Snackbrands

The Challenge

Snackbrands faced the challenge of consolidating two warehouses into a single, more efficient facility. As consumer demand for their snacks continued to grow, so did the complexity of managing production and distribution. The company needed a solution that would optimise storage capacity, reduce manual processes, and improve inventory accuracy—all while ensuring the ability to meet peak demand during busy seasons.

With the consolidation of two warehouses into a single 30,255 square meter facility in Sydney, Snackbrands sought to enhance its distribution capabilities.

The key challenges included:

• Limited Storage Capacity: Maximizing available space to accommodate growing inventory.
• Inefficient Manual Processes: Reducing reliance on manual labor to improve efficiency and accuracy.
• Handling Peak Demand: Ensuring the ability to meet increased demand during peak periods without compromising on delivery times.

The Solution

Key components of the solution included:

• High-Bay Automated Storage: The 30-meter high-bay Unit Load AS/RS for pallets maximizes vertical space utilization and support high-desnsity storage to accomodate a larger inventory.
• Automated Pallet Sorting and Transport: Rail-guided Sorting Transfer Vehicles (STVs) designed to transport pallets swiftly and accurately throughout the facility, integrating seamlessly with the AS/RS.
• Roll-On/Roll-Off (RORO) Stations: Automated systems that streamline the loading and unloading of trucks.
• Outbound Staging Lanes: Multi-stage inclined flow shelves that organize pallets by destination, preparing shipments for efficient dispatch.

The Impact

The implementation of Daifuku’s automation solutions yielded significant improvements across various operational metrics:

• Storage Efficiency: The 30-meter-high Unit Load AS/RS, optimized for palletized goods, significantly increased inventory capacity by enabling high-density storage and efficient retrieval.
• Increased Efficiency: STVs and RORO stations further reduced manual handling, cutting truck turnaround times from 60 to 20 minutes.
• Improved Inventory Accuracy: Real-time tracking minimized stock discrepancies and improved order reliability.
• Streamlined Shipping Operations: Outbound staging lanes organised pallets by destination, facilitating quicker and more accurate order fulfillment.

Summing it Up

By partnering with Daifuku, Snackbrands successfully transformed its distribution operations, achieving higher efficiency, accuracy, and scalability. The integration of advanced automation technologies enabled the company to meet growing demand, reduce operational costs, and maintain its reputation for delivering quality products on time.