Rolf C Hagen, a major manufacturer and distributor of pet supplies, expanded its material handling capabilities and upgraded its distribution center in Mansfield, MA.

Abel Womack presented an engineering solution to Hagen that included approximately 2,000 feet of new conveyor equipment, controls, multi-level pick module and a state-of-the-art RadioBeacon warehouse management software package.  The solution improved Hagen’s ability to deliver more items to their customers with increased cost effectiveness.

The project included:

• New conveyor system with spiral lifts between levels, carton flow rack and packing tables
• Tote routing to picking zones which eliminated the need for pickers to walk long distances to fill orders
• Weigh in motion scale which eliminated excess weigh and postage stations
• Installation of new conveyor system to remove used cartons from picking area
• RadioBeacon order verification software for accurate shipments
• UPS label generating software which allowed for a large number of small orders to be picked, thereby meeting corporate goals for this type of order.

The increase in productivity has been phenomenal.  The new equipment resulted in “… a 400% increase in order lines pulled per day with only a 25% increase in picking labor“, reports Chris Castelli, Warehouse Manager for Hagen.

This project was selected as a case study by Modern Materials Handling Magazine. 

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