With labour markets tight, the trend to automate continues in intralogistics. Automation tends to add complexity to a mezzanine solution in two ways. Firstly, automated projects are usually larger and this scale adds challenge in terms of project management. Secondly, automated systems often mean special requirements for mezzanine floors – they may need to be stronger to support the weight of the automated kit, more rigid to allow for the sensitivity of automation to deflection, or even engineered to minimise electrostatic resistance.
For these reasons, it pays to work with a mezzanine supplier with in-house integration expertise. Experience from recent MiTek projects highlights the ways in which this can avoid delays and minimise costs for customers. Take, for example, the mezzanine solution supplied to Direct Corporate Clothing (DCC), the largest independent workwear and personal protective equipment provider in the UK, at its facility in Oldbury. Designed to support an AutoStore system with almost 130,000 bins and featuring 60 robots, the mezzanine was delivered in partnership with integrator, Dematic. When working with integrators, our design team is able to import their 3D system models directly into MiTek’s software, ensuring accuracy from the outset. In this project, which went live earlier this year, MiTek’s previous experience with AutoStore prompted a proposal for an innovative bracing solution for the mezzanine that would ensure the required rigidity at an affordable cost.
Another example that recently went live involves another leading system integrator. This solution for a UK high-street retailer features almost 25,000m2 of mezzanine in a new distribution centre. The system features the tallest non-clad-rack pallet store that the integrator has ever installed and involves considerable integration with automated systems. For this project, our team developed a new staircase design that enables pre-assembly to make installation easier and faster. Given that the new DC has some 350 staircases, this innovation secured considerable time and cost savings. Other unusual requirements catered for in this project include additional load-spreading beams installed on top of the mezzanine to support pallet conveyor loads; extra loading on protective fencing; minimum clearance height below the mezzanine, achieved through the use of shallower beams; additional steelwork in selected areas to support Davit-arm cranes; and taller columns for pit areas in the building.
Largest project to date
Even bigger in scale was the brand-new warehouse for UK retailer, Next, in South Elmsall, which went live last year. This was MiTek’s largest mezzanine project to date, totalling over 100,000m2 and reaching 24m in height. We worked closely with automation provider, KNAPP to deliver the five-storey solution, which required integration with various automated technologies including overhead garment conveyors, tote conveyors, spiral conveyors and elevators. To facilitate the installation of the spiral chutes into voids between the floors, our design team engineered special supporting steelwork to help lift in and position the chutes. Due to the multi-level nature of the project, we also incorporated special connections between columns and beams to minimise installation time.
Our most recent UK project is not nearly so large but, with seven levels and a considerable amount of automation, still required our in-house engineering expertise and meticulous planning. Supplied to a major dairy products manufacturer in Shropshire, the solution features both chilled and ambient temperature zones. As in all MiTek projects, the customer has benefited from having a single, dedicated point of contact throughout and clear communication via weekly calls. Professional project management ensures the most time-efficient design and build programme – particularly important in installations with automated systems, where many contractors are on site at the same time – to secure the earliest possible return on investment.
Early engagement pays dividends
Automation is always evolving, so there is a need to understand the latest developments and what they mean for mezzanine design. With many qualified engineers in-house and continuous investment in R&D, MiTek is able to maintain its position as the UK’s number one mezzanine supplier. To ensure clients maximise the potential of tapping into MiTek’s expertise and experience, they should engage with us as early as possible in the life of their project; this gives us the greatest opportunity to influence the whole package – building, system integration and installation – in a way that will optimise the value of the mezzanine solution.
