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Client:	Bluebird Foods
Location:	Auckland

Bluebird is one of the biggest snack food manufacturers in the country producing New Zealand’s favourite potato chips in their Wiri factory in Auckland.

Scope

With a requirement to store an additional 30% of product in the same space, PRS worked closely with Bluebird to reconfigure their warehouse to maximise every inch of space.

Challenge

In addition to creating extra storage space, Bluebirds driving factors were site safety and stock rotation. Safety was paramount and their major concern was the possibility that the top pallets could be pushed through the back of the rack and cause an accident.

As a food manufacturer freshness is crucial so they needed a solution that would ensure the correct products were dispatched.

Solution

To achieve the required capacity we added an extra beam level to new taller frames and reconfigured the racking from a three deep to four deep design, with centre rows.

Our team of experts designed a pallet stop that worked through the centre of the new four deep racking so that pallets could not be pushed through the racking. These newly designed pallet stops have become a stock product that have gone on to provide solutions in other installations.

The addition of pallet live pallet racking to the lower level ensured the correct products were dispatched to the market after production following a First In First Out product flow.

Wire mesh shelves were installed on the higher levels to enable non-palletised loads to be stored.

Anti-collapse safety mesh was installed on the outside double bays to create a strong barrier between stock where workers carried out their daily tasks.

Our installation team dismantled Bluebird’s existing racking and reused their beams. Our installers worked to clients tight time frames including after hour and weekend work.

The end result has achieved the crucial addition of 30% more product storage to a warehouse that is now site safe and fit for purpose.