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Nestlé Waters: State of the art Warehouse

Nestlé Waters appointed Davies & Robson to advise on the design of a new warehouse and despatch operation.

The new facility includes four production lines bottling 50 SKUs and receiving and storing imported product.

Key requirements included aligning the warehouse design and function with the factory outputs and loading profiles for despatch, achieving the right balance between product put to storage or loaded straight to vehicles for immediate dispatch and matching the capacity of storage systems and MHE fleet with the varying production rates of each product and bottling line.

The project also involved optimising the layout to allow maximum productivity of the MHE fleet and warehouse team, designing storage solutions for various transit media such as Euro pallets and retailers’ varying semi-pallets and a solution for re-stacking imported pallets at the depot rather than at an off-site location to reduce multiple handing and additional costs.

Following the collection and analysis of large amounts of data relating to production line outputs, batch sizes and despatch profiles, Davies & Robson worked closely with Nestlé Waters managers to evaluate alternative options that met these varying requirements.

This involved calculating the requirement for each storage system, developing layouts to optimise productivity using synthetic standards to determine fleet and staff requirements and preparing specifications for the racking and MHE.

Employing the latest equipment, technology and innovative working practices to minimise costs whilst retaining operational flexibility and resilience, the resulting warehouse design includes a mix of automated shuttle racking for efficiency of putaway, retrieval and optimal storage density, along with block stacking to accommodate seasonal peaks and fast moving SKUs.

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