The Arnott's Group

1. AS/RS Solution - 3 cranes (existing building)
The Arnott’s Group's chocolate products are stored in a 5,840-pallet Unit Load AS/RS with three cranes across two temperature-controlled chambers. Products first enter a warm chamber with one crane to achieve a Supergloss finish, then move to a cooler chamber with two cranes for further storage before distribution. Both chambers are fed by the STV.

2. Goods-to-Person Picking System (GTP)
The GTP system is where pallets are created from a mix of products. The system delivers the product to each picker in sequence based on the order and appropriate layering to ensure zero damage. Once the pick is complete, the pallet is sent to the dispatch lanes, or stored within the AS/RS system.

3. Order-Picking System
Completed customer pallets created in the GTP area are sent in sequence with full pallets for the same order ready for pickup and delivery.

4. Outbound Orders
In preparation for dispatch, pallets arrive at the outbound lanes in strict sequence in accordance with the product characteristics and weight to ensure no product damage during transportation.

5. Manufacturing Palletising Operations
Single SKU unwrapped pallets are transferred from the robot palletising area to the warehouse floor via elevators.

6. Wrappers
Pallets are identified, stretched wrapped and barcode labelled. After the size and product are validated they are automatically transported into one of the AS/RS high bays (1) or (8) by the STV (Sorting Transfer Vehicle) (7).

7. Sorting Transfer Vehicle (STV)
The backbone of the system, the STVs connect all aspects of the warehouse via a single rail loop capable of handling over 300 pallets per hour.

8. AS/RS (Automatic Storage & Retrieval System) - 9 cranes
The high bay system has a capacity of just under 23,000 pallets, with a throughput of 242 pallets per hour. The overall warehouse handling over 330 pallets per hour.