Globl Assists Dairy Warehouse Automation in Achieving Smart, High-Density Storage
This leading dairy product factory, specializing in a daily production capacity of 1,600 tons of nutritious and delicious products like UHT milk, ice cream, and cheese, required an immediate solution to support its massive scale. To maintain this high level of productivity, the factory implemented a smart, digitalized, and fully automated system. The comprehensive Dairy Warehouse Automation solution delivered by Globl included:
- Automated Inbound and Outbound: Automated Guided Vehicles (AGVs) handle goods movement, boosting speed and reducing manual errors.
- Automatic Pallet Unstacking: Introduced in the packaging materials warehouse to enhance speed and safety in material handling.
- Smart WMS: Optimizes the entire supply chain with real-time inventory updates and streamlined workflow efficiency.
1. Initial Challenges: The Need for Dairy Warehouse Automation
Initially, this FMCG product factory encountered several warehousing challenges that severely impacted its operational efficiency and made smart Warehouse Automation a necessity:
- Single-Layer Stacking of Finished Goods: Products were stacked in a single layer, leading to severe underutilization of vertical space. This also caused compression and damage in the ambient milk storage area.
- Disorganized Ambient Warehouse Layout: The layout was chaotic, with the same products placed across different zones. This made picking inefficient, increased errors, and resulted in highly inaccurate inventory data.
- Poor Workforce Management: A lack of structured labor management and an incomplete staff performance system led to inefficient personnel deployment and unclear accountability, driving up overall costs.
2. Globl’s Solution: The Foundation of Dairy Warehouse Automation
Globl implemented a multi-layered solution that transformed the factory’s logistics, establishing a smart, low-labor operation and maximizing space.
2.1 Improved Space Utilization with Dairy Warehouse Automation
To resolve the issue of single-layer stacking, Globl implemented shuttle-based multi-level racking systems. These custom structures were built to fit the optimized layout, increasing space utilization by up to 80%.
2.2 Smart, Low-Labor Operations via Dairy Warehouse Automation
By utilizing Globl‘s four-way shuttle solution, the client achieved a smart, low-labor warehouse operation. Material handling is now fully automated, with inbound and outbound operations handled by shuttles, lifters, and other intelligent equipment, significantly enhancing accuracy and safety.
2.3 Optimized WMS with Barcode Scanning for Dairy Warehouse Automation
The Globl WMS (Warehouse Management System) was configured to enhance the information system. All inbound and outbound goods are now managed using barcode scanning, providing real-time inventory updates and improving data accuracy across the facility.
2.4 Optimized Layout with Integrated Inbound/Outbound Zone
Globl engineers redesigned the site, fixing the messy layout. They implemented a fishbone layout to join the inbound and outbound areas into one simple, integrated flow, greatly improving overall operational efficiency.
3. Digital Transformation: Dairy Warehouse Automation Process Overview
This project operates as a Cyber-Physical System (CPS), driving the client’s digitalization and intelligent transformation goals through seamless integration between the warehouse and production lines.
3A Automated Inbound Process for Dairy Warehouse Automation
- Sampling & Data Entry: Operators sample goods at the workshop line, input production data, and record the information in the WMS via scanning.
- AGV Dispatch: The system queues shelving information and communicates with the AGV dispatch system. The system plans the vehicle path and signals the AGV.
- Material Movement: The AGV picks up the material and transports it to the designated warehouse area.
- Completion: The material is automatically depalletized and sampled for quality; the inbound process is then completed.
3B Automated Outbound/Inspection Process for Dairy Warehouse Automation
- Task Creation: WMS creates the outbound task and the inspection system determines the location.
- AGV Retrieval: The system queues shelving info, the AGV dispatch system plans the path, and the AGV retrieves the sample from storage.
- Inspection Delivery: The AGV delivers the sample to the designated inspection location and notifies the inspection system.
- Result & Action: The inspection system scans and records results:
- Pass: System sends the final outbound command.
- Reinspection Needed: AGV transports goods to the staging or handover area.
- Pass: System sends the final outbound command.
4. Transformation Results: Achieving Smart, Digitalized Dairy Warehouse Automation
By implementing Globl’s Dairy Warehouse Automation solution, the client successfully transformed its operations, moving from disorganized, low-efficiency stacking to a smart, high-density system. The integration of WMS, four-way shuttles, and AGVs ensures:
- Maximized Space: Up to 80% increase in space utilization.
- High Accuracy: Real-time, digitized inventory management.
- Safety & Speed: Fully automated material handling that minimizes human error and risk.
5. Take the Next Step: Partner with Globl for Dairy Warehouse Automation
Is your business struggling to meet high demand due to limited space or manual errors?
Globl specializes in designing and implementing custom, high-density Dairy Warehouse Automation solutions for the toughest industry challenges. Achieve up to 80% greater space utilization and full digitalization.
Don’t let storage complexity limit your potential.
👉 Contact our experts today for a free consultation and tailored solution plan!