AS/RS Modernization Reduces Downtime and Saves Thousands of Dollars at Food Service Facility

AS/RS Modernization

Gordon Food Service, North America's largest privately held and family-managed broadline foodservice distribution company, partnered with viastore to complete a modernization project at Gordon Food Service's 10 aisle pallet crane automated storage and retrieval system (AS/RS) facility in Grand Rapids, Michigan.

Originally installed in 1992, the 10 aisle pallet crane AS/RS handles products across frozen, chilled and ambient temperature ranges. Parts and service for the aging system were no longer available, making the system rapidly becoming obsolete.

Mark Grimes, North American Intralogistics Manager:

“We knew we had to do something in a few years. Completely replacing the system was not an option, but an engineering study determined that the mechanical integrity of the cranes was sound and that they were in good condition. After working with viastore we concluded that a complete retrofit of the crane's controls would get us the level of modernization we needed with no system downtime, and at 1/10th the cost of a complete replacement.”

For the retrofit project, the old proprietary controller was replaced with a modern PLC controller with viastore standard SRM software. Only select electronics and sensors were replaced or added, making the total cost even lower.

viastore was able to re-use most of the existing sensors that were not obsolete. Other than the main function of retrofitting the crane, viastore added two additional features to benefit Gordon Food Service: fine positioning and bin sensing.

Fine positioning sensors were added to take special care of the pallet handling within the existing racks. This feature prevents product loss, is saving Gordon Food Service thousands of dollars, and has reduced downtime.

A bin sensing control system was added that detects when the pick faces need to be replenished. This is an on mast system that detects each location when the crane moves down aisle.

The carefully coordinated upgrade took place during reserved weekend time as the system needed to remain fully operational during the week.

Grimes added:

“The AS/RS is a mission critical application for us and downtime was not an option. Each crane supplies product for replenishment and pick modules, so we couldn’t offload work from one aisle to another while cranes were worked on. The facility had to remain fully operational during the project.”

This is one of the most complicated retrofit projects ever done by Gordon Food Service. viastore's ability to deliver on previous projects was a key factor in being selected for this project. This modernization will give Gordon Food Service's AS/RS system an estimated 20 years of additional life.

Related: Automation Considerations for Frozen Product Storage

Related White Papers

Upgraded Cold Storage AS/RS Boosts Productivity and Labor Efficiency
Cold storage automated pallet storage facility implemented and modified by viastore systems to support new customers’ handling and order profile requirements. Download Now!

---

Modernization of KSB’s Warehouse Results in Enhanced System Efficiency
Software, conveyor and AS/RS retrofit results in ten percent increase in efficiency and higher performance for pump manufacturer's supply warehouse. Download Now!

---

Modernization Secures Terex Cranes’ Ability to Deliver
New WMS, control system and mechanical components help automate Terex Cranes production warehouse system. Download Now!