Sargento Foods, a leading cheese manufacturer based in Plymouth, WI, partnered with Westfalia Technologies to enhance its outbound fulfillment and address critical storage challenges. Facing space limitations and rising distribution demands, Sargento implemented a high-density storage solution designed by Westfalia.
Sargento Foods faced a pressing challenge with its conventional distribution center as increasing demand outpaced available space. Concerns about future infrastructure expansion prompted the need for a solution that would extend the life of the distribution center and support ongoing growth. The company sought a way to integrate manufacturing with warehouse operations while avoiding inefficiencies like double handling and offsite storage.
Westfalia Technologies developed a tailored solution to address Sargento’s storage and fulfillment needs. By analyzing data and understanding throughput requirements, Westfalia designed a phased approach to incorporating automated storage/retrieval systems (AS/RS) and layer picking capabilities. Powered by Westfalia’s Savanna.NET® Warehouse Execution System (WES), the solution optimized order fulfillment, eliminated manual handling, and significantly increased storage capacity.
High Bay AS/RS footprint: 19,700 sq. ft.
Low Bay AS/RS Footprint: 33,756 sq. ft.
AS/RS Storage: 17,465 positions
Storage: 8-deep and 12-deep storage lanes
Outbound Order Staging: 53 lanes x 8-deep, up to 424 pallets
AS/RS directly tied to palletizing
4 S/RMs with Tandem-Pallet Satellite® in 2 aisles, 6 & 10 levels high
Automated layer picking
Automated Outbound Order Staging System
Savanna.NET® WES controlling multiple facilities (Plymouth, Kiel, and Hilbert, WI)
The implementation of Westfalia’s automation solution yielded impressive results for Sargento Foods. The company achieved increased storage density, extended the distribution center’s lifespan by up to a decade, and eliminated manual pallet handling. Automated layer picking and AS/RS technology streamlined order processing, improved floor space utilization, and enabled faster turnaround times on loading docks.
