Britvic increases warehouse pallet storage density with Jungheinrich racking and shuttle solution


Jungheinrich UK has provided leading soft drinks company Britvic with a multi depth, high density under pallet carrier (UPC) shuttle racking solution to optimise its warehouse space in Rugby. The installation, which includes three areas on site, has significantly increased the number of pallet spaces for the storage of raw material used in the manufacture of soft drinks cans.

Use of the available space has been completely redesigned in the warehouse following in-depth analysis of the site and ongoing consultation with Britvic. Utilising existing resource in all its guises was key and, while increasing capacity, a floor plan was also required that would accommodate Britvic’s double pallet handling counterbalance trucks.

For one new area of the warehouse, a multi depth racking system and four shuttle units were deployed, optimising the available storage space. The solution was tailored by Jungheinrich to create more than 300 additional pallet spaces on top of the target Britvic requirement; this project was all about capacity on site.

A second palletised area of the warehouse was designed in place of an existing carousel system, creating an additional 206 pallet spaces with static pallet racking; while a final area was enhanced by unlocking space vertically. Here, block stacked pallets were replaced with conventional racking to deliver an additional 2,186 pallet spaces – resulting in capacity for a total of 3,376 pallets across all three projects. 

Installation at the Rugby site, which was completed at the beginning of April, was phased over two months, while the warehouse remained operational. Raw material stored in the warehouse was relocated in batches in order to clear space for the racking solution, which could then be filled before moving onto the next area. Jungheinrich created a programme of build that would work alongside the Britvic warehouse operation and team, completing the installation one week ahead of schedule.

Patrick Parker, Project Manager, Britvic Soft Drinks Ltd: “We have gone through a significant change at our Rugby site, installing new manufacturing lines to increase our production speed, flexibility and volumes. In order for this change, we worked with Jungheinrich to provide the raw materials storage.

It was difficult to go through a complex construction programme whilst keeping the warehouse live, but the collaboration and hard work from the installation and warehouse teams kept everything working smoothly. It has been a very positive experience working with Jungheinrich on this project.”

Steve Richmond, Director – Logistics Systems, Jungheinrich UK, adds: “We are delighted to have worked with Britvic to optimise the density of pallet storage into its warehouse operation in Rugby. With a large existing fleet of materials handling equipment, it was important to find the right solution for Britvic to maximise this resource within the existing warehouse environment. Working collaboratively, we’re pleased to have provided a solution that surpasses those targets and supports future flexibility for continued growth.”

In total, Britvic has invested more than £100m in the Rugby site as part of a broader £240m three-year investment programme in its GB manufacturing capability. The investment is designed to step-change the speed and flexibility of its production lines while delivering environmental benefits through greater efficiencies.