 | All roads lead to Perry
The new dynamic pallet flow system recently installed at Graphic Packaging International's plant in Perry is symbolic of the new wave of synergies currently sweeping the
Georgia-based company to the very pinnacle of the multi-billion dollar market. In Perry - often referred to as the "crossroads of Georgia" on account of its
exceptionally good highway network - there is no denying the enormous impact of the GPI plant. Boasting 98,000 sq. m. of state-of-the-art warehouse space, this is the largest
and most modern facility of its kind to be found in North America.
Serving an entire nation
GPI has not merely quadrupled its throughput - it has also integrated round-the-clock production into its materials flow. In particular, the manufacturer of packaging for
products such as beverages, foodstuffs and non-food items is now in a position to bundle its existing sorting points into a single distribution centre. As a result, Perry -
which features 32 truck ramps operating day and night - has become the hub for GPI's nationwide distribution activities.
FIFO, gravity, and a touch of class
Darren Farber of system integrator Gilmer Warehouse & Logistics explains the background to this development: "Our customer wanted to restructure its entire business. Our
task was to provide a warehouse facility with an innovative, state-of-the-art material flow system capable of meeting all of the customer's requirements." More
specifically, the system needed to provide full FIFO (First In - First Out) compliance and use the gravity feed principle. At the same time, the system had to provide 25,000
storage spaces for pallets which frequently weigh up to 1.5 tonnes. Finally, it had to feature lanes capable of holding 23 pallets end to end. Quite a tall order, especially as
Interroll, the company responsible for supplying and implementing the pallet flow system, needed to integrate several technical features into the rack system supplied by Pacific
Westeel Racking of Buffalo. A case in point: the system had to be designed in such a way as to ensure the loading of two adjacent pallets simultaneously. The same principle was to
be applied to the removal of pallets.
Smooth operator
"Interroll and Pacific Westeel Racking were head and shoulders above the competition because of their very thorough understanding of the nature of the project and the way
they tackled the intricate details of the challenges posed," explained Farber. The tailor-made conveyor, storage and picking system is geared to the high throughput of
packaging cartons for beverage cans. Pallets are simply loaded using forklifts and flow smoothly through the storage system on three-segment roller tracks at a 4% angle of
incline. Pallets are placed onto extremely durable die-cast aluminium rollers. All intermediate flow system modules are fitted with polycarbonate rollers and ensure the highest
levels of reliability when carrying pallets. And, for total peace of mind, the tandem speed controllers mounted directly on the frame regulate the speed at which pallets move
through the system.
Pallet monitoring at all levels
As Dave Schut, Engineering Manager at Interroll, explains, optimum throughput of pallets with a minimum of deviation is an essential prerequisite for success. "Precision is
an absolute must, especially when you bear in mind the fact that the lanes are 23 pallets deep." Each and every component in the dynamic flow system is manufactured to meet
the strictest tolerances, with the express purpose of ensuring smooth and central movement along the tracks. "Our patented, high-performance tandem speed controllers are
designed to ensure safe transverse pallet movement and carefully controlled transport speeds," says Schut.
177 kilometres of flow storage expertise
Some 1.5 million rollers, 18,000 speed controllers and 177 kilometres of frame components were used in the construction of the pallet flow system at Graphic Packaging
International. Because of the extremely short period of time available - just 7 months from project kick-off to commissioning -, this project represented a real
challenge for Interroll. The company's game plan was simple: 24-hour production and daily deliveries of components. System integrators Gilmer Warehouse & Logistics were
delighted with the results: "Having Interroll and Pacific Westeel as partners in this project was absolutely fantastic."
Customer views
Our own tests have shown beyond doubt that Interroll and Pacific Westeel have fully met all of our requirements. We are confident that the system will provide problem-free
operation well into the future.
Darren Farber
VP of Operations
Gilmer Warehouse & Logistics
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