Heinz Watties NZ
In 2008 and 2009, Heinz Watties - a subsidiary of Kraft Heinz, a leading food manufacturer in New Zealand - undertook a significant upgrade to its logistics operations by installing the cutting-edge APC Storage Technology Radioshuttle system and a state-of-the-art racking solution at its Christchurch distribution centre. This investment was aimed at improving warehouse efficiency, enhancing storage capacity, and ensuring the smooth flow of goods in their facility.
However, little did anyone know that this technological upgrade would go on to demonstrate remarkable resilience in the face of a natural disaster just a few years later.
Before the installation of the APC Storage Technology Radioshuttle system, Heinz Watties - like many large-scale manufacturers - faced challenges associated with traditional pallet storage and retrieval methods.
Their warehouse was often overcrowded, and retrieving pallets from deep storage could be time-consuming and labour-intensive. In addition, the current system at this site utilised block stacking of pallets which introduces its own challenges.
To address these issues, the company decided to implement a semi-automated racking system with Radioshuttle technology, which allowed pallets to be stored more efficiently in high-density configurations while still enabling quick and easy retrieval.
Radioshuttle technology is an innovative solution that uses a remote controlled pallet shuttle on a racking system to automatically transport pallets to the desired location within the warehouse. The shuttles, controlled by radio frequency, can move pallets in and out of racks without the need for a forklift, greatly improving throughput and reducing the time spent handling goods.
At 4.35AM on Saturday 4th September, 2010, Christchurch was struck by the first of a devastating series of earthquakes that measured 7.1 on the Richter scale. The earthquake caused significant damage throughout the Hornby area where there were up to 40 warehouses that suffered some degree of racking failures. Many businesses in the area, including those in the manufacturing and warehousing sectors, were severely affected. Fortunately, due to the time the earthquake struck, most premises were closed and as such there was no loss of life.
At the time of the earthquake, Heinz Watties' distribution centre in Christchurch had already been outfitted with the APC Storage Technology Radioshuttle racking system. When the earthquake hit, the facility was not immune to the intense shaking and violent tremors that rocked the region. Despite the severe impact of the disaster, the Radioshuttle racking demonstrated extraordinary resilience, continuing to operate efficiently and without significant damage.
The strength and durability of the APC Storage Technology Radioshuttle system were put to the test during the earthquake, and it passed with flying colours.
The system’s design, which is based on robust, heavy-duty racking and the precision engineering of the shuttle vehicles, ensured that it could withstand the intense vibrations and physical impacts caused by the quake.
The racking system, which was installed in a seismic zone, was designed to meet the strictest earthquake safety standards.
While the earthquake caused considerable disruption in the region, Kraft Heinz was able to continue its operations with minimal downtime. The APC Storage Technology Radioshuttle system allowed the warehouse to remain functional without losing a single pallet. There was no business interruption, no loss of stock and staff were kept safe throughout the entire period.
The 2011 Christchurch earthquake underscored the importance of designing industrial racking systems that can withstand extreme conditions. For Kraft Heinz, the resilience of the APC Storage Technology Radioshuttle system highlighted the benefits of investing in a high quality racking system. It also highlighted the importance of designing racking structures that are fully compliant with the relative building and design codes.
The APC Storage Technology Radioshuttle system installed at Kraft Heinz stands as a testament to the power of quality, innovation, design, and preparedness — proving that smart investments can provide value and protection, even in the most unexpected of circumstances.
Heinz Watties was originally supplied with three (3) Radioshuttle machines. The environment is extreme as it’s a freezer operating at -20 degrees. The pallet weight is 750kgs but Heinz Watties double stacks their pallets so the Radioshuttle load is a massive 1500kg.
Typically pallet shuttles are rated as having a working life of approximately seven (7) years. Heinz Watties have just taken delivery of three (3) new RS6.0 Radioshuttles meaning their original shuttles were still operating after 16 years, a remarkable feat especially when considering the operating temperature and the pallet weights.
The APC Radioshuttle and Racking really is ‘Built To Last’.