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WE MAKE THE WORLD MOVE<br />

W A R E<br />

H O U S I N G<br />

´


DYNAMIC STORAGE<br />

Dynamic storage, the “heart of logistics”<br />

FOR DYNAMIC WAREHOUSING AND DISTRIBUTION OF MASS PRODUCTS<br />

We can install the most<br />

efficient, cost effective<br />

product distribution system<br />

<strong>for</strong> you, using INTERROLL<br />

Dynamic Storage<br />

technology.<br />

The INTERROLL approach:<br />

There is no better<br />

distribution method as easy<br />

to operate and which offers<br />

such a short pay-back time.<br />

we analyze your turnover and stock rotation needs<br />

we design the ideal system to meet your operational requirements<br />

we work together with you as a team<br />

we test your products (pallets, crates) to insure reliability<br />

we are happy to provide you with customer references<br />

we offer a five year guarantee providing a maintenance contract is in place<br />

…<strong>for</strong> all sorts of goods in crates, cartons, or on pallets


Advantages of the INTERROLL flow storage system<br />

1. Space saving high density storage<br />

2. Time-saving <strong>–</strong> only one input and one output aisle<br />

3. Dynamic <strong>–</strong> “flowing” warehousing<br />

4. Fast <strong>–</strong> immediate access to every product<br />

5. Versatile <strong>–</strong> suitable <strong>for</strong> refrigerator or freezer applications<br />

6. Customized <strong>–</strong> tailor-made design and layout<br />

7. Practical and efficient <strong>–</strong> simple, structured inventory control<br />

8. Safe <strong>–</strong> using INTERROLL speed controllers and safety separators<br />

9. Quickly amortized <strong>–</strong> usually pay back is less than two years<br />

10. “First in/first out” <strong>–</strong> especially advantageous <strong>for</strong> perishable goods<br />

11. Low maintenance <strong>–</strong> reliable operation<br />

12. Environmentally friendly <strong>–</strong> no energy consumption<br />

13. Operation-friendly <strong>–</strong> simple handling<br />

14. Long life expectancy <strong>–</strong> maintenance contract includes five year guarantee<br />

15. Quickly installed <strong>–</strong> possible during operation<br />

16. Tested <strong>–</strong> in-house INTERROLL test facility <strong>for</strong> your application<br />

17. Proven throughout the world <strong>–</strong> more than 2 million pallet positions installed<br />

18. References from every type of industry<br />

ADVANTAGES<br />

1


2<br />

Pallet<br />

Types<br />

& Footprints<br />

Plastic pallets with “feet” are gaining<br />

greater acceptance within industry.<br />

Reliable flow of these pallets can be a<br />

challenge. INTERROLL has achieved<br />

positive results using our Logix 4000<br />

wide roller based flow system.<br />

Pallets with full-length runners in the direction<br />

of flow move freely using INTERROLL<br />

narrow or wide roller conveyor. Pallet<br />

guidance is a desirable feature provided<br />

by use of rollers with built-in flanges.<br />

“Cross-way” pallets have bottom boards<br />

perpendicular to the direction of flow. The<br />

Logix 2000 polycarbonate wheel conveyor<br />

was specifically designed to convey pallets<br />

of this type...even when some bottom<br />

boards are warped or broken.<br />

Slave pallets are used <strong>for</strong> carrying nonconveyable<br />

items such as sacks, drums,<br />

bales, etc. Plywood material is generally<br />

used. INTERROLL’s wheel or roller<br />

conveyors can be used, depending upon<br />

pallet load.<br />

Lightly-loaded plywood pallets are easily<br />

conveyed on steel wheel conveyor.<br />

However heavily loaded plywood pallets<br />

and foam plastic pallets both require<br />

greater support. Use of Logix 4000 wide<br />

roller conveyor is recommended <strong>for</strong> these<br />

applications.<br />

Wire Baskets, skid boxes and other factory<br />

containers are generally conveyed using<br />

rugged roller conveyor. Runners on these<br />

containers tend to be “slippery” and the<br />

use of lagged or knurled brake rollers is<br />

recommended.<br />

Schematiic Footprint / Flow


Table of Contents<br />

1 Advantages of Flow Storage<br />

2 Pallet Types & Footprints<br />

4-14 Application Examples<br />

36-43<br />

15 Variations<br />

16-17 Why Flow Storage ?<br />

18 Steel Wheel<br />

19-20 Polycarbonate Wheel<br />

21 Narrow Roller<br />

22 & 44 Application photos<br />

23-24 Wide Roller Series<br />

25 Pushback<br />

26-27 Speed Controllers<br />

28-29 Pallet Separators<br />

30 Pallet Retainers<br />

31 Floway Carton Flow<br />

32 Flostar Roller Carton Flow<br />

33 Versi Flow Carton Flow<br />

34 1.38” Roller Heavy Duty Carton Flow<br />

35 Flex Flow<br />

Due to our ongoing technological development and improvement, INTERROLL<br />

reserves the right to change the engineering specifications of the products shown in<br />

this publication without notice. For assistance please call our factory.<br />

3


4<br />

The endurance runner<br />

of our flow storage<br />

systems<br />

EXAMPLE: BEST SELLERS<br />

Dedicated areas <strong>for</strong> storage,<br />

transfer and order picking<br />

functions have resulted in<br />

significant improvements in<br />

overall per<strong>for</strong>mance.<br />

This sophisticated<br />

installation at Allkon<br />

perfectly demonstrates the<br />

space efficiency of our flow<br />

storage systems.<br />

Out of a total area of<br />

247,500 square feet, only<br />

16% is used <strong>for</strong> the system,<br />

yet provides 45% of the<br />

total warehouse capacity of<br />

6,000 pallets.<br />

This area is reserved <strong>for</strong> fast<br />

moving items. Loading is<br />

accomplished by wireguided<br />

stacker cranes<br />

operating under control<br />

computer control.<br />

Two blocks are provided<br />

with 8 pallet deep buffer<br />

storage lanes to expedite<br />

order picking delivery.<br />

Each day, each operator<br />

handles between 40 and 45<br />

tons, 50% more than in<br />

conventional warehousing.


• Quick moving items.<br />

• 232 order picking points.<br />

• Transfer of complete<br />

pallets directly from<br />

reserve stock.<br />

• Central computer-control<br />

via infrared data link.<br />

• Speedy order picking rate<br />

of 263 containers per<br />

hour per operator.<br />

• No repairs or replacement<br />

of conveyor rollers<br />

needed since 1984.<br />

5


6<br />

Mobile energy on call<br />

EXAMPLE: BATTERIES<br />

Everyone has heard of the<br />

compact storage batteries<br />

produced by VARTA. Each<br />

day they start millions of<br />

vehicles. They provide<br />

stored energy to change<br />

dark to light, to keep music<br />

playing and clocks ticking.<br />

Over the years, Varta built<br />

15 decentralized<br />

warehouses but was still<br />

unable to keep up the<br />

steadily increasing demand<br />

<strong>for</strong> their products. What’s<br />

more, their classic paperbased<br />

orderpicking system<br />

was not only prone to error,<br />

it was labor intensive and<br />

time consuming.<br />

Varta decided to establish a<br />

central distribution center.<br />

The center was designed in<br />

anticipation of a future<br />

increase in smaller quantity<br />

shipments of lightweight<br />

packages.<br />

The aim was to increase<br />

throughput while reducing<br />

processing time, with a zero<br />

error rate and utilizing<br />

paperless order picking.<br />

These were ideal<br />

requirements <strong>for</strong> an<br />

INTERROLL flow storage<br />

system. An 8 level reserve<br />

stock, each level having 42<br />

flow storage lanes<br />

containing 10 pallets,<br />

supplies fast moving<br />

products to 4 X 42 threepallet<br />

order picking lanes on<br />

two levels.<br />

This is used exclusively <strong>for</strong><br />

picking full case products.<br />

Pallets are withdrawn<br />

directly from reserve stock.<br />

Individual articles are picked<br />

from the separate Pickflow<br />

open flow system.<br />

Using the First in/First out<br />

(FIFO) principle, articles are<br />

instantly available to Varta<br />

customers in Germany,<br />

Europe and all over the<br />

world.


• Dispatching full pallets,<br />

and picking boxed goods<br />

as well as individual<br />

products.<br />

• Error-free FIFO order<br />

picking of segregated<br />

products by using a<br />

computerized, paperless<br />

system.<br />

• Centralization of the<br />

entire Varta stock.<br />

• Extremely short throughput<br />

times <strong>for</strong> urgent<br />

orders.<br />

• Efficient operator activity<br />

in the order picking<br />

zones.<br />

• Up to the minute<br />

in<strong>for</strong>mation flow with<br />

FIFO automation.<br />

• Speed and accuracy are<br />

notable competitive<br />

advantages.<br />

7


8<br />

Help at hand <strong>–</strong><br />

fast<br />

EXAMPLE: PHARMACEUTICALS<br />

The quality of medical care<br />

in Europe is among the best<br />

in the world. A key reason is<br />

the availability of life-saving<br />

prescription drugs.<br />

Hoffmann La Roche set their<br />

sights on same-day<br />

shipment of all orders<br />

received by 2:30 p.m.<br />

This includes individual<br />

packs as well as complete<br />

cartons. Using paperless<br />

technology, individual packs<br />

are picked from an easily<br />

accessible Pickflow storage<br />

lane, while cartons are<br />

picked - also using a<br />

paperless system - from a<br />

The results have impressed<br />

all concerned:<br />

• Modern distribution<br />

principles <strong>for</strong> fast supply<br />

of orders.<br />

FIFO pallet flow storage<br />

system.<br />

The FIFO principle of the<br />

Pickflow order picking line<br />

and pallet flow storage<br />

system eliminates any<br />

• Special strategies <strong>for</strong><br />

urgent order handling.<br />

• All the advantages of<br />

paperless order picking.<br />

chance of accidental<br />

product mix - which could<br />

have serious consequences.<br />

In conjunction with central<br />

computer control, this<br />

improves order picking<br />

per<strong>for</strong>mance by up to 100%.<br />

• Ergonomically optimized<br />

Pickflow storage lanes.<br />

• Precision control system<br />

eliminates order errors.


Small, but flexible<br />

EXAMPLE: FOOD<br />

This relatively small,<br />

compact flow storage<br />

system with 860 pallet<br />

positions can accommodate<br />

several types of pallets.<br />

Pallets are stored in rows of<br />

two in the flow storage lanes<br />

on both sides of the picking<br />

tunnel.<br />

Reserve stock is stored<br />

overhead in reverse flow<br />

lanes on two levels. An<br />

extra feature is the two<br />

insertion lanes to the left<br />

and right, each<br />

accommodating a row of<br />

two pallets positions.<br />

This allows Tengelmann to<br />

maximize space and<br />

improve utilization of the<br />

flow storage system.<br />

• Paired arrival of halfpallets<br />

at the removal<br />

point.<br />

• 2 input lanes with doublespaces<br />

provide a flexible<br />

reserve.<br />

• Integration of 2 zeropressure<br />

accumulation<br />

conveyors in the<br />

receiving area <strong>for</strong> optimal<br />

material flow.<br />

9


10<br />

My home is my garden<br />

EXAMPLE: SEEDS<br />

In addition to 2,000 types of<br />

seeds sold through more<br />

than 18,000 outlets, an<br />

additional 800 types of<br />

flower bulbs, various garden<br />

aids, grass seed and<br />

fertilizers also have to be<br />

stored.<br />

In the 1995/96 season this<br />

added up to 700 tons of<br />

grass seed, 13 million packs<br />

of flower bulbs and 1,000<br />

tons of onion seedlings -<br />

these huge quantities<br />

required special<br />

organization.<br />

Previously, production,<br />

storage and shipment had<br />

been spread out to three<br />

different sites in Solingen,<br />

with a fourth being rented<br />

during peak season.<br />

This warehousing situation -<br />

which was inconvenient and<br />

inadequate - was made<br />

even more difficult with the<br />

opening of the East/West<br />

German border.<br />

An entirely new facility was<br />

constructed.<br />

The new distribution center<br />

now has a total of 215,200<br />

square feet of space on two<br />

levels.<br />

The lower level is reserved<br />

<strong>for</strong> receiving, seed filling and<br />

the high-bay warehouse<br />

with 9,000 pallet positions.<br />

The second level is used <strong>for</strong><br />

picking flower bulbs, grass<br />

seed and fertilizers from a<br />

flow storage system with<br />

1,359 lanes and 3,635 pallet<br />

positions.<br />

All unsold items are returned<br />

to Solingen at the end of the<br />

season and put back into<br />

stock.<br />

This is a service provided by<br />

Flora Frey to guarantee that<br />

only available seeds were<br />

offered.<br />

The INTERROLL flow<br />

storage system is divided<br />

into two blocks, maximizing<br />

use of the full warehouse<br />

clearance of 24.5 feet, with<br />

a product by product<br />

position of the pallets.<br />

In this way, the operators<br />

have instant access to 1,088<br />

articles during the two<br />

seasonal peaks.


• 600 pallet shipments and<br />

750 order picking<br />

processes daily.<br />

Devoted gardeners need<br />

good service to keep up<br />

with mother nature.<br />

• Increased picking<br />

per<strong>for</strong>mance with<br />

improved accessibility <strong>for</strong><br />

the operator.<br />

• Separate FIFO storage of<br />

1,088 different products.<br />

• Host computer and PC<br />

controls material flow and<br />

order picking.<br />

Order picking blocks 1<strong>–</strong><br />

4 with two order picking<br />

levels and reserve<br />

storage.<br />

Order picking blocks 5<strong>–</strong><br />

7 with three picking<br />

levels.<br />

• Separation of storage,<br />

stock transfer and order<br />

picking functions.<br />

11


12<br />

Outsourcing on a large scale<br />

EXAMPLE: DISTRIBUTORS<br />

Knoche & Barth handle the<br />

central distribution of all<br />

Schwarzkopf and Yankee<br />

Polish products.<br />

This requires the handling of<br />

a total of 300 tons daily,<br />

with fluctuations of 50% to<br />

150% to be handled by<br />

operators filling orders the<br />

same day received.<br />

Of 17,500 pallet positions,<br />

11,600 flow storage position<br />

and a complex computer<br />

together meet this daily<br />

challenge of logistic<br />

flexibility.<br />

The pallets are stored in 26<br />

feet or 111.5 feet long flow<br />

storage lanes and are<br />

processed in four stages:<br />

full pallets, de-palletized by<br />

robot layer by layer in<br />

original cartons, picked as<br />

full cartons or broken carton<br />

individual articles.<br />

All selections to complete<br />

an order converge at the<br />

packing station where they<br />

are checked and prepared<br />

<strong>for</strong> shipment.<br />

This sophisticated<br />

automated warehousing and<br />

order picking technology is<br />

based on the economical<br />

interplay of intelligent FIFO<br />

hardware and efficient<br />

computer control.


• 12 order picking zones in<br />

six aisles.<br />

• Modular control concept.<br />

Order picking tunnel with overhead pallet reserve and pick-to-belt levels.<br />

• 4 dispatch types are<br />

simultaneously compiled.<br />

• 2,800 flow storage places<br />

in the perishable goods<br />

area alone.<br />

• A master computer<br />

organizes paperless order<br />

picking.<br />

• 800 orders per day with<br />

order fluctuations of 50%<br />

to 150% at a constant<br />

staffing level.<br />

13


14<br />

FIFO flow storage works in harmony<br />

with conventional shelving<br />

EXAMPLE: HAULAGE COMPANIES<br />

A new warehouse with<br />

10,300 pallet positions is<br />

used by Denkhaus <strong>for</strong> the<br />

storage and distribution of<br />

well-known electric tools.<br />

There are 4,044 flow storage<br />

positions <strong>for</strong> 156 high<br />

volume, fast moving<br />

products.<br />

Divided into two separate<br />

blocks, the first block used<br />

as a reserve, where 5 pallets<br />

are stored in 39 adjacent<br />

flow storage lanes on 10<br />

levels.<br />

In the second block, 39 flow<br />

storage lanes - on the left<br />

and right of the lower level -<br />

each provide room <strong>for</strong> two<br />

order picking pallets.<br />

Above the order picking<br />

tunnel is the reserve stock<br />

<strong>for</strong> the left hand order<br />

picking lanes. This is<br />

arranged on 8 levels in 39<br />

adjacent flow storage lanes,<br />

each with 6 pallet positions.<br />

• Special roller track <strong>for</strong><br />

disposable pallets with<br />

narrow runners.<br />

• Safety separators<br />

guarantee a defined,<br />

zero-pressure<br />

accumulated end<br />

position of the pallets,<br />

even <strong>for</strong> transfer.<br />

The right-hand removal<br />

points are served from the<br />

first block.<br />

This FIFO process,<br />

combined with a<br />

conventional warehouse,<br />

results in high density and<br />

fast processing.<br />

• Gravity test zone in the<br />

receiving area <strong>for</strong> quality<br />

acceptance of each pallet<br />

used <strong>for</strong> storage.<br />

• Integration of the order<br />

picking tunnel in the<br />

reserve block.


CONFIGURATIONS<br />

Flexible storage lanes can<br />

be arranged both laterally<br />

and vertically.<br />

Ideal structure <strong>for</strong> pallet<br />

storage and removal.<br />

Fully automated or manual<br />

options.<br />

FIFO combination with<br />

outside, single line flow<br />

lanes <strong>for</strong> optimal storage.<br />

Compact carton flow<br />

storage system <strong>for</strong> fast<br />

moving products. The<br />

accessible arrangement of<br />

the flow levels increases<br />

picking per<strong>for</strong>mance.<br />

Compact storage system<br />

<strong>for</strong> pallets, using proven<br />

FIFO technology.<br />

FIFO combines reserve<br />

stock and order picking<br />

tunnel accessible on<br />

several levels.<br />

Order picking tunnel with<br />

overhead pallet reserve and<br />

reverse flow lanes.<br />

Pickflow carton flow storage<br />

system <strong>for</strong> high volume order<br />

picking with reduced<br />

operator activity.<br />

Integral conveyor technology<br />

with zonal transfer<br />

accommodates paperless<br />

order picking systems.<br />

Precision and expertise are the deciding factors.<br />

15


16<br />

Why INTERROLL<br />

Flow Storage?<br />

Benefits<br />

INTERROLL Flow Storage systems<br />

increase in popularity because of their<br />

ability to be integrated into complex<br />

distribution systems, ensuring an<br />

orderly flow of product.<br />

INTERROLL Flow storage systems<br />

have been in use <strong>for</strong> more than<br />

25 years in industries such as grocery<br />

distribution and cold storage.<br />

In the last five years, flow storage<br />

has gained acceptance in many other<br />

industries. Applications range from<br />

handling pharmaceuticals to automotive<br />

assemblies and everything in<br />

between.<br />

The increased popularity of<br />

INTERROLL systems is due to<br />

rising capital and operating costs of<br />

alternative storage arrangments.<br />

These include cost of land, building<br />

construction, interest charges, inventory<br />

shrinkage, <strong>for</strong>klift cost, labor and<br />

energy costs - all of which can be<br />

substantially reduced by the use of a<br />

well designed flow storage system.<br />

The “first-in/first-out” (FIFO) principle<br />

is an added benefit <strong>for</strong> date sensitive<br />

and perishable goods. INTERROLL<br />

pushback systems provide a low cost<br />

alternative to flow systems when “lastin/first-out”<br />

(LIFO) inventory rotation is<br />

acceptable.<br />

What is Flow Storage?<br />

INTERROLL flow storage systems<br />

consist of two clearly defined elements<br />

— dynamic conveyor components and<br />

the static rack structure. Of the two,<br />

the dynamic components are the<br />

most decisive in determining<br />

whether a system is successful.<br />

These dynamic components consist of<br />

INTERROLL wheel rails or roller beds<br />

set at a decline to move goods by<br />

gravity from the loading face of the<br />

rack to the unloading position. They<br />

are installed into the rack, which is the<br />

support structure <strong>for</strong> the system and is<br />

made of roll <strong>for</strong>med or structural members.<br />

The resulting flow systems are<br />

typically up to 5 pallets high and up to<br />

20 pallets deep <strong>for</strong> flow systems, or<br />

four pallets deep <strong>for</strong> pushback systems.<br />

This means that loads weighing<br />

up to 4,000 pounds can be stored with<br />

extremely high utilization of the building<br />

cubic volume.<br />

Flow Storage Applications<br />

Control of the pallet speed is<br />

critical to the safe operation of<br />

systems. To achieve this, self energized<br />

speed controllers are used.<br />

They are generally spaced one per<br />

pallet position to gently control the<br />

speed of the pallet to less than 60 feet<br />

per minute. INTERROLL has many<br />

unique controllers that provide durable<br />

and reliable speed control in any<br />

application. Line pressure can be<br />

eliminated from the unload position by<br />

pallet separators that are suitable <strong>for</strong><br />

use with either lift trucks or manual<br />

order picking.<br />

Given the wide variety of pallet types<br />

and sizes used in industry, and the<br />

many materials and construction<br />

techniques used, it’s easy to understand<br />

why no “universal” pallet flow<br />

system has been devised. For<br />

example, a lightly-loaded pallet with<br />

a smooth, hard-bottomed plywood<br />

surface rolls easily on inexpensive<br />

wheel conveyor. However if the load<br />

is increased, the wheels will probably<br />

“dig” into the plywood, causing pallet<br />

damage and consequent “hang-ups”<br />

over a period of time. Use of INTER-<br />

ROLL roller conveyor eliminates the<br />

problem by providing better pallet support.<br />

Staggared polycarbonate wheel<br />

conveyor is a better solution <strong>for</strong><br />

wrong-way GMA type pallets. A wide<br />

roller system is ideal <strong>for</strong> plastic<br />

pallets, and bins.<br />

Making the decision on which is the<br />

“best” system to use is sometimes<br />

difficult. However, by relying on<br />

INTERROLL’s experience and<br />

subsequently verifying the selection<br />

by actual pallet testing, users can be<br />

assured IN ADVANCE of obtaining a<br />

system that is both cost effective and<br />

reliable.<br />

Some of the many pallet types currently<br />

being handled on INTERROLL<br />

FLOW Storage Systems are illustrated<br />

in this catalog. If use of other pallet<br />

configurations is being considered,<br />

pallet tests at INTERROLL’s<br />

facility to determine the pitch and<br />

system type are highly recommended.<br />

We will videotape your test results<br />

and make appropriate design recommendations.


Applications<br />

Shown here is a typical manufacturing and<br />

distribution process. Potential flow storage<br />

applications are identified by the shaded<br />

boxes. INTERROLL Flow Storage can<br />

double warehouse capacity while reducing<br />

wasted space by 50%. Flow storage is ideal<br />

<strong>for</strong> raw material receiving/storage, work in<br />

process, buffer storage, finished goods<br />

storage and cross docking applications<br />

Both INTERROLL flow storage and pushback<br />

systems can be combined in order<br />

picking situations where flow storage is<br />

used <strong>for</strong> the primary pick face and pushback<br />

is used <strong>for</strong> secondary storage above.<br />

This eliminates all <strong>for</strong>k lift traffic in the<br />

picking aisles.<br />

The best solution <strong>for</strong> any given application<br />

is normally a combination of several different<br />

storage techniques. In general, flow<br />

storage systems are suited to applications<br />

where the throughput is high and the number<br />

of Stock Keeping Units (SKU’s) is relatively<br />

small. Pushback is ideal where<br />

throughput is lower and there are more<br />

SKU’s.<br />

IN<br />

Receiving<br />

Raw Material<br />

Storage<br />

Manufacturing<br />

Work in<br />

Process<br />

Manufacturing<br />

Finished Goods<br />

Warehousing<br />

Order Picking<br />

Shipping<br />

OUT<br />

17


18<br />

SKATEWHEEL Flow<br />

Steel Wheel Conveyor<br />

➢ Proven design<br />

➢ 1.9 inch diameter wheels with<br />

1.5, 2 or 3 inch wheel centers.<br />

➢ 2.5 or 3 inch Galvanized channels.<br />

➢ 14 ga. or 12 ga. heavy duty<br />

channels.<br />

➢ Bolted wheel construction.<br />

2.50˝ X 12 GA. RAIL LOAD CAPACITY IN LBS/FT AT VARIOUS BEAM SPANS<br />

Height 36˝ 42˝ 48˝ 54˝ 60˝ 66˝<br />

2.50˝ 626 459 352 278 225 186<br />

2.50”<br />

12 GA.<br />

2.50”<br />

.62”<br />

.81”<br />

1.94”<br />

2.81”<br />

12 GA.<br />

1.90”<br />

DIA<br />

2.95”<br />

SLOTS FOR<br />

5/16 BOLT<br />

➢ SKATEWHEEL Flow is a rugged, inexpensive system <strong>for</strong><br />

handling various pallets<br />

➢ Wheels can be spaced to provide maximum pallet support.<br />

➢ Two runs of double staggered wheel conveyor are frequently<br />

used in 2 pallet deep picking applications with “crossway”<br />

pallets where manual assistance can be provided<br />

➢ In many cases, two rows of wheel conveyor are used<br />

together with a roller conveyor<br />

➢ Speed controllers can be mounted in the 4 inch BFR tracks<br />

4.00”<br />

5.13”<br />

6.00<br />

.62”<br />

1.90”<br />

DIA<br />

2.50”<br />

2.95”<br />

SLOTS FOR<br />

5/16 BOLT<br />

12 GA.<br />

1.62”<br />

2.75”<br />

3.62”<br />

.62”<br />

1.90”<br />

DIA<br />

2.95”<br />

SLOTS FOR<br />

5/16 BOLT


WHEEL Flow<br />

Polycarbonate Wheel<br />

Conveyor System<br />

➢ Proven Design<br />

➢ Impact resistant polycarbonate<br />

wheels<br />

➢ 2, 3, & 4 rail configurations<br />

per lane<br />

➢ Aluminum impact wheel <strong>for</strong> load<br />

and unload positions<br />

➢ Double ball bearing wheel<br />

construction<br />

➢ Sealed bearings<br />

➢ Suitable <strong>for</strong> freezer applications<br />

Wheel Flow was originally developed by INTERROLL specifically <strong>for</strong> handling “crossway” GMA type<br />

pallets without a slave board. The system can be applied using 2, 3, or 4 (or more) tracks <strong>for</strong> 2,000,<br />

3,000, & 4,000 (and higher) pound loads respectively. INTERROLL’s patented tandem speed controller<br />

design and tough polycarbonate wheels make Wheel Flow the most durable and reliable<br />

“crossway” flow storage system available today. Lanes of single row wheels can be used <strong>for</strong> push<br />

lane floor storage. Rugged <strong>for</strong>k lift protectors are also available.<br />

19


20<br />

WHEEL Flow<br />

Polycarbonate Wheel<br />

Conveyor System<br />

➢ Proven design<br />

➢ 2.88 inch diameter wheels with 2, 3<br />

inch (or more) wheel centers<br />

➢ 3.5 or 3 inch Galvanized channels<br />

➢ 14 ga. or 12 ga. heavy duty channels<br />

➢ Bolted wheel construction<br />

➢ Painted or Galvanized wedge stops <strong>for</strong><br />

gentle stopping action<br />

Splice Plate Detail<br />

➢ Splice Plate eliminates need to locate<br />

joints over beams<br />

➢ Bolted joints <strong>for</strong> easy component replacement<br />

BOLT HEX<br />

5/16-18 X 2<br />

NUT HEX 5/16-18<br />

WASHER 5/16 FLAT<br />

BOLT CARRIAGE<br />

5/16-18 X 4<br />

2.88”<br />

.343” DIA x .75” LG<br />

SLOT<br />

.81”<br />

1.10”<br />

1.38”<br />

3.00”<br />

NUT HEX<br />

5/16-18<br />

Tandem Roller Modular Speed Controller<br />

3.50”<br />

.81”<br />

.625”<br />

2.75”<br />

4.37”<br />

Recommended External Beam Detail<br />

4.315”<br />

➢ Palletrail safely nests behind structural beams<br />

➢ Hardware is protected from <strong>for</strong>k lift damage<br />

With cushion traction rollers in tandem, the free fall of a typical GPC (Grocery Pallet Council) type pallet is<br />

reduced to only 5 inches from 9 inches! This is a 44% reduction<br />

in pallet free fall. With recommended Tandem Brake<br />

spacing, the Wheel Flow system offers the ultimate in flow<br />

control, reducing impact and increasing life.<br />

➢ US Patent #5086903<br />

➢ Indirect braking <strong>for</strong> long brake life<br />

➢ Less pallet free fall (5” vs. 9” <strong>for</strong> single drum brakes)<br />

➢ Cushion type elastomere rollers con<strong>for</strong>m to pallet <strong>for</strong><br />

greater speed control of pallets and shock absorption<br />

➢ “Floating” rollers ensure continuous contact between<br />

pallet and brake<br />

.81”<br />

1.25”<br />

4.12”<br />

5.75”


Narrow Roller<br />

Conveyor System<br />

➢ Proven Design<br />

➢ 2.5 inch diameter rollers<br />

➢ Minimum 250 lb capacity per roller<br />

standard<br />

➢ 3, 4 inch or more centers standard<br />

➢ 4 inch BFR standard<br />

➢ Structural frame<br />

➢ Indirect Elastomeric Tandem Brake<br />

BFR<br />

C5X6.7#<br />

BFR<br />

BFR<br />

C4X5.4#<br />

TANDEM SPEED CONTROLLER<br />

WITH FLAT SIDE PLATES<br />

2.50” IMPACT ROLLER<br />

C4X5.4# 3X3<br />

ANGLE<br />

2.50” IMPACT ROLLER<br />

C4X5.4#<br />

Designed <strong>for</strong> the four-way metal bins used in the<br />

Automotive Industry where crossway runners can damage<br />

full width rollers. The structural frames resist abuse from<br />

the metal bins and the high channel on the outer sides help<br />

guide the bins down the lane. The elastomeric rollers on<br />

the speed controllers maintain contact with the runners on<br />

the bins even if the runners are bent. Rollers have heavy<br />

duty bearings, a 0.120 inch wall to resist wear and a drilled<br />

and tapped 11/16 inch hex shaft <strong>for</strong> impact resistance.<br />

”<br />

C3X4.1#<br />

C5X6.7#<br />

BFR<br />

C4X5.4# C4X5.4#<br />

BFR<br />

2.50” IMPACT ROLLER<br />

C3X4.1#<br />

2.50” IMPACT ROLLER<br />

21


ROLLER Flow<br />

Wide Roller<br />

Conveyor System<br />

➢ Proven design<br />

➢ 1.9, 2.5 and 3.15 inch diameter<br />

rollers<br />

➢ 2, 3, 4 inch or more centers<br />

standard<br />

➢ High capacity rollers<br />

➢ Heavy duty galvanized channel<br />

➢ Full width roller or underslung<br />

speed controller<br />

Wedge Stop Detail<br />

Full Width Speed Control<br />

Underslung Speed Controller<br />

Full Width Roller Flow is the most effective system to handle<br />

“right-way” pallets including 3 stringer skids, Euro pallets, plastic<br />

pallets or special bins. Three rollers sizes (1.9, 2.5 and 3.15 inch<br />

diameter) and convenient spacing allow Roller Flow to be<br />

tailored to suit individual applications.<br />

The rugged roller design uses commercial non-precision<br />

bearings due to heavier loads and low speeds. Stub shafts allow<br />

wide BFR’s without the extra weight and cost of a through shaft.<br />

Rollers can be easily replaced without removing the frame rail.<br />

The speed controller can be a full width roller brake where the<br />

centrifugal brake is mounted inside a roller to provide direct<br />

braking contact. The outer surface of the roller can be knurled or<br />

lagged with rubber lagging to increase the grip on the pallet.<br />

Underslung speed controllers offer an indirect mount <strong>for</strong> a<br />

smooth roller surface <strong>for</strong> pallets or bins that are difficult to flow.<br />

23


24<br />

3.82” REF.<br />

External Beam Detail (suggested)<br />

➢ Conveyor nests safely behind structural<br />

channel beams<br />

Conveyor Detail<br />

➢ Splice plate eliminates need to locate joints<br />

over beams<br />

➢ Bolted construction <strong>for</strong> easy roller<br />

replacement<br />

➢ Optional pallet separators allow easy<br />

removal of loaded pallets from lane<br />

Brake Roller Detail<br />

1.90”<br />

DIA.<br />

2.50”<br />

DIA.<br />

Load Capacity Chart*<br />

➢ Limits the speed of the pallet to less than 60 ft.<br />

per minute.<br />

➢ Lagging or Knurled surface are available <strong>for</strong><br />

pallets with “slick” bottom surfaces.<br />

➢ Permanently lubricated <strong>–</strong> no maintenance<br />

required<br />

➢ Brake rollers have full width contact with pallet<br />

➢ Please see pages 26 & 27 <strong>for</strong> additional<br />

speed control systems.<br />

BOLT HEX<br />

5/16-18 X 2<br />

NUT HEX 5/16-18<br />

WASHER 5/16 FLAT<br />

BOLT CARRIAGE<br />

5/16-18 X 4<br />

4.12” REF.<br />

Unsupported Span (in) 36 42 48 54 60 66<br />

Load Capacity (#/ft) 1264 929 711 562 455 376<br />

Load capacity may be limited by either frame capacity or roller capacity.<br />

Check both <strong>for</strong> load limit.<br />

NUT HEX<br />

5/16-18


Push Back<br />

Systems<br />

➢ Proven design<br />

➢ <strong>Interroll</strong> Full Width Roller<br />

and Wheel lanes can be<br />

used as Pushback lanes<br />

➢ Low profile with no stacking<br />

of carts<br />

➢ Full Width Roller pushback is<br />

available with a one way<br />

speed controller that “freewheels”<br />

when pushed by the<br />

<strong>for</strong>k lift truck but provides<br />

speed control on the return <strong>for</strong><br />

increased safety.<br />

One-way Speed<br />

Controllers<br />

25


26<br />

Speed Controllers<br />

➢ Proven design<br />

➢ Drum speed controllers<br />

available in Light, Medium<br />

and Heavy duty<br />

➢ Full width roller speed<br />

controllers are available<br />

only in heavy duty<br />

➢ All are suitable <strong>for</strong> use in<br />

Freezer applications<br />

➢ Max. allowable speed is<br />

60 ft. per minute<br />

R<br />

T<br />

E C T<br />

O<br />

A<br />

Flow<br />

F<br />

T<br />

I<br />

Flow<br />

1/4”<br />

2.64” REF .<br />

INTERROLL Speed Controllers “govern” the speed of loads<br />

flowing down an incline under gravity. They are not a brake, as<br />

such, but more of a speed governor or controller. When the load is<br />

at rest there is no “braking” action. The braking <strong>for</strong>ce is directly<br />

proportional to the rotational speed of the drum. At low speeds,<br />

internal springs limit the travel of the weighted shoes thereby<br />

reducing the braking <strong>for</strong>ce. Consequently a wide variety of loads<br />

can be speed controlled simply and effectively.<br />

Quantity of speed controllers required per lane is dependant on<br />

the weight of the load and the slope of the incline. Testing of the<br />

palletized loads is the best indicator of the quantity of speed<br />

controllers required <strong>for</strong> a given application. Generally the quantity<br />

is ‘N-1’ where ‘N’ is the number of pallets in the lane. The tandem<br />

speed controller is so effective in controlling speed that generally<br />

only 80% of the regular speed controller quantity is required.<br />

3/8-16 X 5" HEX<br />

HEAD BOL T AND<br />

REV . LOCK NUT<br />

2.60” REF .<br />

3.313” REF .


Speed Controllers<br />

Guidelines<br />

Indirect Mount<br />

R<br />

T<br />

EC T<br />

O<br />

A<br />

F<br />

T<br />

I<br />

Direct Mount<br />

R<br />

T<br />

EC T<br />

O<br />

A<br />

F<br />

T<br />

I<br />

Full Width Speed Controller<br />

Underslung Speed Controller Direct Mount Speed Controller Speed Controller with Knurling<br />

Tandem Mount<br />

Tandem Speed Controller Avalable with lagging<br />

27


28<br />

Pallet Separators<br />

For Wheel Conveyor<br />

➢ Proven design<br />

➢ Heavy duty construction<br />

➢ Positive lock in the stop position<br />

➢ Choice of manual or automatic<br />

Pallet Separator Deactivated<br />

Pallet Separator Activated<br />

Pallet Separators facilitate the removal of pallets by hand or lift truck. By<br />

holding back the second and all subsequent pallets until the first pallet is<br />

completely removed, the unloading operation becomes both safe and<br />

easy. In the event of fragile loads, shrink-wrapped loads or pallet<br />

overhang, product damage is minimized.<br />

Operation of the pallet separator can be manual or automatic and<br />

requires no external power source. As the first pallet moves into final<br />

position at the discharge end, it actuates a toggle lever mechanism which<br />

raises a stop to prevent the second and all subsequent pallets from<br />

impacting the first load. The stop allows a gap between the first and<br />

second pallet which allows the first pallet to be withdrawn with zero line<br />

pressure acting on it, thus preventing product damage.<br />

When the pallet is removed, the mechanism automatically releases the<br />

next pallet (an operator must release a manual separator) and it in turn,<br />

moves down and starts the whole cycle again. In this manner, one pallet<br />

after another may be removed from the INTERROLL flow lane.


Pallet Separators<br />

For Wheel Conveyor<br />

➢ Proven Design<br />

➢ Heavy duty construction<br />

➢ Positive lock in the stop position<br />

➢ Choice of manual or automatic<br />

➢ Automatic or Manual release<br />

available<br />

➢ Maximum weight behind stop<br />

shoe is 55,000 lbs.<br />

➢ Contact Engineering <strong>for</strong> weights<br />

beyond maximum<br />

Depending upon total live load in the lane, one or more<br />

separators may be required. For order picking operations<br />

where pallets are unloaded by hand, manual pallet<br />

release is recommended to prevent possible injury to<br />

operating personnel. In such cases a foot operated<br />

“safety” release is used.<br />

➢ Manual Release<br />

➢ 4 Pallets deep or less<br />

29


30<br />

Pallet Retainers<br />

➢ Proven Design<br />

➢ For both Wheel Flow and Roller Flow<br />

applications<br />

➢ For light and heavy duty applications<br />

Pallet Retainers are used where loads need<br />

to be held at a static location. Typically they<br />

are used to hold a pallet while empty pallets<br />

are stacked on top and then released or they<br />

can be used to manually palletize a load<br />

which can then be manually released when<br />

completed.<br />

Flow


Floway<br />

Carton Flow<br />

➢ Proven design<br />

➢ FIFO picking of cartons and plastic totes<br />

➢ Automatic and accurate stock rotation<br />

➢ Walking distances drastically reduced<br />

➢ Picking per<strong>for</strong>mance increased by up to 65%<br />

➢ Floor space savings<br />

➢ Angled pick trays available <strong>for</strong> ergonomic picking<br />

➢ No energy consumption<br />

➢ No maintenance costs<br />

➢ Tracks are laterally adjustable to suit changes in<br />

carton/tote sizes<br />

➢ High density polypropylene wheel on a steel axle<br />

➢ Track has a “locked” ladder design so wheels<br />

cannot come out of the track<br />

➢ Operating temperature -35º to 40º C<br />

31


32<br />

Flostar<br />

Roller Carton Flow<br />

➢ Proven design<br />

➢ FIFO picking of cartons and plastic totes<br />

➢ Ideal <strong>for</strong> retrofitting bottom levels of selective<br />

racking with replenishment above<br />

➢ Ideal product <strong>for</strong> applications where tote and<br />

carton sizes are standardized<br />

➢ Available in nominal 15”, 12”, 9” and 6” widths<br />

➢ 7/8” diameter aluminum roller<br />

➢ Roller pitch 1”, 2” or 3” centers<br />

➢ Tracks are easy to mount to step beams, box<br />

beams and structural beams<br />

➢ Low profile tracks available <strong>for</strong> fitting into<br />

existing carton flow beds<br />

➢ 3” nominal profile available <strong>for</strong> heavy loads or<br />

longer spans<br />

➢ Operating temperature -35º to 40º C


Versi Flow<br />

Carton Flow<br />

➢ Proven design<br />

➢ FIFO picking of cartons and plastic totes<br />

➢ Ideal <strong>for</strong> applications where carton/tote widths vary<br />

➢ Available in nominal 15.38” and 12.5” widths<br />

➢ 1.9” diameter wheels<br />

➢ Axle pitch 2” or 3” centers<br />

➢ Tracks are easy to mount to step beams, box<br />

beams and structural beams<br />

➢ Operating temperature -35º to 40º C<br />

33


34<br />

1.38” Roller<br />

Heavy Duty<br />

Carton Flow<br />

➢ Proven design<br />

➢ FIFO picking of cartons, plastic totes, and metal bins<br />

➢ Ideal <strong>for</strong> applications where carton/tote is heavy such as Automotive Industry<br />

➢ 1.38” diameter steel rollers with ball bearings <strong>for</strong> durability and easy flow ability<br />

➢ Available with galvanized finish<br />

➢ Side profiles available in 2.5”, 3.5” and 4.5” depths<br />

➢ Roller pitch 1.5”, 2”, or 3” centers<br />

➢ Tracks are easy to mount to step beams, box beams and structural beams<br />

➢ Operating temperature -35º to 40º C


Flex Flow<br />

➢ Proven design<br />

➢ Designed <strong>for</strong> ergonomic supply<br />

of materials in Kaizen and<br />

Kanban applications<br />

➢ Available with any of <strong>Interroll</strong>’s<br />

Carton Flow products<br />

➢ Custom designed to suit your<br />

purposes<br />

35


36<br />

When large rolls have to roll on rollers<br />

EXAMPLE: INSULATION<br />

To cope with its growing<br />

range of retail products and<br />

roll material, Sarnafil AG<br />

rented several outside<br />

warehouses.<br />

Separate facilities posed<br />

increasing problems with<br />

order processing times,<br />

handling, and transport.<br />

Costs increased while<br />

efficiency decreased.<br />

Today, 1,200 pallet<br />

positions <strong>for</strong> fast moving<br />

products are located<br />

together in Sarnen.<br />

The facility can store single<br />

Euro-pallets as well as<br />

double pallets handling<br />

oversize roll material.<br />

A secure operational project<br />

with short access times and<br />

all the advantages of FIFO<br />

technology.<br />

• Special solution <strong>for</strong><br />

oversize loads.<br />

• Pallet weights up to 3740<br />

lbs.<br />

• Flow storage lanes<br />

designed to cater to<br />

either individual Europallets<br />

or twin pallets.<br />

• Great operational safety<br />

despite pallet weights.


Advantages of the INTERROLL flow storage system <strong>for</strong> the user<br />

Space-saving ■<br />

High-bay solution<br />

Conventional pallet racking<br />

INTERROLLflow<br />

storage solution<br />

34 m<br />

22 m<br />

22 m<br />

Storage capacity: 4,700 pallets<br />

Löser bakes more than 1.3<br />

billion cones and around 60<br />

million wafers every year <strong>for</strong><br />

confectionery and ice cream<br />

manufacturers throughout<br />

Europe.<br />

Short-term orders combined<br />

with the baking peculiarities<br />

of their products require a<br />

high storage capacity.<br />

Wafers just don’t stay flat<br />

EXAMPLE: WAFERS<br />

70 m<br />

The problem is that freshly<br />

baked wafers distort<br />

immediately after being<br />

baked and must be stored<br />

<strong>for</strong> 2 to 6 weeks until they<br />

flatten out again.<br />

The company expanded, and<br />

its storage space was<br />

bursting at the seams, but<br />

regional ecology associations<br />

and planning authorities<br />

opposed their request <strong>for</strong> a<br />

high-rise warehouse.<br />

Despite the low overall<br />

height limitation,<br />

INTERROLL was once again<br />

successful in achieving<br />

unmatched levels of high<br />

density storage supported<br />

by an efficient electronic<br />

organization.<br />

This success was rewarded<br />

by the customer ordering an<br />

extension <strong>for</strong> a further 5,300<br />

pallet positions<br />

• Unrivaled 210 feet long<br />

flow storage lanes.<br />

• 4,700 pallet positions in<br />

the first phase.<br />

• 5,300 pallet positions in<br />

the second phase.<br />

• Special pallets <strong>for</strong> loading<br />

to a height of 8.5 feet and<br />

weight of between 440<br />

lbs and 925 lbs.<br />

• The flow storage lanes<br />

each have a capacity of<br />

53 pallets (equivalent to 2<br />

truck loads).<br />

• Each flow storage lane<br />

has a capacity of a<br />

complete production<br />

batch.<br />

• Only one operator is<br />

required to handle<br />

storage and removal of<br />

30 pallets per hour.<br />

• The INTERROLL software<br />

can manage up to 10,000<br />

articles.<br />

37


38<br />

Short and to the point: well stocked<br />

EXAMPLE: FRESH PRODUCTS<br />

Edeka-Saarstedt has<br />

segregated its fast moving<br />

products in a compact FIFO<br />

storage system.<br />

As these products are<br />

subject to fluctuating<br />

demand, the 1,872 pallets<br />

are distributed in very short<br />

reserve lanes, each with 5 or<br />

6 pallet positions.<br />

Depending on the demand<br />

situation, several flow<br />

storage lanes can be filled<br />

with the same article, or one<br />

lane may contain as little as<br />

2 to 3 pallets, making the<br />

system extremely flexible.<br />

The order picking zone is<br />

separated from the storage<br />

and removal zones, allowing<br />

smooth order picking from<br />

36 double lanes.<br />

Replacement stock is stored<br />

in a flow system in 4<br />

symmetrically arranged<br />

reserve blocks linked with<br />

the order picking zone via<br />

reverse flow roller<br />

conveyors.<br />

The clear separation of<br />

storage, removal and order<br />

picking provides a<br />

significant reduction in<br />

operator activity, increases<br />

order picking per<strong>for</strong>mance<br />

by up to 50%, eliminates<br />

waiting times and avoids<br />

accidents.<br />

• Short reserve lanes <strong>for</strong><br />

fluctuating demand.<br />

• Separate storage and<br />

removal zones.<br />

• Four reserve stocks.


As everyone knows, good<br />

wine is traditionally matured<br />

in cool cellars.<br />

The structure erected - or<br />

more accurately built into a<br />

hillside - here in the Remstal<br />

area is a masterpiece of<br />

architecture and logistics.<br />

Alone with a million bottles<br />

EXAMPLE: WINE<br />

Over 1 million bottles of<br />

wine are aged in racks at a<br />

depth of 65 feet below<br />

grade using a total floor<br />

space of only 4300 square<br />

feet.<br />

The whole system is<br />

managed on the FIFO<br />

principle, requiring only one<br />

operator <strong>for</strong> warehouse<br />

control and order picking.<br />

A flow storage system and<br />

two stacker cranes ensure<br />

smooth stacking, storage<br />

and removal of a diverse<br />

variety of wines and<br />

vintages.<br />

The oldest wine moves to<br />

the bottom, while the<br />

youngest is stored at the top<br />

- just the way it should be in<br />

a wine cellar.<br />

• Storage and removal<br />

through the roof of the<br />

storage cellar.<br />

• Computerized warehouse<br />

management with just<br />

one operator.<br />

• 160 flow storage lanes <strong>for</strong><br />

2,720 pallets.<br />

• Only 4300 square feet of<br />

floor space.<br />

• Environmentally friendly<br />

building into the hillside.<br />

• Reverse flow roller<br />

conveyor to the vertical<br />

conveyer <strong>for</strong> removal and<br />

transfer of stock.<br />

39


40<br />

Groka holds a stock of 900<br />

food and care products <strong>for</strong><br />

many different pets.<br />

Fast access to tasty tid-bits<br />

EXAMPLE: PET FOOD<br />

The fast moving items are<br />

consigned from a flow<br />

storage system on full<br />

pallets.<br />

Slow moving items are<br />

picked from pallets on a<br />

separate flow storage lane.<br />

Both types of pallet are<br />

conveyed by short routes to<br />

the delivery round<br />

preparation area, from<br />

where they move along<br />

short routes to the trucks.<br />

Although order picking is<br />

structured along differing<br />

lines, the central feature of<br />

this warehouse is its very<br />

clear logistic organization.<br />

• One combined flow<br />

storage system <strong>for</strong> fast<br />

and slow movers.<br />

• Short routes from the flow<br />

storage section to the<br />

delivery round<br />

preparation area.<br />

• The loading ramp area is<br />

clearly defined, with short<br />

distances <strong>for</strong> fast loading<br />

• Short routes from broken<br />

case order picking to flow<br />

storage handling.


Unpacked in a small space<br />

EXAMPLE: MOTOR SCOOTERS<br />

Riding a Vespa is fun. That<br />

is why 200 motor scooters<br />

are delivered daily to Vespa<br />

GmbH in Dierdorf.<br />

Until recently, these were<br />

packed in elaborate, costly<br />

packaging <strong>for</strong> storage.<br />

Today, a three-level spacesaving<br />

flow storage system<br />

organizes 1,620 motor<br />

scooters into 37 types.<br />

Secured to a special<br />

aluminum pallet, each Vespa<br />

is in clear view making the<br />

FIFO storage even easier.<br />

These reusable aluminum<br />

pallets are susceptible to<br />

bending and consequently<br />

are rigidized by special roller<br />

rails with zero-pressure<br />

accumulation with<br />

separators at the removal<br />

point.<br />

A concept with many extras:<br />

• Special centering guides<br />

<strong>for</strong> exact positioning of<br />

the aluminum pallets<br />

during storage.<br />

• Mechanical speed<br />

controller <strong>for</strong> gentle,<br />

impact-free movement.<br />

This is important, since<br />

the loaded pallets are top<br />

heavy.<br />

• Zero-pressure<br />

accumulation of the<br />

pallets <strong>for</strong> removal.<br />

• Precise lateral support to<br />

correct the wandering<br />

tendency of the unevenly<br />

loaded pallets.<br />

41


42<br />

Two birds with one stone<br />

EXAMPLE: OFFICE FURNITURE<br />

Dyes supplies office<br />

furniture - cabinets and<br />

desks - to over 150 outlets.<br />

In the shipping<br />

preparation department,<br />

various items are<br />

stored, productseparated,<br />

and<br />

warehoused in a<br />

1,250 pallet position<br />

system. To ship<br />

these are removed<br />

in a fully automatic<br />

system.<br />

A special foamed plastic<br />

material pallet, required an<br />

unusual engineering<br />

solution, which was<br />

successfully achieved with<br />

some fine tuning.<br />

This flow storage system<br />

has the dual function of<br />

serving as a buffer, to<br />

eliminating production<br />

congestion, and <strong>for</strong><br />

preparing delivery<br />

schedules.<br />

An interesting project<br />

requiring specific expertise.<br />

• Separator designed <strong>for</strong><br />

pallet weights of 88 lbs,<br />

176 lbs and 330 lbs.<br />

• Turnover of 700 items of<br />

furniture daily.<br />

• Smooth transport of<br />

delicate furniture on<br />

special pallets<br />

• High density storage <strong>for</strong><br />

limited floor space.


Transverse storage in half<br />

the space with double the<br />

removal rate<br />

EXAMPLE: BEVERAGES<br />

Henniez has an output of<br />

almost a million beverage<br />

products each day. This<br />

volume could no longer be<br />

efficiently managed using<br />

traditional warehousing<br />

technology.<br />

The most elegant solution<br />

was this flow storage<br />

system with its 1,240 pallet<br />

positions <strong>for</strong> transverse<br />

storage, combined with<br />

other advantages:<br />

• The system now takes up<br />

only half the warehouse<br />

floor space, half the time<br />

to pull product and<br />

simplified the warehouse<br />

management of the<br />

system.<br />

• Newly developed roller<br />

systems enable smooth<br />

transverse transport <strong>for</strong><br />

storage and removal of<br />

two pallets;<br />

simultaneously or from<br />

different flow storage<br />

lanes.<br />

• Fork-lift trucks require<br />

less turning and increase<br />

the storage space.<br />

• Virtually maintenance<br />

free.<br />

The new store was installed<br />

in only 2 weeks, during<br />

ongoing production, and<br />

commissioned in only 1 day.<br />

Henniez logistics personnel<br />

were very satisfied with this<br />

cost-effective installation.<br />

43


<strong>Interroll</strong> Canada Limited<br />

SBU Dynamic Storage<br />

1201 Gorham Street New<strong>market</strong>, ON L3y 7V1<br />

(905) 727-3299<br />

DESIGN CRITERIA SHEET<br />

DRAWING NUMBER: CA-0<br />

SALES ORDER NO.:<br />

CUSTOMER INFORMATION<br />

Customer End User In<strong>for</strong>mation:<strong>Interroll</strong>:<br />

Name: ________________ Name: _____________________ Due Date: ____________<br />

Contact: ________________ Contact _____________________ Initiator: ____________<br />

Telephone: ________________ Telephone _____________________ Date: ____________<br />

E-Mail address(s) <strong>for</strong> final approval of drawings: _______________________________________________<br />

DESIGN CRITERIA<br />

Pallet In<strong>for</strong>mation<br />

# Pallet/Lane ________<br />

# Lanes ________<br />

Load Weight<br />

Maximum: _________<br />

Maximum: _________<br />

Please circle the pallet type (bottom board view).<br />

Please indicate the direction of flow by an arrow.<br />

Pallet Size<br />

Pallet Depth: _________<br />

Pallet Width: _________<br />

Pallet Height:_________<br />

Load Size<br />

Load Depth: _________<br />

Load Width: _________<br />

Load Height: _________<br />

(including pallet)<br />

Load Secured:________<br />

GMA Pallet Block Pallet Single Face Pallet 9 Point Pallet Slave Pallet Other<br />

Material… ________________<br />

Manufacturer:________________<br />

System Parameters<br />

System Type<br />

Skatewheel:<br />

Logix 2000:<br />

Logix 4000:<br />

Diameter: ________<br />

B.F.R.<br />

Outer Track: ________<br />

Centre Track: ________<br />

Roller: ________<br />

Slope<br />

7/16”:<br />

3/8”:<br />

1/2”:<br />

Other: _____<br />

Pallet Separator<br />

Automatic: _____ Manual: _____<br />

Location in Lane ___________<br />

Attached<br />

<strong>Interroll</strong> Quote: ________________<br />

Customer Drawings: ________________<br />

Temperature °F or °C<br />

Ambient: ________<br />

Freezer: ________<br />

Cooler: ________<br />

Humidity: ________<br />

Centres<br />

Brakes # per Lane: ___<br />

Outer Track: ________ Heavy / Medium / Light<br />

Centre Track: ________<br />

Roller: ________<br />

Underslung<br />

Tandem<br />

There are ____bottom boards ____”wide.<br />

Bottom deckboards in relation to travel:<br />

Parallel Perpendicular<br />

Lane<br />

Rack Drawing: ___________________<br />

Copy of PO: ___________________<br />

Lane Length: ________<br />

Rail Height: ________<br />

Max Rail: ________<br />

Impact Length: ________<br />

Wedge Stops<br />

Cast Iron 4” Wedge Steady<br />

Dired Full Width Roller Floor Mount Welded Full Width Full Width<br />

Removing pallet from <strong>for</strong>ks at charge end:<br />

Picking pallets at discharge end:<br />

Additional In<strong>for</strong>mation: ________________________________________________________<br />

________________________________________________________________________________<br />

________________________________________________________________________________<br />

Pawl


D Y N A M I C S T O R A G E<br />

Europe/Nordic<br />

Denmark<br />

<strong>Interroll</strong> Nordic A/S<br />

Hammerholmen 2-6<br />

DK-2650 Hvidovre<br />

Tel.: +45 36 88 33 33<br />

Fax: +45 36 88 33 72<br />

dk-sales@interroll.com<br />

Also responsible <strong>for</strong>:<br />

Finland, Iceland, Norway,<br />

Sweden<br />

Western/Southern Europe<br />

France<br />

<strong>Interroll</strong> S.A.S<br />

SBU Dynamic Storage<br />

310 Rue du Clair Bocage<br />

B.P. 255<br />

Mouilleron le Captif<br />

F-85006 La Roche sur Yon<br />

France<br />

Tel.: +33 251 37 12 32<br />

Fax: +33 251 37 05 78<br />

dynamicstorage@interroll.com<br />

Italy<br />

Rulli Rulmeca S.p.A.<br />

Via A. Toscanini, 1<br />

I-24011 Almè (Bergamo)<br />

Tel.: +39 035 4300111<br />

Fax: +39 035 545523<br />

i-sales@interroll.com<br />

Portugal<br />

Rulmeca <strong>Interroll</strong> de Portugal Lda<br />

Apartado 69, Centro Civico<br />

P-6201-909 Covihã<br />

Tel.: +351 275 330 780<br />

Fax: +351 275 330 789<br />

p-sales@interroll.com<br />

Spain<br />

<strong>Interroll</strong> España S.A.<br />

C.I. Santiga<br />

C/Puig dels Tudons, 5<br />

E-08210 Barbera del Vallès<br />

Tel.: +34 93 729 96 50<br />

Fax: +34 93 718 96 50<br />

e-sales@interroll.com<br />

United Kingdom<br />

<strong>Interroll</strong> Ltd.<br />

Sales Office Dynamic Storage<br />

Brunel Road<br />

Earlstrees Industrial Estate<br />

GB-Corby,<strong>North</strong>ants NN17 4UX<br />

Tel.: +44 1536 74 85 65<br />

Fax: +44 1536 74 85 74<br />

dynamicstorage@interroll.com<br />

Central Europe<br />

Germany<br />

<strong>Interroll</strong> Fördertechnik GmbH<br />

Höferhof 16<br />

D-42929 Wermelskirchen<br />

Tel.: +49 2193 2 31 36<br />

Fax: +49 2193 2 31 22<br />

d-sales@interroll.com<br />

Also responsible <strong>for</strong>:<br />

Austria, Belgium, Luxembourg,<br />

Netherlands, Switzerland, Greece<br />

Eastern Europe<br />

Germany<br />

<strong>Interroll</strong> Fördertechnik GmbH<br />

Höferhof 16<br />

D-42929 Wermelskirchen<br />

Tel.: +49 2193 2 31 81<br />

Fax: +49 2193 2 31 22<br />

d-sales@interroll.com<br />

Also responsible <strong>for</strong>:<br />

Hungary, Slovakia,<br />

Czech Republic<br />

Poland<br />

<strong>Interroll</strong> Polska Sp.z.o.o<br />

ul. Plochocińska 85<br />

03-044 Warszawa<br />

Tel.: +48 22 741 741 0<br />

Fax: +48 22 741 741 1<br />

pl-sales@interroll.com<br />

Turkey<br />

Rol-er Makina SAN. VE TIC. A.S.<br />

Pembegul Sok.<br />

Dostlar Apt. No. 12D. 10<br />

Suadiye 34740<br />

Istanbul, Turkiye<br />

Tel.: +90 216 386 37 75<br />

Fax: +90 216 386 38 22<br />

tr-sales@interroll.com<br />

Near East<br />

Israel<br />

ComTrans-Tech Ltd.<br />

P.O.B. 17433<br />

Tel-Aviv 61174<br />

Israel<br />

Tel.: +972 54 4 27 27 47<br />

Fax: +972 3 7 44 08 64<br />

avi@comtranstech.com<br />

Africa<br />

<strong>Interroll</strong> reserves the right to modify technical characteristics of all its products at any time.<br />

Technical in<strong>for</strong>mation, dimensions, data and characteristics are indicative only.<br />

South Africa<br />

<strong>Interroll</strong> S.A. Pty Ltd.<br />

P.O. Box 3 27<br />

Isando 1600<br />

ZA-Gauteng<br />

Tel.: +27 11 974 19 01<br />

Fax: +27 11 974 18 96<br />

za-sales@interroll.com<br />

<strong>North</strong> America<br />

Canada<br />

<strong>Interroll</strong> Dynamic Storage<br />

1201 Gorham Street<br />

CDN-New<strong>market</strong><br />

Ontario L3Y 8Y2<br />

Tel.: +1 905-727-3399<br />

Fax: +1 905-727-3299<br />

cdn-sales@interroll.com<br />

USA<br />

<strong>Interroll</strong> Corporation<br />

Tel.: +1 877-596-9870<br />

cdn-sales@interroll.com<br />

South America<br />

Brazil<br />

<strong>Interroll</strong> Logistica<br />

Elementos para Sistemas<br />

Transportadores Ltda.<br />

Av. Alexandrina das Chagas<br />

Moreira 945<br />

Bairro Distrito Industrial<br />

Pindamonhangaba - SP<br />

CEP 12412-80D<br />

Brasil<br />

Tel.: +55 (0)12 3648-8021<br />

Fax: +55 (0)12 3648-8164<br />

sa-sales@interroll.com<br />

Asia<br />

China<br />

<strong>Interroll</strong> (Suzhou) Co. Ltd.<br />

Unit 10B, Modern Industrial Square<br />

No. 333 Xing Pu Road<br />

Suzhou, Jiangsu Province<br />

People’s Republic of China<br />

Postal Code: 215126<br />

Tel.: +86 512 6256 0383<br />

Fax: +86 512 6256 0385<br />

cn-sales@interroll.com<br />

Japan<br />

<strong>Interroll</strong> Japan Co. Ltd.<br />

302-1 Shimokuzawa<br />

Sagamihara-shi<br />

JPN - Kanagawa 229-1134<br />

Tel.: +81 42 764 2677<br />

Fax: +81 42 764 2678<br />

jpn-sales@interroll.com<br />

Korea<br />

<strong>Interroll</strong> Korea Corporation<br />

Room 301, Dongsan Bldg. 333-60<br />

Shindang-Dong, Choong Ku<br />

Seoul<br />

Tel.: +822 22 31 19 00<br />

Fax: +822 22 54 36 83<br />

kr-sales@interroll.com<br />

Singapore<br />

<strong>Interroll</strong> (Asia) Pte. Ltd.<br />

386 Jalan Ahmad Ibrahim<br />

629156 Singapore<br />

Republic of Singapore<br />

Tel.: +65 6266 6322<br />

Fax: +65 6266 6849<br />

sgp-sales@interroll.com<br />

Thailand<br />

<strong>Interroll</strong> DS Asia Pacific Co., Ltd.<br />

Amata Nakorn Industrial Estate<br />

700/685 Moo 1, Phanthong District<br />

Panthong, Chonburi<br />

Thailand 20160<br />

Tel.: +662 337 0188-91<br />

Fax: +662 337 0192<br />

s.brown@interroll.com<br />

Australia & New Zealand<br />

Australia<br />

<strong>Interroll</strong> Australia Pty. LTD.<br />

8 Villas Road<br />

Dandenong South<br />

Victoria 3175<br />

Australia<br />

Tel.: +613 9706 44 95<br />

Fax: +613 9706 44 85<br />

s.brown@interroll.com<br />

Also responsible <strong>for</strong>:<br />

New Zealand<br />

www.interroll.com<br />

12/08

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