Case study

Country Style

The perfect recipe for a successful design and installation

The team at Warehouse Systems Ltd know that every job comes with its own unique requirements and every so often a project comes along that pushes the boundaries even further. A perfect example of this is the recent assignment brought to them by baking and in-store bakery specialists, Country Style.

The food industry comes with many specific storage and health and safety needs which must be adhered to at all times – this means that they often have temperature controlled environments which can present some rather unusual challenges for outside suppliers who are drafted in to provide specialist manufacturing solutions.

Being a large and well established business in the bakery goods sector, Country Style has call for an extensive product storage space so that they can effectively manage their customers’ supply demands. In order to help satisfy their need for extra storage, the company asked WSL to provide a solution based on their limited space. Upon listening to Country Style’s requirements and ideas for the project; we settled on a drive-in setup to get the most out of their floor space. We looked to fit 1000 locations into a system 42 lanes wide, 6 racks deep and 4 racks high – quite staggering dimensions! However, the available room heigh fell far short of the space needed to get the 4 pallets in the height. So, with the help of our design department and highly skilled factory, we developed a super low-profile system of brackets and rails made of structural steel to give us the precious millimetres in the height needed to the most out of the project and the best result for Country Style.

But that wasn’t the biggest obstacle to overcome…

No cold shoulder for difficult racking projects

As already alluded to, an effective storage area for this business was never just going to be about getting optimum use of the space available. Once WSL had produced the bespoke brackets and drive-in rails in their factory, the real challenge began: installing them into a refrigerated area operating at minus 25°C.

This super-cold environment presented its own risks, so it was essential that the pre-installation risk assessment was conducted specifically for these conditions to ensure that the work could be carried out efficiently but safely. The methodology for the build also needed to be revised and adapted for the low temperatures, including the need for the construction team to wear special suits at all times for their protection.

As with all of their projects, WSL made sure that everything went according to plan, with 6 installers putting in 750 man hours over 3 weeks to get the racking and rails in place.
Country Style were so pleased with the finished result and the attention to detail provided by WSL, that they subsequently went on to order another 42 bays right away and a 140 sq metre mezzanine extension, complete with a sloped loading bay platform, for their premises in Long Benton, Newcastle. Another interesting project and satisfied customer!

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