Greene King case study

The Challenge

To increase storage capacity at the company’s Morton Hall bottling plant.

Outcome

Drive-In pallet racking is particularly suitable for Greene King’s stock rotation as it reduces the number of aisles required and achieves up to 88% floor space utilisation. Recently, with a steep increase in sales of bottled beer and its plant producing some 25,000 bottles an hour, Greene King identified a need for additional storage and DSL was approached once again.

Our approach

DSL installed storage for 2,600 pallets in a Drive-In Racking system and 280 pallets in standard Adjustable Pallet Racking at Greene King’s new warehouse and production facility in Bury St Edmunds in 2006. Drive-In pallet racking is particularly suitable for Greene King’s stock rotation as it reduces the number of aisles required and achieves up to 88% floor space utilisation. Recently, with a steep increase in sales of bottled beer and its plant producing some 25,000 bottles an hour, Greene King identified a need for additional storage and DSL was approached once again.

The Drive-In concept was still felt to be most suitable for the site, as it allows a dense storage area to be created in a relatively small area of the warehouse. An area previously used for interim storage was chosen and a new block of Drive-In Racking was installed: 20 lanes wide, 17 pallets deep and four pallets high, creating an additional 1360 pallet locations. Due to the fragile nature of the product, pallets had previously only been block-stacked to a maximum of three pallets high. However, DSL proposed a Drive-In Racking system which would instantly increase capacity by over 30% and enable pallets to be stacked four high, fully utilising the available headroom.

Project results

As well as projects at the Bury St Edmunds facility, DSL has worked on reorganising storage and picking at Greene King’s Abingdon warehouse near Oxford, improving the speed and efficiency of the operation. Greene King’s Project Manager Craig Abrahart praised Dynamic Systems’ performance for the firm: “DSL has made a major contribution to the success of several projects for us now and we have been extremely pleased with the service provided and the final results.”

“Our relationship with Greene King has been a successful one and we were very pleased to be working with them once again,” agreed Howard Gillard of DSL. “We understand their business well and have been able to come up with the right solutions to their logistical challenges.”

Combining successful traditional ale brands with modern forward thinking, Greene King has grown steadily from its base in Bury St Edmunds, Suffolk to become one of the country’s leading pub retailers and brewers.

DSL has built an impressive reputation for providing bespoke solutions to help clients achieve the most cost-effective warehouse and logistics operations and improve their profitability. Many systems can fit easily into existing installations, minimising down-time and maintaining productivity.