World renowned logistics company UPS asked Warehouse Systems to come up with a scheme to enhance their cross docking operation in the Midlands. The demands of the site were such that some serious, radical thinking was required. “In fact I think I could write a dissertation on it” says David Wort, WSL’s senior sales manager.

The scheme began with a specially fabricated, inclined, steel base to maintain the open floor area for the larger loads. This provided the structure needed for the 2 levels of pallet live racking which in turn was topped by a mezzanine level, used for repackaging and slower moving lines. The mezzanine was accessed by input and output 3 deep pallet live lanes and also by extra wide pallet gates. A fire break was provided to satisfy the fire regulations, effectively dividing the system in two. The two halves of the mezzanine were then connected by a steel bridge.

“It took hundreds of hours to design and refine such a complex requirement, but we love a challenge.” says David “Thankfully we have a large and experienced team who have seen it all and if it doesn’t exist they invent it!”

What mattered to UPS was a three fold increase of pallet capacity through the cross docking operation. The effective use of ‘in’ and ‘out’ handling considerably improved efficiency and timings.

Even when you’re world number one the only way is UP.