Enhancing Beverage Distribution in Colorado: Meeting Today’s Supply Chain Challenges

Streamlining Beverage Distribution with Tailored Storage Solutions

Beverage distribution faces unprecedented challenges, from the proliferation of craft beers, bottled waters, and health drinks to the complexities of specialized order fulfillment and workforce shortages. Success today demands a fresh approach to effectively address these demands.

Let’s explore key storage racking options tailored for efficient space use, capacity needs, and productive processing:

Full Pallet Storage for Today’s Beverage Distribution

In the past, floor-stacked pallets were common. However, this approach is increasingly outdated due to challenges in SKU volume, space limitations, safety issues, and the availability of more efficient storage and handling solutions. 

Storing full pallets has two main functions. The following storage solutions provide beneficial support depending on your application needs:

1. Reserve storage to feed case picking fulfillment
2. Full pallet in, full pallet out fulfillment

Selective Pallet Rack

Selective rack is the most economical multi-level pallet storage rack. It is a single pallet deep which allows 100% SKU selectivity and relatively easy loading and unloading. You can construct a two-deep system for higher-volume SKUs, but you will need a deep-reach forklift and slight engineering modification to ensure a safe turn radius.

Pallet Flow Rack  

Pallet Flow is an optimal choice for storing high-volume, moderate to fast-moving SKUs. It operates with slightly inclined wheeled tracks to accommodate multiple deep pallets in a compact area. Pallets are loaded on one end and move gradually towards the opposite aisle for retrieval, following a first-in/first-out (FIFO) rotation method. Systems vary in depth from 2 to 10 pallets, depending on specific needs.

These systems support high-density, multi-level configurations for storing reserve pallets. Alternatively, floor-mounted pallet flow rails can efficiently supply a pick line for conveyor systems or mixed-SKU pallet assembly.

For tighter spaces, Pallet Flow can be adapted into a push-back system, using a single aisle for both loading and picking to facilitate last-in/first-out (LIFO) inventory rotation. This setup offers flexibility in handling non-standard pallet sizes.

Pallet Flow systems are designed for minimal maintenance and can accommodate various pallet sizes and types effectively.

Push-Back Rack

Push-Back Rack is a dynamic and dense storage solution that operates within a single aisle, facilitating last-in/first-out (LIFO) inventory rotation. Pallets are loaded onto nested carts sequentially. As each new pallet is added, the top cart is pushed backward to expose a waiting cart behind it. When pallets are removed, the carts move forward automatically to maintain a full pick face. Push-back systems typically accommodate depths of 3 to 4 pallets, optimizing storage space and retrieval efficiency.

Layer Picking

Layer Picking is an advanced order selection method utilized in high-volume staging or mixing centers, enabling the retrieval of entire layers of cases with a single pick. This is achieved using a forklift equipped with a clamp or suction attachment. As the demand for high-volume case picking grows to accommodate expanding SKU volumes, layer picking has become increasingly favored for its significant increase in pick rates compared to manual methods.

ASRS Pallet Shuttle Storage Rack

Automated storage and retrieval systems (ASRS) offer substantial benefits for beverage distribution operations. By leveraging vertical space and operational efficiencies, ASRS systems can operate continuously, 24/7/365, boosting throughput without incurring overtime costs or risking worker injuries. They enhance inventory accuracy, streamline response times, and adeptly manage seasonal fluctuations and evolving consumer preferences. ASRS technology has evolved significantly over the past decade, progressing from semi-automated setups to fully integrated, customizable systems that cater precisely to individual operational requirements and updated fire code safety regulations.

Carton, Case, Bottle, Keg Storage

Carton Flow (Case Flow)

Carton flow provides a dynamic solution for picking full or split cases of slower-moving items, compared to pallet-based picking for faster movers. Organize ready-reserve inventory in designated SKU lanes for efficient loading and picking. With separate loading and picking aisles, carton flow supports FIFO inventory rotation. The downward slope of the design ensures continuous replenishment of the picking face with reserve stock immediately after the front item is selected.

Keg Storage Racking

Kegs can be stored on standard selective racks or within a gravity flow system –especially suitable for refrigerated keg rooms. Constructed with durable rollers, the flow rack gently moves kegs toward the picking aisle while maintaining upright and orderly placement in designated SKU lanes. Keg flow accommodates all sizes and shapes of kegs (full and partial, including 1/2, 1/4, and 1/6 barrels), ensuring precise picking and loading to reduce labor requirements and time spent in the cooler. The dynamic design allows for both LIFO (push-back) or FIFO (separate loading and picking aisles) inventory rotation strategies.

Bottle Flow Rack

Bottle flow is designed for slower-moving individual bottles, separating SKUs and consolidating inventory to maximize storage rack space. Individual bottle troughs fit seamlessly into standard pallet racks, providing a cost-effective solution tailored to specific storage needs without customization costs.

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Integrated Pick Modules for Beverage Distribution

 Pick Modules

Pick modules are versatile multi-level order fulfillment systems that combine various storage mediums such as carton flow, pallet flow, push-back, or shelving with conveyor systems to create highly efficient picking environments. By centralizing picking activities and minimizing travel distances, pick modules optimize space utilization, enhance picking rates, and reduce labor costs. They are particularly useful in beverage distribution to effectively manage the varied SKU inventories and high-volume processing.

Ultimately, the ideal configuration of storage systems depends on your specific space configuration, workforce, and fulfillment needs. Your local Apex Colorado team is ready to assist you in navigating these options and delivering a comprehensive solution tailored to meet your operational goals. Contact us today for full-service, expert support.