How Portwest’s Daifuku Automation Tenfolds Warehouse Productivity and Transforms Logistics

Revolutionizing Warehouse Efficiency with Automation

Portwest’s distribution centre in Barnsley, UK, has undergone a remarkable transformation, thanks to the installation of a fully automated storage and retrieval system (AS/RS) designed by Japanese automation expert Daifuku. This upgrade shifted the warehouse from a purely manual operation to a state-of-the-art, automated process, drastically enhancing its ability to meet growing product demand.

The impact on productivity speaks volumes: where once the team could handle only 30 boxes per hour manually, the new system now enables the warehouse to pick and dispatch an impressive 300 boxes per hour. This tenfold increase exemplifies how embracing automation can breathe new life into logistics operations, especially those tasked with handling bulky or large volumes of stock such as safety wear and personal protective equipment (PPE).

Key Advantages of Daifuku’s AS/RS Setup

Located in a 15,000 square meter facility, the system features four high bay aisles serviced by four twin-fork Mini-Load cranes. This high-density racking with over 76,000 unique storage locations is among the longest install of its kind in the UK, extending more than 130 meters.

The design cleverly utilizes a double-deep storage approach, allowing the cranes to store and retrieve two cases at once, dramatically boosting storage capacity and retrieval speeds. This intelligent setup supports a high throughput, fulfilling both bulk orders and pick-and-pack shipments smoothly.

How it Works: The Technology Behind the Magic

At its core, the system operates through a central in-feed conveyor that directs cartons to specific zones within the high bay racking based on demand profiles. This process is powered by a bespoke programmable logic controller (PLC), integrated with the warehouse’s existing software systems, ensuring seamless communication and real-time order fulfillment.

Mini-Load cranes at the heart of this system can deftly maneuver plastic containers, trays, or cardboard cartons, adapting flexibly to different inventory types. Having supplied over 34,000 stacker cranes worldwide, Daifuku’s technology is globally renowned for its reliability and energy efficiency, with lighter materials and smaller motors reducing power consumption.

Operational Flow and Dispatch Efficiency

Once cartons arrive, they are scanned and routed into the system where they wait until called. When requested, items exit the AS/RS into one of three lanes:

• Lane One: Replenishes the adjacent AutoStore system for picking and packing.
• Lanes Two & Three: Fulfill bulk customer orders ready for next-day delivery dispatch.

Such streamlined flow drastically reduces errors like mis-picks and improves service levels, ultimately boosting customer satisfaction. Russell Hutchinson, Daifuku UK’s sales manager, highlights the system’s ease of use—inputting a carton barcode is enough for the system to automatically manage storage and retrieval.

Broader Implications for the Logistics Sector

Portwest’s journey underscores how strategic automation investment can double warehouse capacity without compromising workforce size or quality of jobs. Rather than cutting jobs, automation reshapes roles into more enriching positions focused on managing, monitoring, and improving systems rather than repetitive manual tasks.

For logistics broadly, this means improved efficiency, reduced order errors, and better capacity handling to meet fluctuating market demands. Businesses moving high volumes of freight—be it garments, PPE, or bulky shipment items—can glean valuable lessons from Portwest’s approach, particularly when paired with comprehensive software controls to synchronize inventory management with customer orders.

Highlights and Reflection

The cornerstone of Portwest’s success lies not just in faster picking speeds but also in enhanced accuracy, expanded capacity, and a maintained workforce morale. These aspects perfectly illustrate automation’s role in modern warehousing: a powerful lever to upscale operations while fostering positive employment growth.

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Looking Ahead: Logistics Trends and Automation

Although the immediate impact of Portwest’s automation might be localized, it echoes a global trend of integrating technology into logistics workflows. Automation is progressively shaping freight handling worldwide, driving a shift in distribution and warehouse management strategies.

For companies operating globally, understanding and adapting to these technological advancements is crucial. As automation optimizes raw throughput and minimizes mis-shipments, platforms like GetTransport.com stand ready to complement these efficiencies by offering seamless, reliable, and cost-effective transportation solutions across borders. Start planning your next delivery and secure your cargo with GetTransport.com.

Conclusion: Efficiency Meets Innovation in Modern Warehousing

Automation at Portwest serves as a shining example of how integrating advanced systems like Daifuku’s AS/RS can transform warehouse operations, leading to tenfold productivity gains, significant error reduction, and increased storage density—all while maintaining a committed workforce. This leap in warehouse technology not only enhances fulfillment for high-demand items such as PPE but also reinforces the essential role of smart logistics in today’s supply chain.

For businesses looking to enhance their shipping, dispatch, or relocation efforts, leveraging platforms like GetTransport.com offers an efficient, reliable, and budget-friendly bridge to managing cargo and freight needs—whether for bulky furniture, vehicle transport, or international shipments. In today’s logistics landscape, innovation and dependable transportation go hand in hand to keep goods moving and customers happy.