Automatic Consignment Storage for Plasterboards

Australian plasterboard producer is investing in an automatic storage system

(PresseBox) (Herford, ) In order to meet their significant operations in the USA and Asia, one of Australia’s largest building and construction material suppliers invests in a new automatic storage system, built by SYSTRPLAN, a German manufacturer of material systems and specialist in warehouse technique when it comes to flat materials. The concept exactly adapts to the given requirements and has been developed in cooperation with Hubtex Australia.

The Australian company produces and distributes a wide range of construction materials as clay bricks and pavers, clay and concrete roof tiles, concrete masonry products, plasterboard, windows and timber. Primarily customers in the building and construction industries are served with operations concentrated in three key geographical markets - Australia, the USA and Asia. The company has leading market positions in all three geographic markets.

Pick Size “One”

Those who aim to succeed must be able to produce more quickly, even more flexibly and most important of all: more economically.
The market demands top quality and just-in-time delivery. The company wants to meet this requirments with an integral concept designed to allow more flexible, more profitable delivery for every plasterboard size and right down to pick size “one”.

Automatic Working System For Picking Single Boards

This can only be realized with an automatic working picking system. Single boards are directly picked with the rack serve carrier. The consignment stack is being built directly inside of the rack serve carrier.
The picking starts with the longest boards of 6 m and then successively picks shorter boards down to the smallest length of 2,4 m. Reference is one end, which means the commission stacks are straight on one end getting shorter with the boards on the other end.
The stacks will be buffered on conveyors till a fork lift driver takes the stack off. At the same time a batch card will be printed and attached to the stack.

Laterally Movable Telescopic Arms

The upper platform has 4 telescopic arms, each equipped with a suction frame for the picking of single boards. The suction frames are separately controllable. In order to handle the range from 2.400 mm up to 6.000 mm boards two of the vacuum frames move laterally. With these frames rainbow stacks can be build on the lower platform of the rack serve carrier.

Two Independent Working Platforms

Consigning directly on the rack serve carrier with two separate working lifting platforms allows efficiencies that cannot be achieved with standard systems. Regularly the systems will be fed with unmixed stacks. The storage software supplies the information what kind of material is needed in order to complete the next picking jobs. The stacks will be intermediately stored on conveyors until the rack serve carrier takes the stack with a stack lifting platform into storage. According to the length of the stack the telescopic arms on the stack lifting platform will be positioned sideways.

Extra Performance With Separate Pre-Picking Area

The feed area is equipped with a bypass in order to split complete stacks with a vacuum gantry. The gantry is pre-picking orders of high volume products and large lots in the order. These stacks will be taken over by the rack serve carrier to complete the commission with single boards from the storage.

Highest Efficiency With Two Independent Lifting Platforms

Both platforms have individual lifting drives and load lifting members, which can extend to both sides of the aisle. Even the separate working lifting platforms yield to a 20 % increased output in comparison to conventional systems. Moving speeds up to 200 m/min and telescopic speeds of up to 60 m/min guarantee highest performances when commissioning.

Damage-Free Handling

One of the most important advantages is the damage-free handling of the material. The sensitive boards are appropriately prepared for resell in the shortest possible time whilst the automatic working rack serve carrier is continuously working. The system can arrange a consignement of 10 optionally chosen boards within five minutes.

Total Inventory Control

Systraplan’s storage and control program can be operated under the Microsoft operating system Windows. This guarantees that today’s and tomorrows’ requirements will be met also in future in respect of system design, flexibility and links to standard systems and standard software.

State Of The Art Graphical Screen Interface

The application has a state of the art graphical screen interface. The user screens are clear, application orientated and easy to use – either by keyboard or by mouse. All information is stored in a standard database.

SYSTRAPLAN GmbH & Co. KG

Since the company was founded in 1974 more than 70 qualified staff members have been serving the board and furniture, glass, plastics, metal-working and rubber industries. Our special field is material handling and storage engineering. The systems we develop are always custom-made, exactly adapted to the given requirements.

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