Introduction

of Cold Store
Automated Storage and Retrieval System
(AS/RS)

SM-P-Cold Storage ASRS-14001-00

15 Jan, 2014
Prepared by Daifuku Singapore.

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 What is ASRS ?
Automated Storage and Retrieval System

An Automated Storage & Retrieval System, also referred to as AS/RS or ASRS, is a

combination of equipment and controls that handles, stores, and retrieves materials
with precision, accuracy and speed.

Systems can vary from relatively simple, manually controlled point of use storage
structures to computer-controlled storage and retrieval systems that are completely
integrated into the manufacturing and distribution process.

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 Effects of Automated System Installation

Space Saving
•Use vertical space effectively to minimize square footage

Optimize Labor Cost

•Repetitive movement eliminated
•Only touch material to add value

Speed up processes
•Supplier more responsive to customer
•Shorten flow throughout factory and distribution center

Effective use of company resources

•Real time inventory data allows optimum production and procurement planning

Hygiene and Safety

•Less human presence increase hygiene level (food, pharmaceutical)
•Dirty, difficult, dangerous operations eliminated.
•Improved ergonomics
•Increase security

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 Unit Load (Pallet) ASRS

Unit-load AS/RS are designed to store large loads of roughly 1,000 Kg or more. These loads are
typically stored on pallets or in pallet-sized containers. Some specialized systems handle
oversized loads such as furniture and long rolls of carpet.

A unit-load AS/RS can rise beyond 40m high, but a typical system height is less than 20m. A
standard AS/RS stores loads in steel pallet rack designed specifically for automated systems.

This rack, like drive-in rack, stores loads on rails that run perpendicular to the aisles. (Standard
pallet rack stores loads on cross beams that run parallel to the aisles.) AS/RS rack can be
configured single-deep, double-deep or as deep-lane rack with several pallets stored one behind
the other.

The load-handling mechanism for a unit-load AS/RS is usually a telescoping device called a
shuttle that reaches out into the storage location, slides under the pallet, and then pulls the pallet
back onto the carriage.

A unit-load AS/RS can provide dense storage in a finished goods warehouse, buffer storage for
work-in-process in a factory, a dynamic pick face for a case-picking operation, or parts
sequencing for an assembly line.

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 Load Types by Storage Retrieval Machine (SRM)

Unit Load AS/RS Mini Load AS/RS

( 100~3000kg ) ( ~150kg )

Double deck pallet Stacking type tote

Skid pallet
Collapsible tote

Sheet pallet
Carton box

Box pallet
Tray

Roll box pallet

Special pallets

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 Equipment in & around AS/RS System

SRM Pick and Deposit Stations

Fixed Table

Powered Cart

+ Conveyor

Rack
Storage Transfer
Vehicle
(STV)

Automated
Guided Vehicle
(AGV)

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 Address Terms of AS/RS
Below are general terms used in Daifuku.

OP

5
4
3

Level

2
1
2 1

HP 3
4

~
5
4
3
2 Bay
1

Bank

(The example is Double deep system)

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 Single Deep Pallet AS/RS

• One SR Machine serving 2 Banks of racking

• Typical Throughput: 35 to 50 Pallets/hr./SR Machine

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 Double Deep Pallet AS/RS

• One SR Machine serving 2x2 Banks of racking

• Typical Throughput: 20 to 35 Pallets/hr./SR Machine

*most suitable for compact cold storage system*

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 Introduction of Cold Storage AS/RS
(0 to -40 deg. C Storage Environment)

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 What is Cold Storage?
•Chilled storage to preserve food: chilled or refrigerated conditions in which perishable
items, especially food, are kept to preserve them.

Refrigerated
Products Stored Life Time
Warehouse

+10ºC
Fruits; Vegetables 4~5 weeks;
1~2 weeks
C3 Grade -2ºC Beef; Pork

C2 Grade -10ºC

Frozen Beef; 4~5 weeks;

C1 Grade -20ºC 12 months
Ice-cream

F Grade -40ºC Frozen Tuna 3~6 months

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 Key Factors of Refrigerated Warehouse

 Cut down / reduce capital investment overlay

 Keeping good quality of products

 Greater flexibility in serving a huge but changing market trends

 Controlling warehouse and logistics costs

 Providing high levels of sanitation

 HACCP* Certified storage procedures

 Provision of all kinds of related services

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 Daifuku’s Cold Storage ASRS Installation History

•The first minus 40 deg C ASRS in 1973 Japan installed more than 180 system
in Japan alone
• Est. 600 sites and total 300,000 SR machines

Built to Suit
• Wide scale application

• Total solution provider

– Warehouse management
system
– Automated material handling
system
• General construction

• Refrigerated system

• Turnkey operation support

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 Refrigerated Warehouse

Design Concept
* Responding to the change in physical distribution since extra-market distribution has
been increased
* Responding to chronic shortage of overnight workers and personnel working under
extremely cold environment

Effect of System Installation

* Reduced operating staff and drastically reduced personnel cost by utilizing part-time
workers
* Decreased electric power expense
* Thorough quality/ inventory management is realized.
* Drastically reduced time needed for storing/ retrieving loads in/ from store room

Points to Be Noted for Physical Distribution System

* Automated system that can meet the business custom unique to fisheries industry
market (short-time volume retrieval, “additional retrieval”, and no scheduled data for
receiving/ shipping)
* System that can respond to the decreased storage efficiency resulting from small-lot
retrieval (system for consolidating 2 or more items/ assorting fractional pallets)

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 Refrigerated Warehouse
Insulated doors with shifting conveyor helps maintain constant temperature

The insulated door

Opening: 4W x 3.8D x 3.8H (m)
Conventional = 57.76m3 > 7.776m3 (7X More!!)
Forklift Cold Air
Operation Cold Air
Cold Air
Out rush of cold air
Cold Air Forming mists and icing problems
Cold Store
Incurs higher utility costs
(Refrigerated/Freezer)
Ante Room

The insulated door

Cold Storage Opening: 1.8W x 1.6D x 2.7H (m) = 7.776m3
ASRS
Loads have smoother
ASRS movement between conveyors
Cold Air
(Refrigerated/Freezer)
Ante Room

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 System Concept

• Instant response system that is directly connected to production

• Handling extremely small lot retrieval (1 to 2 cases per order)

Aim of the System System Solution

Prompt shipping, while handling the Arrangement of Max. No. of output ports, adoption of
additional retrieval request high-speed crane

Increased storage efficiency while Mixed load pallet consolidating 2 or more items,
handling small-lot retrieval assorting fractional pallets

Flexibly responding to various load Combined system of AS/RS and floor-loading store room
sizes

Eliminating the work under cold

Automatic storage/ retrieval using AS/RS
environment

Using part-time workers for Picking can be conducted easily/ without mistake using
overnight/ skilled labor the display unit.

Complete inventory/ Inventory control for every pallet,

quality control no load damage due to rack storage

Drastically reduced electric power Little heat ventilation due to decreased opening area of
expense thermal insulation door and no lighting device

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 General Image: Single Floor Operation

ASRS
(+5 to -40 deg.C)

Store In/Out
Station

Conventional
Block Stacking

Floor loading
staging area

Proceed to Receiving/ Shipping berth

Production (Container Loading Ramp)

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 General Image: 2 Floors Operation

ASRS Picking Area

Floor loading
cold storage

Receiving/
shipping berth

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 Comparison Between ASRS & Conventional Models (-25 deg. C)

Automated Model Conventional Model

Layout

No. of pallets 8 Banks x 27 Bays x 8 Tiers - 42P (5 Banks x 13 Bays x 4 Tiers) x 2P

that can be stored = 1,686 Pallets = 520 Pallets
Aisle Width ASRS Rackmaster: 1,500W Forklift Turning Aisles: Min. 3,500W
Number of
needed personnel 4 12
Profitability
(Turnaround) 3~4 years 4~6 years

Building Area 535 m2 552 m2

(Excluding office/ appentice) (Excluding office/ appentice)
493 m2 510 m2
Floor Area (Excluding office/ appentice/ virtual floor) (Excluding office/ appentice)
Forklifts Q’ty 1 unit 2~3 units

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 Compare ASRS & Conventional Storage
Conventional Cold Store ASRS
1. Manpower Minimum 20pax for existing operations. Can be downsized to only 2 or 3pax.
Fast and accurate load transfer.
Time loss in searching and inaccurate.
Variable acceleration rate.
2. Operation Slow and operator dependence.
Reduced operator fatigue.
Labor intensive. Work in cold room.
Worker work at ambient temperature.

Low. Dependant on human factors. (Judgment,

3. Throughput High. Dependant on machine specifications.
Experience)

Safety improved. High speed operations while

4. Stability / Damage Accident Prone. Damage Prone to Cold Panel.
maintaining load stability.

Lighting are not required during operations. Saving

5. Lighting Adequate lighting are required.
in energy cost.

Est. S$ 383,000 based on 24hrsx7days. Est. S$ 150,000 based on 24hrsx7days.

6. Yearly Utilities shutter door big opening and forklift operator usually Shutter door opening same to pallet load size,
don’t shut it cause drop of temperature resulted food integrate with ante room keep minimum cold air out
freshness can’t maintain and waste electricity. rush. Cold room temperature always maintain.
First-In-last-Out (most of the time difficult maintain
7. Retrieval First-In-first-Out.
FIFO because all block stacking)
WMS with Integration to HOST for automated
8. WMS No WMS & Pallet Load Tracking.
invoicing etc.
No Icing or Mist as Shutter doors are interlocked
9. Icings & Mists Abundance of Icing & Mist Problems.
with Conveyor System.

10. Pick Errors Possible of human picking errors. Nil with WMS Controls.

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 Reference Cold Storage AS/RS

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 Daifuku Singapore Cold Storage ASRS Track Records

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 Case Study (I) Refrigerated W/H, Japan

Function:
Refrigerated warehouse
(F class) Bidding Area
- Storing frozen fish
- Supplying for bidding area

Site Area: 22,800 m2

Building Area: 4,300 m2
Floor Area: 6,800 m2
Steel Construction
3-Storey Building (18 m)
Nominal Weight: 10,200 ton
(AS/RS: 8,300 ton
Floor Loading: 1,600 ton
Ultra Low Temp.: 300 ton)
Racking System: 3,840 pallets
(-25C)
SRM: 6 units
STV: 12 units
Lifter: 1 unit
Powered cart

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 Case Study (II) Refrigerated W/H, Japan

Function:
Refrigerated warehouse
(C/ F class)
- Increased storage volume
- Securing the distributive
processing space
- Responding to small-lot
retrieval

Racking System: 12,110 pallets

SRM: 5 units
(C class: 2 units, F class: 3 units)
Input/ output conveyor: 1 set
Lifter: 2 units
Automatic binding device: 1 unit
Shipping indicator lamp: 4 sets

- Reduced operating personnel: 20  8 people

- Increased storage efficiency
- Improved productivity by 24-hour operation
- Perfect inventory control
- Introducing high-level communication system

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 Case Study (III) Refrigerated W/HB, Japan

Function:
Refrigerated warehouse
(C/ F class)
- Distributive processing
- Sorting by store

Building Area: 3,400 m2

Floor Area: 6,900 m2
Steel Construction
3-Storey Building
AS/RS (-30): 9,000 pallets
SRM: 8 units
Sorting transfer vehicle
(loop/ shuttle type)
Lifter: 2 units
Sorter: 4,500 cases/hour

Load profile correcting device: 2 units

Stretch wrapping machine: 1 unit

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 PT Indomaguro
(Indonesia, Jakarta)

• The proposed system consists of a SNI Seismic Zone 3 ASRS racking with 6 units of -30 deg
C, 33m(H) Double Deep Euro Fork Pallet ASRS and storage of 14,144 pallets.

• Results of Implementation of Freezer ASRS:

– Significant savings in electricity / energy consumption in the Freezer ASRS warehouse
observed after 6 months operations (one Freezer ASRS warehouse equivalent to 10
conventional freezer storage compartment warehouses)
– Increased productivity and operator morale in handling automated system
– Increased throughput and operational efficiency
– Improved work place Safety, hygiene and cleanliness
– Reduced picking errors
– Integrated real-time inventory management

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Sakae Holdings

• 2 units of -30 deg C, 4.5m(H) Double Deep Euro Fork Pallet ASRS
• Storage Capacity of 1,080 pallets.
• Load Size 1,200W x 1,00L x 700/1,000Hmm
• Load Weight of 250kg

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Invitation to Visit Daifuku Exhibition Center
Hini Arata Kan Expo Center
Material Handling & Logistics Systems
Daifuku's unrivalled, full-scale exhibition center for Material
Handling & Logistics Systems. Our experienced staff will guide
you through an array of our latest material handling innovations
operating under one roof.

Hiniaratakan Corporation – a Daifuku company -

1225 Nakazaiji, Hino-cho, Gamo-gun, Shiga 529-1692 JAPAN
Toll free (in Japan): 0120-074-854; TEL: 81-(0)748-53-3970 FAX: 81-(0)748-53-3921

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