Faster Layer Picking – See This New Take on Mixed-SKU Pallet Building

Pick Mixed-SKU Pallets as You Go with Layer Pick Attachment + Pallet Forks

The dynamics of warehousing, storage, and distribution are rapidly evolving. The pace is faster, and the product variety is much broader, particularly in the grocery and beverage sectors. As a result, distribution centers are receiving more mixed SKU pallet orders than full pallets of single SKUs. 

Creating these pallets manually is a slow and expensive process that eats into operational margins. However, setting up a mixing center with a layer pick application can equip you to fill high-volume orders 5x’s faster using a single worker vs. multiple workers. That’s time and money in the bank.

Why Layer Picking?

• Reduces reliance on labor force
• Saves order processing costs
• Supports just-in-time inventory systems
• Improves order processing time
• Increases order-pick accuracy

The magic of layer picking allows for picking and placing whole layers of cartons with a single pick vs. individual cartons to complete a mixed-SKU pallet. One forklift operator can manage 1250 cases per hour vs. a laborer’s 250… and that’s a significant savings.

Note: an important consideration before implementing a layer pick system is to ensure that the inventory received is divisible by the number of cases that fit in each layer.

Traditional Mixing Center Set-Up vs. New Fork Pallet Design

Traditionally, a mixing center for layer picking involves pallet lanes on either side of the aisle and a layer pick-equipped forklift in the center. The driver picks one layer or more – drives to the end of the lane – deposits the carton layers on an empty pallet –  and returns to the lane for more picks. Once the pallet is complete, a second lift operator moves it to shipping.

However, innovation has led to creating the mixed SKU pallet even faster. The forklift operator begins with an empty pallet on the forks. As carton layers are picked, they are deposited onto the pallet. When the pallet is complete, the driver places it at the end of the lane for pick up and then secures an empty pallet to start the process again.

A New Way to Build a Mixed-SKU Pallet

1. 1. Set up lanes of individual high-volume SKUs on one or both sides of the pick aisle.
   2. The forklift equipped with the layer pick clamp or suction tool drives to the end of the lane and secures an empty pallet on the forks.
   3. The driver proceeds to build the pallet by selecting one or more layers per pick from the variety of products in the SKU lanes.
   4. The pallet will resemble something like: Layer 1 — SKU A, Layer 2 — SKU B, Layers 3 & 4 — SKU C, and Layer 5 — SKU D.
   5. When the order is complete, the driver deposits the pallet at the end of the lane and picks up a new empty to begin the process again.
   6. The completed pallet is retrieved, wrapped, and moved to dock staging for shipment out or to a storage position.

Make Your Layer Picking More Dynamic with Pallet Flow and Push-Back Rack

Pallet flow rack is a dynamic storage option that stores ready reserve pallets in each pick lane. Boost your restocking efficiency by using pallet flow lanes in the mixing area. The two most significant benefits are:

• The reserve stock automatically replenishes the pick aisle as empty pallets are removed vs. waiting for restocking.
• The reserve stock is added from an adjacent aisle minimizing congestion in the pick area and allowing you to use standard forklift equipment.

The steps for layer picking from pallet flow are as follows:

1. Each SKU is in a dedicated lane. As pallets are loaded, they flow to the center pick aisle. A device in the pallet flow lane, called the pallet separator, locks and holds the rear pallets approximately 6-12” behind the front pallet. This isolates the front pallet so that the clamping attachment can easily access all four sides of the inventory.
2. Once the front pallet is emptied, the operator extracts it, and the rear pallets automatically begin to flow forward. As the pick face pallet flows into place, the rear pallets are again locked for the picking process to begin.

You can even take this dynamic approach up another level… or several levels, by adding push-back above the pallet flow lanes. This setup maximizes warehouse space by using vertical space above the mixing area. One caveat to this method is that your application needs to be a full-pallet pick and not a partial-pallet pick. For full-pallet applications, this can be very effective. Here’s how that would look:

Cut Through the Layers and Call Apex for Full-Service Support

The Apex team can work with you to determine if layer picking is a cost-effective solution for your operation. Did you think our services stopped there? Not by a long shot. With our full-service family of companies, we can work with you from concept & design through installation and equipment purchasing. We also offer specialized forklift operator training, forklift service, warehouse safety inspection, repairs, and more. We simplify the process for you to concentrate on what you do best. Call Apex today for a free consultation.