industrial storage system for the turbine manufacturer, including an <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile system product details">ActivRAC 16P motorized racking solution</a>. Because of the high weight capacity—the ActivRAC 16P can store up to 16,000 lbs. per carriage—the system was idea for storing a large amount of parts and materials and still offer 100% accessibility. The mobile racking moves from side to side with the push of a button, leaving enough room in the aisles for the facility’s forklifts to navigate in and out.</p>

<p>“It was the right tool for the application and exactly what they needed,” says Lassiter. “We essentially helped double their storage capacity within the same footprint they normally would have filled with static pallet racking.” As ActivRAC is designed to work in tandem with existing racking, it was even more of a cost-effective solution for the turbine company, as they didn’t have to invest additional capital in purchasing all new racking for the system.</p>

<h2>Planning for the Future</h2>
<p>It didn’t take long after the install for Mark’s managers to understand the value of the <a href="/products/high-density-mobile-systems/heavy-duty-mobile-racking" aria-label="heavy duty mobile system product details">ActivRAC system</a>. The increased storage capacity was the main priority, but the added value was the durability of the system. “We’ve never had to worry about any instances of damage, maintenance issues, anything,” Mark says. “It just keeps running, which is an important aspect of any warehouse situation—especially this facility.” Additional carriages were added to the system soon after to accommodate even more legacy materials and parts—and when the company decided that they absolutely had to expand, one of the first things to be purchased was an ActivRAC system.</p>