Costa Coffee, part of the Whitbread Group, has completed its new-build roastery and distribution centre in Basildon, Essex. The site covers over 85,000 square feet and has a roasting capacity of 45,000 tonnes per year, which produces over 2bn cups of hot drinks.

Express Logistics Ltd (Harrow)

Background & Brief

Locators were introduced to Costa by their design consultant as they are able to supply all types of storage systems and materials handling equipment. Locators design storage systems to work seamlessly with their range of forklifts and warehouse equipment.

The design brief was for a high-density storage system for finished goods and pallet racking for the storage of packaging material. Costa wanted to automate the warehouse process to improve operating efficiency and reduce the travel distance for the materials handling equipment.

Express Logistics Ltd (Harrow)

Solution

Locators proposed a semi-automated pallet shuttle to move pallets within lanes. This shuttle system is ideally suited to FIFO applications where dense storage of a low number of SKUs is required. The design also incorporated a powered conveyor system which was configured to move packaging pallets through to the production area. These pallet transit systems reduce forklift activity in the warehouse and production area which minimises the risk of product contamination.

Mesh systems were installed to prevent load spillage and ensure pedestrian safety, and barriers and rack armour was fitted to reduce the risk of damage.

Locators specified two Aisle-Master articulating forklifts which are able to work in areas with restricted space and narrow aisles. Locators is also authorised distributors of Dulevo cleaning machines and they supplied a model 52EH electric sweeper and Boost 150 electric scrubber dryer for cleaning the production area floor. 

Pallet Racking

Space is expensive, yet there’s always a need to store more within your available volume. This is why adjustable pallet racking (APR) is such a sought after commodity, as it’s a low-cost system. Its modular design can also adjust to store different sized goods.

Dulevo Sweeper 52-74

Power supply

Petrol or battery

 

“Being able to work with one supplier for storage and materials handling has been a benefit to us. Locators managed the complete installation and ensured the correct materials handling equipment was specified for their design. They also service and maintain all of the equipment they have supplied and offer a rack inspection service to make sure our warehouse remains a safe working environment. We are very happy with our new facility and we believe we have made the best use of the available space.”

Marc Congdon

Engineering Manager, Costa