Optimized Warehouse for This Food Packaging Leader

Company Overview

i2R is a producer and distributor of smooth-wall and wrinkle wall aluminum containers, widely used in the food industry. As the leading manufacturer of aluminum trays in Europe, they produce more than 1.2 billion products each year. They serve many major food producers and retail brands, as well as wholesale and distribution markets worldwide, including Central and Northern Europe, Asia, North and South America, and Australia.

Located in Telford, UK, and founded in 2007, i2R is a young and innovative company determined to offer a genuine alternative in the aluminum packaging sector, disrupting and redefining the industry. Since its inception, i2R has experienced significant expansion in the UK and internationally, leading to the opening of their new manufacturing and warehouse facility in Brampton, Ontario.

 

Initial Situation

Wishing to extend their global development, i2R is now establishing itself in Canada to launch a manufacturing and distribution centre. The company started from scratch in Canada for their first North American plant. They were, therefore, seeking a partner on Canadian soil to help with the design of their warehouse. This is where the MSK Canada team comes into play. The technical level of the company and their turnkey offer convinced the British company to trust them to oversee the warehouse design aspect of their expansion project. Thus, it is in the hands of MSK Canada to optimize i2R's warehouse by providing the necessary pallet positions for their production and distribution, according to the available square footage.

Challenge #1: Optimizing Racking Without Prior Experience

Since it was a new factory in a new country, the company had not yet inhabited the location, which meant there was no prior information about employee movements or the tools and lifts they typically use. This left MSK Canada with a blank slate to optimize the space.

Additionally, the dimensions of the products could pose a certain problem concerning the accuracy of their sizes and weights. MSK Canada was unable, due to the distance, to measure or analyze the dimensions of the products and pallets, which required the company to rely entirely on the accuracy of the information received from partners in England.

 

The Solution: Effective Communication and Organization

To meet the company's long term logistical requirements, an in-depth analysis of shipping needs was conducted. With a high volume of 35,000 boxes, or 1,000 pallets shipped each month, it is essential to optimize employee movements within this 38,000-square-foot space to ensure optimal efficiency. This includes strategies to minimize time losses, such as effective organization of storage and order preparation areas, while keeping in mind a future phase of process automation in the coming years. By streamlining these operations, the company can improve productivity and reduce costs associated with downtime and unnecessary movements.

This success is due to the exemplary collaboration between the teams at MSK Canada and i2R. Unable to take measurements and analyze the products themselves, the specialists at MSK Canada delegated this task to the employees of the English company, who brilliantly rose to the challenge. Although this task may seem trivial, it is crucial for optimizing a warehouse. Accurate dimensions allow designers to maximize the use of available space according to product size, thereby improving the volumetric profitability of the warehouse.

Challenge #2: Respecting the Point Load on the Slab Applied by the Racking

Respecting the point load on the slab applied by the racking is a key element with which companies like MSK Canada must work and consider in all their design projects. These loads are often very heavy, concentrated on a relatively small surface area. Several stakeholders are involved in the design of a warehouse: clients, architects, the general contractor, the design team, and the installation team. A problem with the slab or a lack of precision in evaluating the load it can support can delay the entire process and result in additional unforeseen costs.

The Solution: Single-Depth Racking

MSK Canada remains committed to providing its clients with optimal solutions tailored to each context, thanks to a meticulous analysis of internal and external requirements. This project is no exception. Our specialized team conducted a comprehensive assessment of all aspects, ensuring precise recommendations to address the particular challenges of this client. Following this analysis, adjustments were made to the base plates, which were widened to ensure an adequate distribution of the pallet rack load. The racking configuration was also optimized to minimize the impact of the weight on the concrete slab, notably by adding racking above the warehouse garage doors to maximize space utilization and, at the same time, increase the total number of pallet positions in the warehouse. This allowed for the distribution of the total load on the slab across different areas. These measures also enabled the project to meet the planned deadlines and budget. The choice of these solutions stems from the thorough review conducted by the MSK Canada team, which was preferable to other more costly options in terms of time and money.

Final Situation

Thanks to the solutions provided by MSK Canada, the project was completed without exceeding the planned deadlines or costs. The meticulous analysis conducted by the MSK Canada team allowed for the implementation of specific solutions, thereby avoiding potentially more expensive alternatives in terms of time and money. This case study highlights the importance of recognizing the inherent complexity of each project, even those that may appear simple. The intervention of a professional team like MSK Canada proves invaluable at all stages of the process, offering expertise and support to overcome the challenges encountered.