ALF Aquatic Distributors has increased warehouse capacity and streamlined stock handling after introducing Toyota Material Handling UK’s Radioshuttle technology at its Bedford operation.
The aquatic products wholesaler launched the project as it looked for ways to support further growth without the cost and disruption of moving to larger premises.
Founded in 1988, ALF supplies retailers across the UK and overseas with products including fish food, water treatments, pond equipment and accessories.
Demand increased during the Covid-19 pandemic as more people took up fishkeeping and pond care, putting additional pressure on the company’s existing warehouse.
Picking had become labour-intensive, while available storage space was not being used as effectively as the business wanted.
Stock rotation was another concern, particularly for fish food and water treatments with limited shelf lives.
ALF was also experiencing disruption from conveyor motors overheating and triggering the warehouse fire alarm system.
With larger warehouse space locally described as scarce and relocation carrying significant costs, the company instead looked at increasing efficiency within its existing footprint.
After examining different storage options, ALF approached Toyota Material Handling UK about the use of Radioshuttle technology.
The companies reviewed the warehouse operation using principles from the Toyota Production System, including the concept of *muda*, which focuses on removing activities that consume time, space or resources without adding value.
Toyota recommended starting with a pilot installation rather than carrying out a complete warehouse redesign.
Nine Radioshuttle lanes were installed across two levels, replacing nine lanes of drive-in racking previously spread over three levels.
The ground level can be accessed using hand pallet trucks, while pallets within the racking are moved automatically to make stock easier to put away and retrieve.
Although the overall number of pallet locations remained broadly similar, ALF said the change has improved the way stock is accessed, replenished and controlled.
The system has also given the business greater control over stock rotation, helping reduce the risk of products approaching expiry and potentially being written off.
Picking and replenishment have been simplified because workers no longer need to manually move as many pallets to reach the stock they require.
Instead, the Radioshuttle system brings pallets towards the front of the racking, reducing manual handling and speeding up replenishment of picking locations.
ALF said the redesigned storage area has also increased back-stock capacity and improved access to inventory.
This has allowed the company to accommodate continued growth without increasing the size of its warehouse.
Removing the conveyor motors that had been prone to overheating has also addressed a recurring source of disruption to day-to-day operations.
ALF opted for a pilot project so the system could be tested in a working warehouse before committing to a wider rollout.
The company said the initial installation demonstrated sufficient benefits for it to consider extending the technology to other parts of the site.
ALF now plans to continue working with Toyota Material Handling UK on additional Radioshuttle and racking installations across the warehouse.
The business says the project has provided a route to expanding capacity, improving stock control and reducing unnecessary handling while remaining at its existing Bedford premises.