Founded shortly after Prohibition in Bardstown, Kentucky, Heaven Hill Brands has become a leading global spirits producer. As the company’s portfolio expanded and market demands evolved, optimizing warehouse operations was crucial. Confronted with space limitations and inefficient manual processes, Heaven Hill Brands sought to implement advanced automation technologies to streamline logistics, enhance efficiency, and effectively manage their expanding range of bourbon and whiskey products.
As Heaven Hill expanded, they encountered significant challenges with limited warehouse space and inefficient manual workflows. Managing a diverse portfolio of spirits required scalable solutions to address these constraints. The potential need for multiple off-site warehouses underscored the urgent necessity for a comprehensive automation strategy to enhance storage capacity and operational efficiency.
To address their logistical challenges, Heaven Hill Brands partnered with Westfalia Technologies, a leading provider of automated storage and retrieval systems. Integrating Westfalia’s high-density Automated Storage and Retrieval System (AS/RS) and the Savanna.NET® Warehouse Execution System (WES), Heaven Hill undertook a transformative journey toward automation. This collaboration ensured the seamless integration of advanced systems with existing infrastructure, significantly improving efficiency and scalability.
High bay AS/RS footprint: 90,934 sq. ft.
AS/RS Pallet Storage: 27,313 positions
Storage: 4-deep and 6-deep storage lanes
Outbound Order Staging: 48 lanes x 10-deep, up to 480 pallets
AS/RS directly tied to palletizing
4 S/RMs with Tandem-Pallet Satellite® in 2 aisles, 9 levels high
Automated Layer Picking System
Automated Outbound Order Staging System
Savanna.NET® Warehouse Execution System (WES)
The implementation of Westfalia’s automation solutions yielded impressive results for Heaven Hill Brands. The installation of four tandem storage and retrieval machines (S/RMs) and a fully automated layer picker resulted in a 40% increase in storage capacity. Additionally, the Savanna.NET® WES streamlined warehouse processes, reducing turnaround times by 49% and facilitating the shipment of approximately 50,000 cases daily. The consolidation of operations into more efficient cycles led to a fourfold increase in shipment throughput, marking a significant advancement in operational excellence.
