New Industrial Mezzanine is the Rx for Optimized Order Picking | Apex Project Spotlight

Medical Supplies Company Embraces Upward Momentum with New Industrial Mezzanine

The Apex team has just “wrapped up” a major upgrade for a leading medical supplies company! This is no mere bandage; it’s a strategic enhancement poised to transform their picking process and streamline order fulfillment. By adding a new third-story industrial mezzanine to their existing pick module, they’ve significantly boosted capacity and pick rates. With automated conveyor systems and dynamic gravity flow racking, this project is all about optimizing space and refining operations. Dive in to discover what makes this project an optimized pick module.

Productivity on the Rise — Industrial Mezzanine Level 3

Mezzanine Frame	Mezzanine Flooring

Third-Level Addition

Construction Time: 3 weeks

The Process:

The first step of the process began with the columns going up. Once beams and joists were bolted in the crew began installing B-deck subflooring and finished up by placing the top-level resin decking.

The team created eight trash chute openings to discard corrugated materials onto the empty carton removal conveyor running under the mezzanine level. Staircases were added to access the south and north sides, and protective handrails and kickplates completed the mezzanine surround to safeguard workers.

Empty Carton Removal Automated Conveyor System

ECR Catches Empty Cartons Discarded Via Trash Shoots	Empty Carton Flows to Baler

 

Conveyor System Installation

Construction Time: 3 weeks

The Process:

Once the third-level industrial mezzanine was in place, we installed conveyor lines below the trash chutes. The two conveyors lead off the south end of the mezzanine, where they join into one that runs the boxes to a baler. To reach the baler, racking was installed, creating a run over multiple aisles. Goalpost guardrails were installed to protect the conveyor system and provide an added layer of safety in areas where forklifts traveled.

 

What is an Empty Carton Removal Conveyor?

For those unfamiliar, empty carton removal conveyors transport empty corrugated materials from the picking areas to a centralized collection point. By automating this process, customers eliminate the need for manual handling, breaking down, and removal of empty cases. No more frequent trips to trash receptacles; just streamlined waste collection. These conveyor systems are highly valuable in pick module environments where piece picking and unpacking produce significant amounts of waste.

 

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Carton Flow & Pallet Flow Rack Installation

Carton Flow Rack	Case Pick with Pallet Flow

Gravity flow solutions completed the pick module design to streamline picking activities. Level 2 of the pick module is equipped with carton flow along the West side of the industrial mezzanine, and both carton and pallet flow along the East side. The new third level is equipped with carton flow racking along the edges of the East and West sides, creating optimized pick aisles. With the gravity flow solutions installed, the pick module project is complete.

By adding a third level to its existing mezzanine and integrating advanced conveyor and flow rack systems, this medical supply company is better positioned to meet its efficiency goals. This expansion underscores our commitment to practical solutions that enhance workflow and optimize space utilization, ensuring our clients can easily meet growing demands. Contact the Apex team for innovative solutions that drive tangible improvements in warehouse logistics and client satisfaction.

Recycling Baler