Trevelyan’s is the largest single-site kiwifruit and avocado packhouse in New Zealand. For their state-of-the-art facilities located in Te Puke, Shelving Shop Group fitted them out with a drive-in racking system.
Trevelyan’s previously relied on bulk stacking of their export-quality kiwifruit pallets, but this method posed significant safety concerns. The weight of the stacked pallets often compromised the structural integrity of the lower pallets, causing them to collapse and fall apart. Recognising the need for a safer and more reliable storage solution, they sought an alternative approach to ensure secure bulk storage.
In addition to the serious safety concerns posed by collapsing pallets, the damage to their export-quality kiwifruit was another major issue. When the pallets gave way under the pressure of stacking, the fruit stored within would often become bruised or otherwise compromised, rendering it unsuitable for export. This not only affected the quality of their product but also resulted in significant financial losses due to wasted inventory.
Bulk stacking of pallets is an efficient method for maximising storage capacity, making it a popular choice for bulk storage. However, transitioning to a racking system, while addressing safety concerns, posed a significant drawback: it would occupy more space and reduce the overall efficiency of storage. For Trevelyan’s, the primary concern was the potential loss of storage capacity, which could impact their operational efficiency and ability to manage large volumes of export-quality kiwifruit.
The drive-in racking system seamlessly integrated into Trevelyan’s existing operations by maintaining a similar workflow for staff. Employees could continue using familiar stacking processes, minimising the need for extensive retraining or adjustments. This continuity ensured operational efficiency while benefiting from the added safety and structural support of the racking system. By preserving the ease and familiarity of their workflow, the solution provided a practical and effective way to enhance storage capabilities without disrupting daily activities.
Although the racking system occupied more floor space, it allowed Trevelyan’s to leverage the height of the packhouse effectively. Unlike bulk stacking, where the risk of pallets collapsing limited stacking height, the drive-in system provided the structural support necessary to stack pallets much higher. This innovative approach ensured that Trevelyan’s did not lose storage capacity while also addressing safety and efficiency concerns.
Improved Safety
The drive-in racking system significantly enhanced safety in the storage area. By eliminating the risk of collapsing pallets, it created a safer working environment for staff and reduced the likelihood of damage to equipment and products. The structured design of the racking system ensured that pallets remained stable and secure, addressing the critical safety concerns associated with bulk stacking.
Tremendous Savings
Switching to the racking system resulted in considerable cost savings for Trevelyan’s. The reduced damage to export-quality kiwifruit minimised product loss and preserved the integrity of the fruit, avoiding the financial impact of wasted inventory. Additionally, the increased efficiency of storage management lowered operational costs over time, creating a highly cost-effective solution.
Similar Storage Capacity
Despite initial concerns about losing storage capacity, the drive-in racking system maintained a similar level of storage efficiency. By utilising the full height of the packhouse, Trevelyan’s could stack pallets higher than was possible with bulk stacking, compensating for the space occupied by the racking infrastructure. This innovative use of vertical space ensured that the transition to racking did not compromise their ability to store large volumes of product.
The implementation of drive-in racking proved to be an excellent alternative to bulk stacking. It not only addressed safety concerns but also demonstrated how a well-designed system could maintain storage efficiency while improving overall operational reliability. By leveraging the vertical space available, Trevelyan’s discovered that drive-in racking could meet their storage needs without compromising capacity or workflow. This solution highlighted the importance of balancing safety, efficiency, and space utilisation in storage operations.
The savings achieved through reduced product damage have enabled Trevelyan’s to reinvest in their operations, leading to the implementation of similar racking systems in multiple other cool stores. By minimising losses from bruised or damaged kiwifruit, the company freed up resources to fund these projects, ensuring that the safety and efficiency benefits of drive-in racking are extended across their entire storage network. This strategic expansion has further strengthened their commitment to quality and operational excellence.
