Project Spotlight: Retail Fulfillment in Manchester, NH

Storage Solutions completed a project for a longtime client for their 400,000 square foot facility in New Hampshire. The client was condensing their operations to free up warehouse space and required a creative solution to completely reverse the flow of their outbound conveyor system and re-locate their shipping sortation race-track conveyor.

However, the challenge with this project was the integration of the new conveyor with their existing conveyor system. The design had to factor in their need to have the conveyor interact with their existing pick modules. There was also a time crunch associated with the project, so proper planning and design were integral at the early stages to ensure the project would be completed on time and within budget.

Additionally, at the time, lead times for new conveyors were estimated at 20 weeks, while the client only had an 8-week window to complete the project. So, our engineers got to work while our account representatives and project managers began procuring the proper equipment.

Because of our vast network of partners, we could find a portion of what we needed from new product sources while using some of the client’s existing conveyors. We also found mechanical and electrical installers who were up for the challenge and had a strong base of product knowledge and experience.

We integrated the new conveyor material with their existing system, used TGW’s motor-driven roller (MDR) conveyor to create a 180-degree curve, and Russell Conveyors for spurs, curves, and merges. We were able to utilize a conveyor loop design – similar to a horseshoe – to maximize the use of space. Our engineers and product managers made site visits to ensure everything was on schedule and provided guidance on reprogramming all of the different components to make everything run together properly.

Ultimately, we were able to take a complicated problem like designing and reversing a conveyor system within a smaller footprint – when new conveyor lead times were around 20 weeks – and complete the project with minimal downtime in 8 weeks to the day. This success is just one reason why our clients continue to be repeat customers and it shows that delivering creative solutions can be accomplished because of our internal teamwork and diverse set of expertise.

Our scope of work included: