Small Item Storage: Mechanised Systems (Vertical and Horizontal Carousels)

Vertical Carousel

This is an automated vertical storage device which saves valuable floor space. The vertical construction of carousel can go up to a maximum height of 7 m. The storage shelves are arranged in two rows and are held in special carriers. These are suspended at each end in heavy duty roller chains. The shelves can be designed to carry any type, size and quantity of items. For small items, plastic bins of suitable are used.

The movement of the vertical train of shelves is effected by an electro-mechanical device at the heart of which is a micro-processor based logic circuit. At the press of the particular button, the required shelf traverses the shortest path (either up or down) and stops before a window in front of which is a working table. The operator picks up the item easily. Thus the operator does not have to walk around looking for the desired item. The storage and retrieval operation becomes error-free and fatigue-free. As a further step for automation, the carousel can be interfaced with a computer thus making available additional information like stock position, etc., at the touch of a button.

The advantages of Vertical Carousels are:

• Uses a fraction of floor space used by static shelving, usually around 80 sq ft or around 25% of what static shelving would use;
• Simplicity (high reliability, low requirement for electronic coordination of moving parts);
• High speed in picking multiple parts (machine presents all parts in all order requests in one rotation) - when multiple machines are used in conjunction with software, parts can be picked by one person up to 5 times faster than they could be picked from static shelving by that person;
• High weight capacity - up to around 1500 lbs per carrier;
• Flexibility using different configurations of additional shelves in each carrier and reconfiguring when needed;
• Security (when the door at the workstation is locked, the machine is a sealed box); and
• Better ergonomics (all parts are presented at waist level, minimising back problems).

Horizontal Carousels

In Horizontal Carousels, shelved storage 'baskets' are suspended from a continuous overhead chain, which is driven forward or backwards to bring the required stock to the operator. The horizontal carousel is best used when the customer has low ceilings, light parts, or a distribution operation. When multiple machines are placed in a single group to be operated by one individual, that individual can pick from those machines with very little walking. In a group of 4 machines, there is only 12 ft between the pick faces of all 4 machines (as shown below).

The advantages of Horizontal Carousels:

• Ability to be installed under low ceilings;
• Uses between 40 and 60% of the floor space required by a static shelving system;
• Simplicity (high reliability, low requirement for electronic coordination of moving parts);
• High speed in picking multiple parts (machine presents all parts in all order requests in one rotation). When multiple machines are used in conjunction with software, parts can be picked by one person up to 5 times faster then they could be picked from static shelving by that person;
• High weight capacity - up to around 2500 lbs per wire bin;
• Flexibility using different configurations of additional shelves in each bin; and
• Ergonomics (using software "Golden Zones" the faster moving parts are presented at waist level, minimising back problems).

Odd Size Storage: Long Loads

Long Loads are loads such as carpets, linoleum and engineering materials such as rods, bars and tubes that require special storage and handling.


Cantilever Racking

Items with such odd shapes can be loaded in a horizontal racking but this can involve manual handling of the bars into position.

As seen in the attached pictures, the rods are held horizontally onto the racks. This is using the cantilever principle that stacks the rods at different levels. Mechanical handling is usually by means of side-loaders, four directional reach trucks or overhead cranes, which enable access without requiring especially wide aisles.

Pigeonhole Racking

Pigeonhole Racking (as shown above) gives good protection and good access to the stock. The gangway area in front of the racking must be wider than the length of the items being stocked, which reduces overall space utilisation. There are also various systems for mechanised storage of long loads.

The advantages of Long Loads system are:

• Easy storage and retrieval;
• Flexibility of design - number and length of arms, inter-arms spacing, height of the rack, etc., can be suitably designed to store any type, size and weight of material;
• For long and small items, storage channel or a panel can be provided;
• Can be made as single-faced or double-faced units; and
• Tie-bar can be provided at the top for extra stability of the system.

Storing of Dangerous Goods (DGs)

Dangerous Goods (DGs) are substances that may be corrosive, flammable, explosive, spontaneously combustible, toxic, oxidising, or water-reactive. These goods can be deadly and can seriously damage property and the environment. Therefore, it is important that they are stored and handled safely.

The area where DGs are stored, a DG warehouse should be:

• Well ventilated and well lit;
• Separated from ignition sources;
• Secured from the public;
• Protected from temperature fluctuations and direct sunlight; and
• Shelving and cupboards should:
  - Be contructed of chemically resistant materials; amd
  - Provide a lip at the front of the shelf.

Also, at the warehouse, secondary containment such as spill trays should be considered for liquid dangerous goods stored outside of a chemical storage cabinet.

For storage of DGs of quantities below a certain level, requirements are less stringent as the risks posed are lower. This means that storage of low level of DGs in the laboratory can exist without the need to purchase an Australian Standard approved cabinet. However, for storage of DGs exceeding the specific quantities, there is a need for consideration to purchase Australian Standard approved shelving or cabinets for their storage.

Storing of Hazardous Chemicals

Storage on Shelves

Hazardous Chemicals should be stored in chemical storage cabinets or laboratory cupboards. For chemicals that are kept on shelves or racks, they are subjected to the following restrictions:

• Shelving must be compatible with the goods stored;

• Shelving systems must be designed to hold the maximum holding capacity of the chemical containers;

• Incompatible chemicals should not be stored together on shelves. Keep a distance of 3 m between them. The space between can be used to store non-hazardous substances;

• Chemical packagings should not be kept on the floor;

• Solid chemicals should preferably be stored on upper shelves above liquid chemicals;

• Secondary containment is essential for large containers (eg. the 20 L waste cubes). It also makes sense to bund any container with capacity of 2.5 L and above. As a priority, all DGs of this size should be bunded;

• Shelves should have raised edges to reduce the likelihood of dislodging;

• The most dangerous chemicals should be stored at easily accessible heights (eg. 1.5 m from the floor);

• Chemicals should not be stored under direct sunlight; and

• Where refrigerated storage is required, do not use domestic refrigerators. Options include intrinsically safe refrigerators or domestic refrigerators that have been made electrically safe by a licensed electrician.

Storage in Cabinets

Each chemical storage cabinet must have a designated personnel responsible for its management. Their duties would include ensuring that:

• Appropriate emergency spill measures are in place;

• Emergency first aid is accessible and in working state;

• The storage location appears on the building manifest and on the annual notification to WorkCover;

• A risk assessment for storage of DGs is completed for the particular storage location; and

• Disposal of old and unwanted chemicals occurs regularly.

Warehouse Labeling

Warehouse Labelings are important for it serve its purpose to inform warehouse personnel where to locate the particular inventory.

Below are some types of warehouse labeling:

Labels holder

Magnetic and self adhesive Label Holders, enables instant identification or labeling of racking and shelving in the warehouse, storeroom or offices. The C Profile of the magnetic and self-adhesive shelf edge label holders allow fast and easy updates of product information.

Ticket holder

Self adhesive and magnetic Ticket Holders with a pull forward front allows easy loading and updates of information. Barcodes can also be scanned without removing the card. Ideal for pallet racking beam, shelf location and general warehouse labeling.

Document Pocket

Industrial Document Pockets with welded edges are ideal when documentation needs to be kept clean, or simply for control of fast moving stock. They can be used on steel cabinets or racking and shelving.

Aisle Markers

End of aisle identification markers are manufactured in two highly visible colours. Available in white and yellow styrene, these robust Aisle Markers can be fixed flush with the end frame or used as flags, to identify bays along the aisles, with 90 degree flange. Markers are supplied pre-drilled in all four corners unless flanged or otherwise requested and can be supplied with the option of self adhesive or magnetic fixing options.

Bay Marker

The highly visibile Bay Markers can be used for clear identification throughout the warehouse. A formed aluminium section with either a magnetic or self-adhesive edge, enables the marker to be easily mounted onto steel racking without drilling. When locations need to be changed, the magnetic markers can simply be lifted and relocated.