Online cycle retailer consolidates DCs

After a rigorous tender process, CSL’s ability to provide a well demonstrated solution was key to meeting the brief and winning the contract. This included using the latest 3D CAD drawing software to help visualise the system as a life-like operational representation in the new building.

The brief was to combine packed consignments from 3 pick/pack areas over 3 floors and sort them down 12 lanes into 4 dispatch zones for separate carriers and services. The system needed to cope with up to 90 boxes per minute of varying sizes and weights, from very small parts and clothing up to large boxes of bicycle wheels.

The conveyor system was designed by CSL at over 900mm wide and was engineered in detail after taking into account observations by both management and operators at Wiggle, plus the vast array of shapes, sizes and weights of products to be handled and overcoming operational issues.

The mezzanine consists of 2 upper floors, which along with the ground floor, form three independent pick/pack zones and sortation areas. These were designed specifically to avoid issues caused when one combined system is stopped for maintenance/repairs.

Wiggle’s Dan Corrigan says: “As this was a new facility it was difficult to visualise the conveyor system prior to the mezzanine floor installation, but CSL provided a detailed 3D drawing which included both the mezzanine and the conveyors which brought clarity to this. The install process was smooth and the end results have allowed us to increase control, flexibility & volumes.”