Every few years, I get involved in a really cool project, so I thought I would share some details on a recent one. We started working on this project two years ago, and it is just finishing this month.

Tackling Temperature-Controlled Challenges

Several years ago, a biopharma company in Massachusetts contacted us regarding storing WIP and finished goods in a high-density system as part of a planned building expansion. As the discussions progressed, it became clear that many of the challenges they faced could be solved by a vertical lift module (VLM) AS/RS system fully enclosed in freezer panels and built into the building similarly to an elevator integrated into a building.

Here are several of the project highlights:

• Two-level access

The manufacturing of finished goods required multiple-level access to the storage system to eliminate the need for storage space on each floor. The two-level solutions also removed the need to move products from floor to floor using conventional stairs or elevators in ambient temperatures.

• Kardex XP 500 VLM AS/RS

Four 30-foot tall Kardex XP 500 Shuttle VLMs provided the capacity, redundancy, and throughput to move the product from floor to floor. Each of the four machines has (35) 3-foot-deep x 12-foot-wide trays with custom dividers to physically manage the products on the tray. Both floors have access to all four machines simultaneously.  Associates can be picking, putting, or working with eight trays simultaneously.

• Full SAP integration

Kardex’s Intralogistics software, Kardex Drive, controls the movement of the trays from each access opening to either a storage location or another level’s access opening. Kardex Drive is loaded into SAP and accessed through SAP screens without switching to another application to work with the AS/RS system. Kardex Drive also operates the pick-to-light functionality described below.

• Pick-to-light functionality

Each access opening includes pick-to-light functionality that directs associates to a specific location and provides point-of-pick information. Data displayed includes but is not limited to part #, lot #, serial #, description, quantity, location coordinates, and visual indicators of which location is being picked or replenished. A 40 mm LED spot also moves above the tray in the access opening and points to the location, making it easier and more accurate for the associates.

• Redundant cooling and dehumidification

Because of the sensitive nature of the products and materials stored in this cold environment, they cannot be stored outside of the temperature range. In case of a mechanical failure, a fully redundant cooling and dehumidification system automatically switches on in the event of a malfunction. The system is mapped, validated, and integrated with the building management system to display warnings and sound alarms. You can view current and historical data from several places in the system.

• -20C freezer

The freezer panels are custom fitted to three sides of the Kardex units with space for maintenance and cold air flow behind them. Controls are in stainless steel cabinets that are heated or in ambient spaces. The products on the trays are accessed through heated glass freezer doors.

• 4C anti-rooms attached for access to the freezer

To keep the products within the temperature range, associates first enter a 10-foot deep 4-degree C anti-room attached to the front of the freezer. In addition, the cooler temperature and humidity-controlled environment ensure no frost builds up around the freezer doors. The room also provides storage space on each floor for products requiring only 4C temperatures.

• Fully integrated into the new building expansion

To maximize the space savings of a system like this, we were able to work with the architect early in the process and design openings in the floor as well as the structure of the floor to accommodate a freezer with -20C temperatures.

Goods-to-person technology pays off

The coordination with the architect and general contractor produced a system that integrates very nicely with the surrounding architecture and has a clean and finished look that is also very functional to process orders on two levels. There was a lot of teamwork with our installation team, the general contractor, and the client- which ultimately paid off.

As in many medical, biopharmaceutical, and medical device applications, a high-density, environmentally controlled automated system can save space in an industry with a high per-square-foot cost. The added benefits these kinds of systems provide in terms of process improvements contribute to the ROI.

If you are looking for a unique solution for your operation, give Abel Womack a call. We love a challenge and have many more cool solutions.