Motorised Racking in Warehouse

Maximise storage space.
Ease of movement of MHE inside the storage area.
Sturdy maintenance-free system.
24/7 operations.
Palletised storage.

The material is stored on a standard pallet, and handled using a MHE for storage and retrieval. Size of pallet is defined and available vertical storage space is used. Each pallet weighs 1 ton and needs to be safely stacked and retrieved from a height of 6 m.

Kompress Motorised Racking was offered as the best solution. The entire room was divided into two storage sides countering the presence of pillars in the room. The layout ensured enough space for easy movement of men, material and MHE. The rails of the system were supported on a section of the floor. They were made flush with the floor level in a slope condition. The carriages were mounted with all necessary safety features. The superstructure was then built. The entire system was wired and integrated with a control panel. Apart from ease of storage retrieval, an appreciation of 70% in space utilisation was achieved over conventional racking in the same space. An intelligent application of product utilisation indeed!

The entire project was completed within 90 days.

Low decibel product
Low running cost
Maintenance-free
Highly secured

Offshore Platform about 80km into the sea from Mumbai shoreline.

It was a huge logistic challenge to transport all the material from Kompress Factory to client base (Oil Platform) situated 80km into the sea.The same could only be transported by boat and hauled up by cranes. The task became even more formidable because of choppy weather and heavy rain.

Apart from the weather and transport logistics, confined spaces, challenging work environment, safety procedures and survival and fitness certificates for workmen further heightened the daunting task. Most of the storage rooms were comparatively small with unique profile.

The entire material had to be packed in sea-worthy condition with absolutely no scope for shortage or damages.

All the various stores on the platform were identified along with their intended product storage and a suitable solution was devised.

The products supplied included Heavy Duty racking, Heavy Duty Mobile Compactors specifically made to store heavy spare parts, high value products and controls products.

Storage space is most critical and very precious in such remote locations. Our storage solution helped drastically increase storage capacity by almost 60-65% within the same storage space.

6 months including inclement weather

RMSCL, Headquarters in Jaipur serves as the Government procurement entity for all medical facilities activity for the entire State of Rajasthan. Under the Mukhya Mantri NishulkDava Yojana it was decided to create medical storage warehouses across all 33 districts and various Government medical colleges in the state.

The work was supposed to be carried out across the length and breadth of the state spanning 33 districts. The terrain weather, logistics and the challenge of completing the project within time. Interaction with various teams at the client’s end, documentation compilation and submission.

The solution proposed was long-span racking along with required material handling equipment (MHE). The layout of the racks was evolved to counter the presence of pillars and facilitate easy movement of man and material and follow all mandatory rules for medical warehouses. The supply had to confirm all the required technical norms required by the client and certified by the warehouse manager. Site verification, supply and documentation had to be accurate and to be completed within time.

Initially before we provided the storage system and MHE, the material was randomly stored all over the floor, stacked one upon the other. This posed a huge challenge in terms of retrieval, shortage of storage space, damages, high dependences on manual labour and inefficient work environment.

The client could thus achieve almost 300% more storage due to optimal utilization of space using our long-span racking supply. Storage and retrieval time were greatly shortened, and the use of MHE helped cut down human effort drastically. All of this helped increase work force efficiency many times over. Damages and rejections of medicines were reduced to negligible levels.

4- 6 months night from site assessment to commissioning.

Cantilever to keep special size of pallets

Rittal are manufacturers of industrial enclosures, electronic packaging, etc. Rittal was having a special metallic pallet of size 2.1 mtr. X 1.2 mtr. having a load capacity of 800 kg/pallet. These pallets were used to keep the unfinished goods (metallic panels) in their factory which were used during production and had to be moved to multiple locations for different jobs and assembly lines. Being a bulky product it was difficult to stack the things in a conventional racking system. Rittal was finding it difficult to store the pallets and were desperately looking for some solution.

It was difficult at first instance to store such type of system by any conventional method. To design something special was a costly affair and also time consuming. After going through 2-3 meetings we understood their requirement and suggested cantilever racking system with different sizes of bracing to accommodate the pallets.

KOMPRESS designed a cantilever storage system which were used to keep pallets instead of long items. Normally pipes, aluminium, profiles and other architectural materials are kept in a cantilever racking system but here by doing minor modifications in the size of the bracings we were able to keep the pallets instead of longer items.

Here to use the vertical space we gave a cantilever rack of height six meters having arms of size 1200 mm to accommodate the pallets. The rack was having size storage levels thereby increasing the capacity six times and having an option of random pickup of materials.

Storage solution for a steel industry giant in Durgapur, West Bengal

• Dense Storage

• Storing bulky materials of variable sizes

• Conventional storage system could not provide the required capacity asasasasas

Kompress examined the requirement, space and the material inflow and outflow of the warehouse. It was observed that the same type of material was keptbatchwise and they required different materials from time to time to prepare their mixture in the plant. Kompress therefore suggested two types of storage solutions: 1. Drive-in Racking and 2. PushBack Racking. The challenge with the Drive-in Racking solution was that it would require procurement of specially designed MHE for the drive-in system and in that case each row would have to be assigned for one kind of product. The advantage with the Push Back racking system was that there was no additional cost or requirement to procure new MHE, as the existing MHE could do the operation and also each level of every column could be dedicated to one type of product. So instead of one batch per row it would have 4 batches per row.

• The operations became simpler for MHE operators as there was a clear classification of aisle and rows.

• Easy storage and retrieval of material lead to minimum turnaround time.

• Extra storage capacity of more than 60% was achieved as compared to the previous conventional racking.

• Utilization of vertical space.

4 months

Storage solution for Indian Navy, Port Blair

• Logistics along with product mix, weather and manpower was the biggest challenge.

• An assortment of materials were required to be stored at the newly constructed warehouse on a small isolated island which was 1350 km away from the mainland.

• Space was a major constraint and it had to be optimized keeping in mind the ease of storage and retrieval along with the value of the stored items.

Kompress Heavy Duty Storage System provided the ideal solution to overcome the constraints and fulfil all the storage needs. Warehouse which would have offered only 2000 sqft of storage space using conventional storage methods now offered about 3800 sqft of storage space along with providing all the conveniences of a modern storage system.

• Space optimization.

• All steel construction wasdust resistant,termite resistant andeasy to use.

• Scientific storage methods withseparate space for every store, longer shelf life and stock identification.

6 months including inclement weather.

Customized storage solution for Indian Navy, Kochi, Kerala

• 3000 SKU’s of varied shape, sizes and weights to be stored in one area.

• High energy consumption as the client had to keep the lights on through the day

• Due to lack of organization the warehouse was in a mess and all the materials were lying on the ground with entire vertical space being wasted.

After thorough examination and on-site inspection of material movement, storage and retrieval frequency and product knowledge, we observed:

• Though there were 3000 SKU’s, the quantity was not big but the items had to be stored in a single location

• The size variation was too high.

• All parts were identified by a special number and that was already fed in the internal data bank.

On the basis of our observation, we provided a very unique and customized solution to the client. Compactors with Drawers where total 10 loading/storage levels were createdand, in each face-outbottom 5 were drawers and top 5 were shelving. All the drawers were of variable size ranging from 50mm, 100mm, 150mm, 200mm and 250mm height.The drawers of height 50mm and 100mm were specially designed to store small parts like washers, nuts, bolts etc. and a mesh was provided which was adjustable depending upon the size of SKU. Therefore, multiple SKU’s couls be stored in the same place and could be identified with indexing provided.

In order to use the vertical space, the height was elevated up to 12ft (3600mm) where top levels were identified to store the SKUs that were rarely retrieved.

Now addressing the elephant in the room, the major challenge of energy consumption… We devised a unique solution wherein the mobile compactors were integrated with limit switch and lights. They work in such a way that only the light of the aisle space that has been opened will be in ON position and rest all will be OFF. This reduced the energy consumption as the entire warehouse did not have to be lit throughout the day.

• Reduced energy consumption by almost 1/5th

• After completion they were able to keep all the SKU’s as per the scientific group classification.

• Able to easily store, identify and retrieve as all the drawers, shelves and compactors bay were indexed and the data of all SKU’s location were stored in the IT Data bank system.

• Operation became easy, effective and clutter-free.

Mumbai

The client is in the business of manufacturing high-value perfumes. Typically, its products are stored in bottles of sizes ranging from 100 ml to 2000 ml. The challenge lay in storing all the bottles, big and small in one place, yet making storage and retrieval easy, and all of this while maximising capacity.

The biggest challenge lay in identification and retrieval. A huge challenge because both the bottle and contents are very expensive. They have to be imperatively stored upright and, irrespective of their shape or dimensions, have to provide full frontage for instant label recognition. Given all the issues, stability of the stored bottles was always at risk.

Thebrief demanded that both, the final design and solution, had to be absolutely unique. Carefully analysing the need, Kompress decided on a compactor with a step-style of shelves. Each shelf would hold 2-3 rows of bottle, and each subsequent shelf on the next level would similarly hold 2-3 rows… and so on. The entire system represented a step-ladder format which made identification easier. Every step was fitted with bottle stoppers to prevent the bottles from toppling over whenever the compactor was moved. The storage capacity increased three times.

The design was indeed very unique – unseen anywhere else. Equally unique was the fact that the site of installation was well beyond Kompress’ regular territory – it was in Sharjah, in the Middle East. Yet again, Kompress overcame all odds to design, develop, transport and help assemble the entire system offshore, to the client’s extreme satisfaction.

Two months.

Mumbai

The Indian Navy has its ships out on the high seas, but each of those need to regularly dock at port in order to replenish supplies. The regular practice for this is an assigned sailor, on the instruction of the captain, going ashore and picking up the list of supplies against a debit-card type of instrument, from a Naval approved store.

Needless to say, these stores would be crowded with a plethora of products – over 1000 SKUs of each, with many multiples in inventory – which made display, storage and retrieval a small nightmare. Kompress were invited to conceptualise, commission and deliver, exclusively for the Navy, a mall-like store that would eliminate the said problems.

The challenge was rendered a bit more complex because the Indian Navy runs these stores via its exclusive software; hence any software designed by Kompress would literally have to plug and play into the existing architecture.

Kompress roped in its in-house software arm, CRIBS, who successfully designed the module that seamlessly integrated with the existing mother software, without any glitches right from Day One. Meanwhile, Kompress’ designing team were busy working out the storage architecture that, in consonance with the software, would make the entire store-functioning a breeze.

Conventionally, malls have static racking on which a variety of material – from small pieces to large, bulky units – are placed or stored. Keeping this in mind, Kompress switched the format to a combination of Long Span and Mobile Racking, which resulted in a saving of space and a sense of openness and airiness; but most of all the flexibility of storing anything and everything in a limited space. It made identification and retrieval very easy too.

It was virtually a turnkey solution with trolleys, checking, check-out and billing counters also part of Kompress’ offering. Along with the software, all compatible hardware such as RFID readers was also provided. The entire system allowed the store to comprehensively manage every bit of inventory data, as well as maintain a log of every customer who had ever shopped over the years.

Two months.

Patalganga

The client is a world leader in biological solutions, with a strong portfolio in enzymes for the food, beverages and household care industries. The dual challenge that confronted Kompress was that some of the required material could only be stored in a stainless steel base, and the volume of storage was high as compared to the available space. This was further complicated by varying dimensions and sizes of the to-be-stored material.

The only way out was to develop a unique compactor completely in SS304 grade of steel. This itself represented a new challenge because it was never done before – hence, special machinery and a special procedure would have to be followed in both manufacturing and installation. Cost was another huge issue, because SS304 is expensive material, and yet, the final product had to be delivered within a specified budget.

The problem was put forth to Kompress’ R&D department. After minutely scrutinising the requirement and challenges, and discussing the issue threadbare, followed by a detailed technical analysis, a manufacturing and installation protocol was defined and religiously followed.

Intelligently calibrating the manufacturing process, the design was intricately modified. The compactor was uniquely built to withstand loads of up to 100 kgs per shelf, which worked out to a total load of 7-8 tons per base. The colossal weight rendered moving the compactor units a huge challenge, but Kompress’ ingenuity won out again, much to the delight and approval of the client.

The project ensured that the client had enough capacity to fulfil their entire storage requirement under one roof – saving them the inconvenience of scattering the same over different locations. The entire design and execution also met the norms laid down by the Audit of Food and Beverages Industry.

3 months.

Taloja

A significant and extremely reputed business client had hired a consultant and an architect to design and construct a special facility exclusively for storing legacy documents, antiquities, paintings, and highly confidential documents. The architect established themed interiors that had an ancient, classic, and antique feel to them. Kompress was then entrusted to come up with a viable solution for secure storage and retrieval that didn't compromise the aesthetics.

The client also needed a space for storing bulk materials that would need to be sorted from time to time.

Kompress evaluated the specific requirements and built a totally modernised and tailored storage system that blended into the space and aesthetics after a series of meetings with the client and their architects.

Mobile Compactor for oversized documents: For the old documents, some of which had larger dimensions, Kompress built a compactor with greater depth.

Mobile Compactors with in-built drawers: The client wished to store some of their antiques as well as old / vintage pieces from their ancestors in a safe and confined environment. Kompress resolved this by incorporating a built-in drawer system within the compactors, which made storing and retrieval much easier.

Art / Painting Storage: Precious artifacts like paintings required an altogether sublime level of care and caution. For these, very special and unique art storage compactors were designed to store paintings of different sizes.

Display Units: Additionally, special display racks encased in glass were constructed for the benefit of viewing by guests who would visit the gallery.

Storage unit with In build sorting table: Twin-level storage was constructed, with each level having its own individual lock and key system. Sorting space was also strategically provided at an ergonomic height to facilitate instant checking and sorting of files.

The sheer variety of storage material and their dimensions rendered it all a mixed bag. To overcome what could have been chaos in storage and retrieval, Kompress provided an indexing system of all racks and shelves so that retrieval is quick and efficient.

A coordinated solution ensured everything was attained with least damage and within the timeline. Kompress met all storage needs by offering a variety of SKUs.

The entire project, with all its complexities, was satisfactorily delivered to the client within four months.

Bhiwandi

A major retail company, housing a definitely wide variety of products, was essentially facing a typical issue: A large variety of SKUs (from hardware and electrical components to stationery, toys and jewellery to car and mobile accessories) needed to be efficiently stored within the existing storage space, in a significant degree. The sheer contrast of the storage items presented a nightmare – ranging, as they did, from tiny generally hand-picked SKUs to palletized bulk items.

The demand was for a state-of-the-art facility of about 50,000 sq. ft. that would for the most part, maximize the storage capacity without compromising really high throughput. The chief issue was proper, logical storage and management of the large variety and number of SKUs – a solution that would facilitate a sort of quick identification, retrieval and movement in a big way. A fairly tight deadline of just 60 days added to the degree of challenge.

Kompress’ Heavy-duty Multi-Tier Racking System ticked all the boxes and was offered as the best solution. 11 metres in height, it would literally scale four tiers. It was basically conceptualized and customized to ensure quick identification, picking and movement of SKUs.

A unique proposition of grating walkways designed for heavy HPT and trolley movement, enhanced the efficiency and convenience of the entire facility, contrary to popular belief. The use of 501 Grade Stainless Steel resulted in low running costs, pretty high security and maintenance-free operations in a subtle way. Aspects of live load, ventilation and lighting definitely added further enhancement to the facility.

A collaborative approach of functions involved in the chain of executions ensured everything was actually achieved with minimum disruption and within the timeline, which is quite significant. It once again basically proved Kompress’ ability to particularly execute really large projects.

• Raw material used: Approx. 600 tons

• Area covered: Approx. 50,000 sq. ft.

• 18,300 meters of vertical upright

• 26,100 meters of beam sections

• 25,200 meters of frame bracings

The entire project was delivered to the utmost satisfaction of the client within three months.

DDA, Delhi approached Kompress with a unique and challenging requirement: Conversion of its existing area into a central record storage. The challenge lay in the depth of the brief – the storage capacity had to be maximized in the storage area, which is to say, exploit every square inch of available space. Naturally, a storage system had to be developed that maximized every efficiency in file storage, retrieval and manual access. The entire filing system had also to be properly indexed to help pinpoint location of each file.

As is their wont, the Kompress team visited the site, examining and assessing it across every dimension. Working in close co-ordination with DDA’s own engineers, Kompress shortlisted several alternative solutions. By mutual consideration it was established that the Double Decker Compactor Storage System delivered the best outcome.

There still were major logistical issues to overcome. Scrutiny of the site revealed that there was excessive glazing on two sides, while the remaining two sides constituted open area. As such, there was no scope to take support from any wall or column. As always, the experienced Kompress team applied intuitive thought and decided that the support would come by diverting the load towards the ground through vertical and self-supported structures. To validate and certify the same, Kompress appointed a third-party structural engineer. To ensure complete peace of mind for the client, the certification was also submitted for inspection and approval to DDA’s engineers.

Clearances received, Kompress designed the Double Decker Compactor in such a way that the entire horizontal (floor) and vertical space was maximized. Two separate staircases provided access from different ends. Being independent of each other, it also ensured access in case of emergency.

• Floor Space: 140 square metres (approx)

• Clear height: 4.4 metres

• Existing Storage: Nil

• Desired Storage: 7000 box files (Minimum 140 Almirah Space)

• Storage provided: 20000 box files (Approx 400 Almirah Space)

• Height Utilized: 4.3 meters

• Mezzanine Height: 2.4 meters

• Staircases provided: 2

• Safety railings on open ends

In Kompress trademark fashion, the entire system was designed, developed, executed and handed over for inspection within the stipulated time frame. Since the project was the first-of-its-kind for the client, a third-party stability certificate was also delivered.

It may be noted that thanks to Kompress, storage nearly three times the desired quantum was delivered, much to the amazement of the client.

A Specially Designed Compactor for storing Trays.

AIIMS encountered a unique challenge in storing small cassettes for tissue culture. The cassettes, which were 1" x 1" x 1/2" in size, required specific positioning in a specially designed tray. Additionally, each cassette had a QR code that needed to be scanned by a thermo fisher machine, and the location of the tray within the storage system had to be identified. The primary challenge was to maximise the capacity of the thermo fisher scientific equipment tray while ensuring efficient storage, retrieval, and identification of the cassettes.

ATo overcome the challenges, AIIMS engaged in extensive discussions with the user lab operator, thermo fisher technician, and Lab Director to understand the entire storage and retrieval process. A customised solution was devised, centered around a specially designed compactor for the storage of trays.

The compactor was engineered to minimise wastage of vertical space by reducing the gap between tray levels to a mere 5mm, as opposed to the conventional shelving height of 30-35mm. This optimisation allowed AIIMS to store 20 lakh cassettes in one location, ensuring easy identification, storage, and retrieval. Each tray contained 240 cassettes, all of which had readable QR codes for the thermo fisher machine to scan. Additionally, every tray had its own unique QR code that identified its specific location within the compactor storage system.

By implementing the specially designed compactor and optimising vertical space utilisation, AIIMS achieved several significant advantages:

• Increased Storage Capacity: The solution enabled AIIMS to store 20 lakh cassettes, maximising the capacity of the tray.

• Efficient Retrieval: The QR codes on each cassette, combined with the thermo fisher machine, facilitated easy and accurate retrieval of the cassettes from the tray.

• Space Optimisation: The compact design of the compactor reduced the wastage of vertical space, allowing for better space utilisation within the limited storage area.

• Quick Identification: The unique QR codes on the trays and the cassettes ensured prompt identification of both the tray's location and the cassettes stored within it.

The entire project, encompassing the development and implementation of the customised storage system, was successfully delivered within a span of four months.

AIIMS effectively tackled the storage challenges posed by the small cassettes for tissue culture. By collaborating closely with stakeholders and developing a customised solution, they optimised space utilisation and achieved efficient storage, retrieval, and identification of the cassettes. The successful execution of this project demonstrates AIIMS's commitment to innovation and its ability to overcome unique challenges in the medical field.