Three strategies for mixed-SKU palletizing in frozen food warehouses

Alessandro Brusatori 29. august 2024

Læsetid: 5 minutter

Frozen food manufacturers and distributors are automating pallet storage and retrieval to increase deep-freeze capacity, enhance throughput and efficiency, and minimize the exposure of warehouse personnel to freezing temperatures. As they plan for automation, operators should consider the role that automated storage and retrieval systems (ASRS) can play in helping them meet the growing demand for mixed-SKU pallets of frozen foods. Integrating palletizing processes into the design of the ASRS can create opportunities to optimize fully automated, semi-automated, or manual mixed-SKU palletizing.

Robot-based mixed SKU palletizing for frozen food logistics

Building mixed-SKU pallets in deep-freeze environments

While the demand for mixed-SKU pallets of frozen food products is growing, the volume is still typically lower than what exists for ambient or chilled foods. This can create a challenge for deep-freeze warehouse operators because when volume is high, the investment in fully automated depalletizing and palletizing solutions, such as Swisslog’s ACPaQ, is much easier to justify. Frozen food warehouse operators don’t typically have the volume required to justify that level of automation.

The other challenge frozen food warehouse operators face, of course, is the deep-freeze warehouse itself. Product integrity must be maintained during the palletizing process and manual palletizing can be time- and labor-intensive. Building pallets in the freezer is one of the most demanding jobs in the supply chain and most operators limit the amount of time employees can work continuously in the freezer, increasing the cost and complexity of palletizing in this environment.

Integrating palletizing with automated storage and retrieval systems (ASRS) can help operators successfully overcome these challenges because the ASRS can support more efficient palletizing processes while reducing exposure of personnel to the frozen environment. If you’re planning to automate pallet storage and retrieval, consider integrating one of these palletizing strategies with your chosen ASRS.

Swisslogs ACPaQ-løsning udfører blandet kassepalletering i et dm-drogerie markt lager.

1. Layer picking in the deep-freeze warehouse

For operators with steady demand for mixed-SKU pallets, a layer picking and palletizing system integrated with the ASRS can be an effective and feasible solution. Working together, the ASRS and layer picking system—connected by automated conveyors—enable efficient, fully automated mixed-layer palletizing that keeps personnel out of the freezer.

As with any palletizing solution, the feasibility of layer picking for a particular warehouse is dependent on customer order profiles and the volume of pure mixed-layer pallets required. But remember that even if a full layer isn’t required for every mixed-SKU order, it can still be more efficient to customize a mixed-layer pallet to order requirements by swapping out some cases than it would be to build the entire pallet manually.

Swisslog has implemented layer picking solutions integrated with our Vectura pallet crane and PowerStore pallet shuttle ASRS solutions for a number of leading food manufacturers. Swisslog ProMove conveyors transport pallets to the layer picker from the ASRS where mixed-layer pallets are built and then moved outside the freezer or back into the ASRS for storage, with the entire process controlled by our SynQ software.

2. Case sequencing to optimize manual palletizing outside the freezer

While highly efficient, layer picking isn’t right for every application as it may not easily support the SKU variety customers are requesting. In this case, a light-goods shuttle system, such as the Swisslog CycloneCarrier, or mini-load crane, such as the Swisslog Tornado, can provide case storage and sequencing to support optimized manual palletizing.

When cases are required for an order, the shuttle delivers them in the exact sequence required to pickers working just outside the freezer. Because of the efficiency of the process, product isn’t outside the freezer long enough to jeopardize quality and pickers are able to work in a much less harsh environment. Height-adjustable load holders at the picking station position the pallet or roll cage at the right height for each layer so the picker never has to bend down to place cases on the bottom layer or lift cases to build top layers, minimizing back strain and optimizing ergonomics. This solution also supports a smooth transition to fully automated palletizing as robotic palletizing modules can be added later to take the place of manual pickers.

This is the type of solution Swisslog deployed for Apetito, a European leader in frozen convenience foods that needed to modernize an aging frozen food warehouse that was unable to keep pace with growing demand. The solution deployed by Swisslog includes automated depalletizing robots that provide cases to an 18-aisle mini-load ASRS. The ASRS is connected via conveyor to the picking and shipping areas, in this case within the frozen area. The precise sequencing of cases presented to each picker by the ASRS enables orders to be fulfilled with maximum efficiency and accuracy.

3. Optimized manual palletizing within the freezer

Where warehouse space is limited or the volume of mixed-SKU pallets doesn't justify automation, a pick tunnel can be an effective strategy to increase the productivity of manual palletizing processes. With this approach, the ground level of selected aisles in the ASRS is designed to accommodate manual picking and palletizing. Conveyors enable the ASRS to replenish the pick tunnel on demand and remove completed pallets from the tunnel, eliminating the need for forklift operators to support palletizing. By organizing products efficiently and reducing picker travel and wait times, pick tunnels improve the efficiency and accuracy of mixed-SKU palletizing operations. Eliminating the need for forklifts in the freezer also enhances picker safety.

Managing storage and palletizing in the deep-freeze warehouse

Regardless of the approach selected, software plays a critical role in managing storage, palletizing and order fulfillment processes. Swisslog SynQ software includes capabilities to manage inventory levels and replenish picking areas as standard, providing “out-of-the-box” support for mixed-SKU palletizing. With its full suite of capabilities and modular design, SynQ provides comprehensive control over deep-freeze operations that can be tailored to customer requirements.

SynQ uses an event-based control strategy that allows for real-time adaptation to changes and increased flexibility in warehouse operations. This is particularly useful in deep-freeze storage and palletizing as it supports detailed tracking of movements within the warehouse, both in terms of stock changes and physical location, to enable temperature-based inventory control and traceability.

SynQ also provides a Single-Point-of-Control (SPoC) capability that integrates warehouse systems and processes, allowing users to access and control all aspects of the operation from a single interface. SPOC also ensures consistency in the user interface across systems to improve efficiency and reduce training times.

Meeting the demand for mixed-SKU palletizing in the deep-freeze warehouse

If you’re considering automating pallet storage and retrieval and have demand for mixed-SKU pallets, consider integrating fully automated, semi-automated or manual palletizing with the ASRS to enhance the overall value of your solution and ensure you are prepared for future demand. Swisslog regularly works with deep-freeze warehouse operators in the design and implementation of storage and palletizing solutions, analyzing site requirements, processes and data to deliver solutions that meet objectives in the most efficient and cost-effective way.

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