Bru Textiles, leading provider of furnishing fabrics and upholstery, today distributes ten million meters of fabric produced mainly in India, Bangladesh and Africa.
The fabrics come form suppliers in rolls about 1.6 meters long and of varying diameters, according to the type pf product. The high handling outgoing and incoming of these rolls entailed considerable effort for the logistics department, which still handled the tissues within baskets positioned on conventional shelves, moved through trilateral conducted by an operator and monitored by a computer system.
The need for an automated warehouse was welcomed by Automha as a challenge for the lowering of time needed to picking phase and reduction of error margins. The proposed solution has created a fully automated warehouse from the 12000 unit load capacity, handled by 13 stacker cranes through a surface of about 4800 sqm.
The goods, always labeled to ensure the traceability of each roll, comes in stock through two telescopic strips that lead to the control stations. The rolls that fail the checks flow into a titling station, where they are sorted according to the type of problem found; others proceed toward the lower part of the warehouse, within the three input bays. Here, thanks to 7 belt conveyors, the rolls are unloaded from the shuttle and picked up by the stacker crane, which enters the rolls in stock. These are stored in multi-depth on layer of 7 stage, supported on specially designed cradles to avoid damaging the tissues. One of the biggest strengths of the system designed by Automha is the ability to never leave any empty location: when a roll is taken, in fact, the location is immediately filled by another roll entered in stock. This allows you to never have any lane with empty locations. When the rolls are called by the system to the exit, the stacker crane travels to the indicated position and proceed with the withdrawal; arrived at the head transfer the tissues of a three-level machine (one for each stacker), capable of seating 21 rolls, from which it takes the picking operation by a further stacker with telescopic forks. At the end of the line, the rolls placed in the shuttles are taken by a cartesian robot that predisposes the load in a single batch for delivery or for cutting. Once completed, the batch flow into a second warehouse, smaller but always automatic, from which operators shall have the final actions of the rolls management.
Thanks to the solution proposed by Automha, Bru Textiles can today boast the world’s largest automatic warehouse for storage of tissue rolls.