Distribution centers are experiencing challenges in streamlining their layer-picking process because of the ever-increasing demand from consumers and retailers for a diverse range of products. To resolve this staging centers and high-volume mixing is transforming the traditional layer-picking process into a highly automated solution.

Distribution centers and warehouses are forced to adapt automated layer picker equipment. The automation requirement for the picking process popped from the retailer’s need like great SKU varieties in less quantity, less inventory at store and warehouse as well as an increase in deliveries for replenishment. TopIndustries is the leading engineering facility for customizing a suitable full automation pallet system.

Global supply chains have to manage the building of mixed SKU pallets [rainbow pallets]. Therefore it needs extra staff and energetic labor picking. Both can easily pressurize the supply chain. With an automatic layer picking system mixed SKU layer is built quickly and accurately. In comparison to manual picking and creating rainbow pallets, the robots significantly complete the process seamlessly, speedily, effortlessly, and accurately.

Layer-picking technology investment offers the distribution center a scalable solution. Some of the layer picking equipment has minimal footprints, so you can retrofit existing picking zones and helps to enhance warehouse productivity.

What’s layer picking?

Layer-picking systems are designed for high-volume packing and staging inside the warehouse. With an increase in supply chain demands, new innovative solutions are designed. Layer picking was either done manually or using a forklift in the past. They are viable methods even today, but the efficiency of automated options is more.

Layer-picking automation reduces the likelihood of manual errors as well as speeds order fulfillment process. The layer-picking equipment can lift 992 lbs. per layer, so the need for labor is reduced.

Cold storage, food, and beverage along with several other sectors customize automated layer-picking systems for speed, efficiency, and productivity.

Types of layer-picking solutions

Layer-picking solutions can be categorized into manual, semi-automatic, and automatic.

Manual order picking

Manual order picking is a tedious and suboptimal process. The employees spend 55% of their time in order picking and traveling, 15% in finding the right product, and 30% hauling out, doing paperwork, or other tasks. For high-volume orders, manual layer picking is a bad option because more than 50% of the operating cost is associated with order picking.

Forklift with suction/clamp attachment

It is a semi-automated layer order-picking method. A trained forklift operator uses suction/clamp to pick layers and build the pallet. The pallet is created in central mixing zones and transferred for delivery or storage.

Standalone robotic layer picking

It is a flexible automatic solution with low height constraints. It operates efficiently with pallet-to-pallet and pallet to descrambler applications. The unit can work at freezing and high temperatures.

Overhead gallantry automated layer-picking solution

For high-volume pallet inventory handling, this is the best option. The gantry system can serve every level of layer-picking needs. It works great in multiple environments and can handle below-freezing and high temperatures.

Layer-picking systems are used in multiple sectors. Check TopIndustries YouTube videos to get an idea on how the layer-picking automated system offers versatility and flexibility!