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The Vertical Reciprocating Conveyer (VRC) Subcommittee of the Conveyor & Sortation Systems industry group is comprised of the industry’s leading suppliers of material lifts intended to meet the safety requirements of ASME B20.1 – Safety Standard for Conveyors and Related Equipment. These members design, manufacture, and install VRCs worldwide for use in a wide variety of industrial, commercial, and institutional operating environments. A VRC, Vertical Reciprocating Conveyors, also known as a freight lift, offers one of the most efficient ways of moving heavy materials up or down between two or more fixed levels. A VRC is a type of vertical conveyor and sortation system that is actuated by either electro-hydraulic or electro-mechanical means that allows you to move products between multiple levels by using a platform to lift or lower products. A VRC can be custom designed to move product between 2 to 10 levels carrying loads up to 200,000 pounds at varying speeds. A VRC is designed to move materials only and is not designed to carry passengers or an operator. VRCs are used within manufacturing, retail, wholesale, or distribution facilities where one or more overhead storage, floors or mezzanines are utilized. They are highly customizable for any operating environment and footprint size. VRCs can be operated automatically or manually, or a combination of both. There are many types of VRCs, the most popular models use mechanical or hydraulic actuation, using cables, belts, or chains to hoist their platforms. VRC’s fall under ANSI B.20 code. VRC Subcommittee members meet regularly to review, discuss and implement programs which effectively communicate and promote the safe application, design, installation and operation of vertical reciprocating lifts. The VRC Programs Include: The publication and promotion of technical literature on the application, installation, training, inspection, safe use, and maintenance of VRCs. The ongoing review of, and revision to, nationally recognized safety standards which effect vertical reciprocating lifts. The discussion and adoption of industry best practices as it pertains to the application, design, installation, and safe operation of VRC equipment. The preparation and distribution of educational and promotional materials which explain the benefits of VRC equipment solutions. The regular review and discussion of regulatory and legislative activity – at the federal, state, and local levels – which may effect the vertical reciprocating lift industry, and respond to that activity as an industry when deemed necessary. The establishment of liaison relationships with those private and governmental agencies establishing policy which effects the application and use of VRC equipment and technology.
Garlock Safety Systems’ fall prevention solutions represent over 35 years of industry experience, quality, and rigorous testing to federal standards. Garlock is driven by a passion for protecting people, their lives and their livelihoods. Garlock’s mission is simple: to build high-quality products that leave no doubt about safety and protect the most important asset - your people. The systems are installed in thousands of facilities across North America, including warehouses, distribution centers, and manufacturing plants, while protecting workers without compromising productivity. From pallet flow lanes to mezzanines, dock doors, and forklift traffic areas, Garlock delivers reliable fall protection where it’s needed most. These solutions include protective guarding, safety gates, and fully engineered systems tailored to meet each facility’s unique needs. By partnering with OEMs, and leading distribution partners, Garlock offers OSHA compliance solutions to help save lives.
SAVOYE North America is a customized logistics solutions engineering company that provides manual, semi-manual, mechanized, highly automated or robotic turn key material handling systems. These systems can include any of the technologies SAVOYE manufactures or produces (X-PTS shuttles, Goods-to-Person pick stations, Intelis conveyor, AiRVOS™ warehouse execution software, Odatio warehouse management software, Jivaro case erecting and sealing equipment). SAVOYE North America also offers integration services of 3rd party equipment consisting of high-speed case sortation conveyors, unit sortation (cross belt, tilt tray, bombay), AGVs, AMRs, mini or unit load cranes, robotics, vertical carrousels, palletizers, mezzanines, storage racking, and shelving.
DACS manufactures corrugated steel decking and fire code compliance products for warehouse and distribution facilities. DACS is the one source for patented Punch Deck®, Punch Deck® Plus and FlueKeeper®. Punch Deck open area rack deck has over 50% open surface area. Punch Deck is FM (Factory Mutual)?Approved and NFPA 13 compliant. Punch Deck Plus is open area rack deck with an open area flat cap, ideal for storage of items with legs or point loads. Punch Deck Plus is FM Approved. FlueKeeper allows your sprinkler system to function as designed by providing 3" of clearance between rack posts and stored materials. DACS offers original, heavy duty, fixed length and structural FlueKeeper models. Recently introduced Center FlueKeeper pallet dividers maintain center flue spaces between pallet loads, and Rear FlueKeeper maintains horizontal flue spaces at the back of rows of racking. DACS also offers fire barriers, solid corrugated steel rack deck and mezzanine deck.
InCord manufactures protective guarding products for material handling and warehouse storage, including protective safety netting used for rack, conveyor, and mezzanine guards. From large mesh netting systems for pallet constraint to small mesh and solid liner material used to contain debris and liquids below conveyors, InCord has a netting solution for every fall protection need. InCord manufactures custom safety netting solutions for a range of industries. Our women-owned Colchester, CT manufacturing plant is an ISO-9001 certified facility. InCord was founded in 1995 and is a Connecticut Top Workplace. To discuss an application, request a quote, or obtain technical guidance, please call (860) 537-1414 or email us at netting@incord.com. Contact a Netting Expert Directly: Brian Stevenson, VP of Sales: brian@incord.com / 502.523.5253, Jack Stevenson, Sales Manager: jstevenson@incord.com / 860.531.1086, John Belinsky, Sales Manager: jbelinsky@incord.com / 860.303.6672
BlueSkye Automation has opened an Innovation Center in partnership with LiftOne. This state-of-the-art, 6,500-square-foot facility dedicated to showcasing the latest advancements in warehouse robotics, forklift technology, and integrated solutions.Conveniently located at the LiftOne South Atlanta branch—just minutes from Hartsfield-Jackson Airport, the Innovation Center offers a fully functional warehouse environment, allowing customers to experience cutting-edge automated robotics and see how our solutions boost efficiency, maximize productivity, and reduce costs.“We’re excited to unveil the Innovation Center,” said Will Gillespie, Vice President of Operations at BlueSkye Automation. “This space reflects our dedication to driving innovation, fostering collaboration, and strengthening partnerships with leaders like Geek+, VisionNav, and others. We welcome our customers to experience firsthand how these advanced solutions can elevate their operations.”The Innovation Center serves as a dynamic space designed to further customer engagement and collaboration. Visitors can experience BlueSkye’s approach to warehouse automation firsthand, gaining valuable insight into how our solutions come to life in a real-world warehouse environment. The facility also features an impressive mezzanine that overlooks the operational space—an ideal setting for meetings, presentations, and group gatherings.To discover more about the Innovation Center watch the video.
FOR IMMEDIATE RELEASE – CARLSTADT, NEW JERSEY / – APRIL 28th, 2025 – Element Logic®, one of the world’s largest AutoStore integrator and a leading global provider of automated warehouse solutions, is proud to announce the acquisition of ABCO Systems. ABCO Systems is a U.S.-based system integrator specializing in storage and automation solutions. This acquisition marks a pivotal milestone in Element Logic’s strategic expansion in the Americas and reinforces its commitment to revolutionizing warehouses worldwide.A powerful partnership built on shared strengthsWith over 30 years of experience in warehouse design and automation, ABCO Systems, previously owned by The Zaf Group – the family office of Mike and Robin Zafirovski, has established itself as a key automation player in the US market. Founded in Carlstadt, NJ, the company has built a strong reputation for delivering racking, pick mezzanines, storage solutions, and shelving systems - while steadily expanding its capabilities in automation. E-commerce, 3PL, retail, food and beverage, pharmaceuticals, and cold storage are some of the sectors ABCO serves. They provide tailored solutions including robotics, goods-to-person systems, and automated sortation to improve operational efficiency and scalability. Today, with approximately 50 employees, ABCO has shown tremendous growth by helping clients implement tailored, forward-thinking solutions.“We are thrilled to welcome ABCO Systems into the Element Logic family,” Krish Nathan, CEO of the Americas of Element Logic, said. “This is more than an acquisition - it is a powerful partnership. Together, we can combine ABCO’s customer relationships and expertise with our automation capabilities to provide holistic warehouse solutions tailored to the North American market.”Supporting long-term strategy to become a full-spectrum automation partnerThe acquisition continues to strengthen Element Logic’s U.S. presence. ABCO and Element Logic’s complementary offerings are perfectly positioned to accelerate the adoption of AutoStore and other automation technologies in a market still ripe for transformation.“Element Logic and ABCO create a unique and powerful company within the industry. Very few systems integrators have the ability to implement a full turn-key solution which includes anything from storage to platforms to automation and everything in between.” Seth Weisberg, CEO of ABCO Systems, said. “Most have to farm out various aspects of any given project. Element Logic now has the ability to do individual solutions in brownfield buildings if that is what is required, or an entire greenfield solution.”This acquisition aligns seamlessly with Element Logic’s long-term strategy to broaden its diverse technology portfolio and serve as a full-spectrum automation partner.“This acquisition is a significant milestone in our journey to revolutionize warehouse performance worldwide,” Ankush Malhotra, Group CEO of Element Logic, said. “ABCO’s strong market position, deep domain and industry expertise and customer-centric approach make them a perfect fit. Together, this gives us the scale to be a full-spectrum automation partner in the Americas and bring world class innovation solutions to the market and our customer base. We are delighted to have the ABCO team join the Element Logic family.”About Element Logic®Element Logic optimizes warehouse performance through cutting-edge technology, AI-driven software, and tailored solutions that enhance efficiency, accuracy, and scalability. Element Logic is a global technology company founded in 1985, with more than 900 employees across 30 countries specializing in intelligent warehouse automation, and it’s the world’s first and largest AutoStore partner.With a strong heritage rooted in innovation, Element Logic empowers businesses across industries to maximize success by automating workflows and improving logistics operations. Their unique combination of expertise, proven track record, and commitment to both, people and technology, make them the preferred partner for warehouses aiming to gain a competitive edge.At Element Logic®, people are the greatest resource. It is their bravery, passion, and reliability values that enables them to deliver smarter solutions for their customers to succeed. Optimizing warehouse performance is not just a slogan - it is their mission.Learn more at www.elementlogic.us and follow them on LinkedIn and YouTube.About ABCO SystemsABCO Systems is a full-service systems integrator specializing in end-to-end material handling and automation solutions. They design, build, and support scalable systems that combine racking, mezzanines, conveyors, sortation, robotics, pick modules, and more - tailored to the unique needs of each facility.As consumer demand accelerates and supply chains grow more complex, ABCO helps businesses stay competitive by integrating smart, flexible technologies that streamline every stage of warehouse operations - from order picking and packing to storage and fulfillment. Their solutions are built through trusted partnerships with leading automation and storage manufacturers, ensuring long-term performance and ROI.Whether modernizing existing infrastructure or developing a new distribution center, ABCO Systems is committed to guiding clients through every stage of the process - from concept and engineering to installation and ongoing support. Delivering systems and building lasting solutions.ABCO Systems was exclusively advised by Stillwater Capital Corporation.ContactAnkush | Malhotra Group CEO - Element Logicankush.malhotra@elementlogic.net | +44 7970102032Krish Nathan | CEO Americas Element Logickrish.nathan@elementlogic.us | +1 818 554 8274Seth Weisberg | CEO – ABCO Systemssethw@abcosystems.com I +1 212 242 7514Visit us at: elementlogic.us | abcosystems.net
Hinwil (Switzerland), February 11, 2025 – Fnac, a European leader in entertainment product distribution, collaborated with intralogistics expert Ferag to establish an Omnichannel Distribution Center in Lisbon, Portugal. This venture marked the second successful partnership between the two companies, following a first project in Madrid, Spain. Ferag was entrusted as the general contractor for this transformative project, which started in April 2023 and achieved operational status end of 2023.Technology Integration for Efficiency BoostFnac's new distribution center faced several challenges, including the need to streamline operations for both B2B and B2C orders within its Omnichannel framework while optimizing space utilization. Previously, the manual and semi-automated zones operated disjointedly, leading to inefficiencies and space constraints. Furthermore, the process of preparing goods for shipment to shops required significant manual labor, hindering productivity and order fulfillment.Ferag engineered a comprehensive solution designed to Fnac's specific requirements, integrating modern technologies including TGW's Stingray Shuttle System, Interroll's conveyor systems, and Sealed Air's I-Pack® packaging system to enhance efficiency and operational performance across the Omnichannel distribution process. The software integration for this system at MFC and WCS level was carried out by Ferag.Optimizing B2B and B2C ProcessesThe B2B material flow in Lisbon includes fulfillment and dispatch of the orders, originated from the 46 Fnac shops across the country. The categorized and labeled SKUs (including technology, books, music, and more) are placed into containers and transported via roller conveyor to 4 of the 6 inductions of the ferag.denisort allocated in a mezzanine-level , where the orders are fulfilled in 302 destinations. At these destinations, serving as pivotal hubs, the items undergo initial sorting in preparation for subsequent processing.Once the items are sorted, they move along the conveyor belt, transitioning to the roller conveyor system and transported to the Shuttle system, able to handle containers and cartons as well as trays weighing up to 50 kilograms. Fnac’s Shuttle System serves as a shipping buffer and sequencer until the containers are ready to be dispatched.When a truck is ready for loading, the operators release the shipments in the Warehouse Management System. The system organizes the bins from the Shuttle system in the strict sequence demanded by the receiving shops. The fully automated tote stackers label the containers and stack them onto roller cases, additionally maximizing throughput performance in the distribution center. With this process complete, the roller cases are loaded onto the trucks for immediate dispatch. On average, the distribution center loads 6 or 7 trucks per day, supported by a system capable of handling up to 700 containers per hour.Space and Cost Savings Through AutomationThe B2C material flow process begins with orders placed through the web platform, accommodating both single and multiple items per order. A standardized carton box, of a single size, is utilized for packaging, replacing the former array of sizes for simplicity and cost-effectiveness. Once items are placed in the carton, they proceed along a conveyor line to reach the I-Pack packing machine, streamlining the packaging process, making it faster, more reliable, and cost-effective. The system calculates the product dimensions in real-time, optimizing package dimensions, reducing order volume and shipping costs. Cartons are then labeled automatically with shipping information, forwarded to the buffer zone before being conveyed to the shipping area for dispatch.But this is not all. In parallel, same buffer system manages return orders efficiently, ensuring seamless handling of returned items back to the provider. This streamlined process enhances efficiency and reduces complexities associated with varying carton sizes and by using one zone for different functions, ultimately improving overall logistics operations.Future-proof Logistics Solution for FnacThe successful implementation of Ferag's intralogistics solution at Fnac's Omnichannel distribution center in Portugal yielded remarkable results. “With a focus on integrating manual and semi-automated zones intelligently, Ferag overcame operational challenges while delivering tangible benefits in terms of efficiency, space utilization, and scalability” says Tiago Figueirôa, e-Commerce, Supply Chain & Logistic Director at FNAC Portugal.Ferag's solution provided numerous benefits. Productivity increased exponentially, with the labeling process achieving a five-fold improvement compared to previous methods. By employing the Shuttle Buffer, space utilization was optimized, resulting in space savings within the distribution center. The modular design of the solution ensures scalability, allowing for seamless future expansion to accommodate Fnac's evolving needs.Ferag's collaboration with Fnac exemplifies its expertise as a system integrator and reinforces its position as a key player in the intralogistics industry. “By leveraging innovative solution design and fostering a collaborative partnership with other intralogistics providers and the Fnac’s Supply Chain specialists, we have demonstrated our commitment to delivering tailored solutions that drive operational excellence and business growth to our customers” says Alberto Mateos Sánchez, Sales & Customer Service Manager at Ferag. “We have empowered Fnac to achieve new efficiency and performance in its Omnichannel distribution operations, setting a new standard for retail logistics”.About FeragHeadquartered in Hinwil/Zurich, Ferag AG is a renowned Swiss family-owned company that has been a global leader in the development of conveying and processing systems for the printing industry for over 65 years. Since January 2025, the company has been restructured into two independently operating entities: Ferag GraphiX and Ferag Solutions.Ferag Solutions focuses on developing innovative conveying, sorting, and automation solutions for intralogistics. As a system integrator, consultant, and innovator in the field, we design, manage, and coordinate complete in-house logistics systems. Our core mission is to provide tailor-made solutions that enhance efficiency and flexibility across a wide range of industries. We offer comprehensive supply chain solutions for e-commerce, omnichannel distribution, as well as postal and 3PL automation.Our product portfolio includes the powerful ferag.doWarehouse software for warehouse management and process automation, complemented by innovative hardware solutions such as the ferag.skyfall pouch sorter and the ferag.denisort sorting solution. These cutting-edge technologies stand out for their flexibility, innovation, and scalability, providing significant value to businesses in an increasingly digitalized and automated world.Ferag Solutions operates across the world with dedicated sales and service teams to address the specific needs of local markets. Our Technologies division continuously drives research, development, and innovation, always with a strong focus on market and customer needs.With references in over 50 countries worldwide, Ferag Solutions is ideally positioned to take a leading role as a system integrator, consultant, and innovator in intralogistics.ContactFranziska GrafHead of Global Marketing & CommunicationT: +41 44 938 60 00D: +41 44 938 76 33Franziska.Graf@ferag.com
Waukesha, WI – December 2, 2024 – Wildeck, Inc., a leading manufacturer of industrial work platforms (mezzanines), vertical reciprocating conveyors (VRCs), rideable material lifts (RMLs), custom ladders, access platforms, and safety guarding products, is excited to announce the completion of its new corporate headquarters and innovation center in Waukesha, Wisconsin. Located at 1900 E. North Street, the new campus spans over 21.97 acres, and is triple the size of the previous headquarters, which Wildeck operated at 405 Commerce Street (also in Waukesha) for nearly four decades.VJS Construction Services led the construction and design for Wildeck’s new 40,000-square-foot office which includes state-of-the-art, new facilities for training, research, and customer engagement. Wildeck’s new office connects to an expansive manufacturing space which has involved recent capital investments, including an automated powder coat paint line, automated structural steel fabrication line, and fiber laser.Remaining in Waukesha, a hub of skilled manufacturing talent, was crucial to Wildeck. With deep roots in Southeastern Wisconsin, the company is proud to contribute to the area’s strong manufacturing tradition and benefit from its skilled labor pool. Located conveniently off I-94, the new headquarters ensure an easy commute for Wildeck’s employee-owners, most of whom live nearby.Dan Lorenz, President of Wildeck, emphasized the significance of the new headquarters: “Our new headquarters is a game-changer for Wildeck, helping us attract top talent, offering a prime space for customer tours, and providing a cutting-edge training facility to ensure our team’s continued excellence. We’re grateful to VJS Construction Services and the city of Waukesha for their support in making this project a smooth success.”The new facility not only supports Wildeck’s operational growth but also strengthens its role as a top employer in the region, regularly hiring manufacturing positions including welders, material handlers, machine operators, and painters, largely from the Waukesha area. The company’s expanded headquarters enable the development of new and innovative products, the ability to attract top industry talent, and best-in-class training resources for dealer partners.“VJS Construction Services is proud to have led construction for Wildeck’s new facility, supporting their growth and creating job opportunities for Waukesha and nearby communities,” said Katherine Kawczynski, Partner and Director of Architecture at VJS Construction Services.As Wildeck embarks on this new chapter, the company remains committed to driving innovation and providing superior solutions to its customers across the country. The company looks forward to continued collaboration with the city of Waukesha and other local partners as it grows its footprint and impact in the region. Images of its new headquarters can be found here: www.wildeck.com/wildeck-completes-move-to-new-wi-hqAbout Wildeck, Inc.Wildeck, Inc. headquartered in Waukesha, WI, is a subsidiary of Holden Industries, a 100 percent employee-owned company. Founded in 1976, Wildeck has grown to become a leading manufacturer of industrial mezzanines, material handling lifts, and safety guarding products in the United States. With a focus on safety, quality, and innovation, Wildeck supports warehouses, distribution centers, and manufacturing facilities nationwide. For more information, visit www.wildeck.com.About VJS Construction ServicesBased in Pewaukee, Wisconsin, for more than 76 years, VJS Construction Services has served as a leading general contractor, construction manager, and design builder, playing a pivotal role in shaping and revitalizing communities throughout Wisconsin. Their areas of expertise span various sectors, including K-12 Education, Higher Education, Senior Living, Multi-Family Housing, Corporate, Civic and Community, Manufacturing/Industrial, Aviation, Religious, Retail and Hospitality, and Healthcare markets.ContactDan LorenzPresidentinfo@wildeck.com
The mezzanine platform from Steel King is a combination of single and two-level platforms that creates a triple-mezzanine structure, providing more than 230,000 square feet of working space to support operations, conveyor and vertical lift module (VLM) picking stations along with other means of automation.
An international fashion retailer faced a capacity squeeze in its main store replenishment distribution center. To support the company’s throughput and storage needs, Swisslog configured a four-aisle, 16-level CycloneCarrier system with inbound and outbound elevators on each aisle. The system stores approximately 50,000 totes and is connected to the goods-to-person picking center located on the warehouse mezzanine by a 7,000-foot conveyor system. The entire system is controlled by Swisslog’s SynQ software, which is integrated with the customer’s ERP system.
A project located in Manchester, U.K. had a three level mezzanine with 220,000 sqft per level. The flooring system that was selected was 3/4" ResinDek HD with the TriGard® ESD finish and corrugated steel decking.
A German-based chain of discount supermarkets has worldwide operations with more than 9,000 stores in different parts of Europe. To properly service these stores, high efficiency warehouse distribution centers are required within a short distance. The mezzanine had to store large heavy pallets of dairy products that had to be moved about with an electric pallet truck. ResinDek® MAX was chosen because of its economical solution and its exclusive warranty.
A structure consisting of vertical posts, horizontal floor beams, and a flooring surface that provides additional usable space by taking advantage of the unused vertical clearance within a building. Unlike a building ‘mezzanine’, it is not considered a permanent part of the building.
A stand alone mezzanine structure constructed within an existing building or structure which is designed to maximize clear space under and above the mezzanine. Also referred to as a "free standing, wide span mezzanine", this type of mezzanine incorporates wide column spacing and high PSF (pounds per square foot) capacity. Usually engineered for a specific need.
A mezzanine storage system built as an integral part of a building's structure. Generally put into the initial design of a building to serve a specific purpose. This type of mezzanine can utilize the building's structure for support and therein can incorporate wider span between support columns and thereby increasing the clear span of the system.
A standardized, pre-fabricated mezzanine structure built in "packaged"/"off the shelf" sizes, loading capacities and spans. Usually limited to lighter PSF (pounds per square inch) capacities and rapid delivery and rapid installation are benefits of the modular mezzanine.
This is a paid advertisement. Panel Built mezzanines provide a cost-effective solution for maximizing vertical space, creating additional levels within a building without extensive construction. They are quick to install and can be customized to meet specific needs, making them ideal for expanding storage, offices, or equipment areas.
This is a paid advertisement. There are many things to consider when choosing a mezzanine floor. Will it need to be flexible for future modifications? Is saving time and money important? Is an ergonomic solution required? Will robotic fleets be present? How will the flooring product impact the environment? This video includes feedback from industry experts to help highlight the differences of ResinDek® flooring compared to concrete on elevated platforms. Watch Now!
This article, which first appeared in MHI Solutions, Q1, 2016, provides guidance on integrating barrier protection with ergonomic equipment as a means to avoid injury in the workplace. Workcells, machinery, assembly lines, conveyors, walkways, and mezzanines are all areas in which barriers and ergonomic equipment should be considered. The article also provides guidance on selecting the appropriate safety equipment for your application.For more information, visit the Protective Guarding Manufacturers Association (ProGMA) at https://www.mhi.org/progma.
To complement a new educational video, thought leaders representing the Protective Guarding Manufacturers Association (ProGMA), an MHI product group, discuss the importance of protecting personnel, equipment, and inventory in industrial facilities.ProGMA has recently launched the second in a series of videos about the importance of protective guarding products in the material handling industry. The video titled “Proper Safeguarding for Elevated Work Platforms” followed the inaugural, educational video titled, “Essential Safety Barriers for Automated / Robotic Workcells”. (http://www.mhi.org/progma/videos)Here, representatives of member companies expand on the themes explored within the latest video in the group’s first blog.Before we start, says Arlin Keck, corporate research and development engineer at Steel King (a manufacturer of pallet racks, mezzanines and guardrails), it’s important to clarify what we mean by “mezzanine” in this context. “The technical term for what my company and other members make is work platforms. Mezzanine was an old term for these systems; however, the word mezzanine had to be dropped because mezzanine, as defined in the building codes, refers to a specified type of floor within a building structure and carries with it added requirements for fire safety, egress, parking, and so on,” Keck explains.A typical work platform is design to support the site-specific load that will be placed on the floor, be it palletized loads, pallet jacks, foot traffic, work equipment, filing cabinets, racking or shelving units, to name just a few possibilities.Keck says that the main purpose of an elevated work platform is to add additional floor space into a building or room by taking advantage of surplus ceiling clearance that may exist in a warehouse or manufacturing facility. Aaron Conway, president at Mezzanine Safeti-Gates Inc. (a manufacturer of safety gates to secure the ledges of pallet drop areas on mezzanines and rack picking systems), says, “A company that has utilized all of its ground space can build upward. An elevated platform allows one to use the space for workflow or to store product.”As Hue Schlegel, director of marketing at Wildeck Inc. (a manufacturer of mezzanines and work platforms), puts it, “Move up, not out.” He adds, “Depending on the available height in a building, platforms can be one, two, or three levels high, with the most common height being 10 ft. top-of-deck and supporting a floor load of 125 lbs. per square foot. Their length and width are only limited by facility size.” Importantly, he explains, they cannot occupy more than two thirds of a fire-rated area within a building.Keck says work platforms are also used to create catwalks between separated platforms, and to serve as sortation and conveyance areas for mechanized systems. Conway agrees, adding, “Companies that supply elevated work platforms can fabricate them in virtually any configuration. They can be designed to accommodate specific workflow operations or to fit with existing structures in the building.”Industrial buildings are getting bigger and elevated work platforms are scaling up with them. Say, 50 years ago, facilities were much smaller and ceilings lower so there were fewer requirements for elevated platforms. Further, the equipment to load at such heights didn’t exist. Now, the capability of equipment is greater and taller structures are being utilized as a result. Within them, work and storage takes place on multiple levels.These multi-level work platforms present a danger of personnel and objects falling from height.As the latest video warns, the pallet drop area of elevated work platforms can lead to accidents if the ledge is open without adequate guarding. Falls to lower levels cost employers $5 billion annually in compensation claims in the U.S. alone. OSHA reports that it costs on average 16 lost working days per injured employee.Conway says, “Falling from an elevated level, whether it be people or products, is a serious danger and both should be addressed proactively, securing the situation before an incident occurs.” Schlegel adds, “The worst case, of course, is death; while the best scenario is that a worker survives a fall from the typical mezzanine height of 10 ft. sustaining only broken bones, fractures, and other injuries from hitting the concrete floor below. It is a serious matter not to be taken lightly.”Traditional railing or guarding systems are effective at preventing falls from height as long as they include a kick plate that is installed in conjunction with ANSI MH 28.3-2009. Adding netting or expanded metal and safety products to traditional railing systems provides added protection by capturing small objects that might otherwise fall into the work area below.OSHA Standard 1926.502, meanwhile, requires paneling or screening where tools, equipment, or materials are piled higher than the top edge of a toe-board or kick plate. ProGMA members also manufacture both netting and wire mesh panels that comply with that standard.However, David Brentz, chairman of ProGMA and vice president of member company Industrial Netting (a manufacturer of plastic netting), says, “That’s only a minimum requirement; added protection is financially prudent. The cost to install netting or wire screens around the perimeter of an elevated work platform pales in comparison to the cost of a single lost time accident. ProGMA members offer several simple, cost effective solutions to protect employees below loose objects that may fall or be kicked off work platforms.”Conway says, “In the past, properly guarding a pallet drop area or installing netting or wire was something that would be retrofitted, either after an incident occurred or after someone pointed out the issue. Designing proper safety guarding for the structure at the time of purchase makes for a much better fit; when retrofitting, there is often insufficient room for proper guarding and concessions have to be made. But, it is important to note that even if proper guarding wasn’t designed with the structure, it still should be installed. There are companies in the ProGMA that can customize solutions to fit these areas.”He continues, “Don’t confuse luck with judgment. If I visit a facility that was built, say, 20 years ago, I’m sure to find open pallet drop areas or insufficient guardrails. Just because these areas have been around for a while isn’t a reason not to properly secure them. I’ve heard the line, ‘Well, we’ve been doing it this way for 20 years and nobody has gotten hurt’. To that I say, ‘You’ve been lucky!’”Schlegel says, “The biggest safety risk is when a forklift access gate on mezzanine is left open creating a fall hazard for someone off-loading a pallet at the upper level. There are many products, provided by ProGMA members, that prevent the gate from being left open or that keep the operator at a safe distance, which should always be installed.”ANSI says, “Any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift up, leaving an unprotected opening in the guarding are not acceptable.”Dual gate systems such as a rolling gate ensure that the operator is separated from the ledge as well as the load. A pivoting gate ensures the operator is never exposed to the ledge and does not require him or her to walk near an open ledge to operate the gate.Unfortunately, sometimes it can take an incident and a facility to be shut down during an investigation for companies to understand the serious financial consequences of a workplace injury. There are many other companies that understand the risks and proactively secure their work areas. These diligent companies end up ahead in the long run:1. They typically get better solutions because they had the time to design them correctly;2. They get a better price because they can take their time and research the solutions;3. Safety solutions are in place before they need them.Conway concludes, “The large majority of people don’t want to get hurt and are not acting recklessly on the job. Typically, they are performing a repetitive operation, and in their process miss a step or push something too far and someone gets hurt. Proper guarding should be in place to prevent injury if this happens.”About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at http://www.mhi.org/ProGMAAbout MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals. http://www.mhi.orgContactAnupam Berry Boseabose@mhi.org704-676-1190
The Protective Guarding Manufacturers Association (ProGMA) has published a blog to supplement its latest video on safety at pick modules. The video can be viewed at mhi.org/progma/videos.Here at ProGMA, we have produced a series of educational videos on protective guarding equipment in the material handling industry. ProGMA members provide fixed protective guarding products to protect personnel, equipment, and inventory in industrial facilities. A variety of such items are designed for installation at pick modules, which are multi-level structures typically constructed out of pallet rack that allow multiple pallets of product to be stored, broken down, picked, and packaged into specific orders for shipping.Our video is targeted at end users, system integrators, material handling warehouse design consultants / engineers, distributors, and safety professionals in manufacturing and distribution centers in the material handling industry, as well as students studying the sector. Many household and industrial goods we interact with every day were once stored or passed through a pick module. At the distribution centers of companies like CVS Pharmacy and Rite Aid Corporation, for example, goods are stored before being repackaged and shipped to individual stores.As the 2:23min-long video says at the outset, pick modules can have several elevated levels of materials that are handled by both automation and personnel. Although everything in the material handling industry is becoming more automated, separation of full stored cases into smaller, individual shipments is still being completed manually. The size of pick modules has been increasing over the years; in the past, you may have seen a floor plus one level system, then a floor plus two levels, and now it is not uncommon to see three or even four elevated levels. This increases potential hazards.As the video continues, it is of paramount importance that proper guarding is used from the ground up to protect structures, the product they hold and, most importantly, the people working within and around them. Rack upright columns can be difficult to replace and costly to repair because often the area has to be closed off, product has to be removed, and multiple sections need to be disassembled. These components are all dependent upon one another, so if one part fails, the entire system can fail.The video highlights three “easy and affordable” solutions: Free-standing pallet rack column protectors Post cushions Bumper guardsHowever, ProGMA members offer a variety of products for ground-level protection including guardrails, bumper guards, column protectors, bollards, rack guards, and product containment enclosures (i.e., wire mesh or netting); and for upper-level protection, such as side and back product containment enclosures (wire mesh or netting) to prevent products from falling below.What does ANSI say?The video continues, and quotes American National Standards Institute (ANSI) 6.4.3, which states that “…any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift or leave an unprotected opening in the guarding are not acceptable.”However, it is important to note that there are many mezzanines that were installed before the ANSI standards were created that used more conventional gates, such as removable, sliding, or swinging systems—and that is the same for pick modules. Systems can be retrofitted to achieve conformity with current standardization. There is no grandfather clause for ANSI (or OSHA) so all systems whether new or old should follow their guidelines. Note that many of the protective guarding products found in the video and on the ProGMA site are easily retrofittable to these older systems.As the video stresses, only dual-gate systems should be used. The same gates used on a pick module are also the preferred method for securing all elevated pallet drop areas whether they are in pick modules, on mezzanines, or on elevated work platforms such as storage or production / blending areas. The ANSI standards that recommended the use of dual-gate systems were written specifically for elevated work platforms and since a pick module is a type of elevated work platform that should be applied.The video demonstrates how a dual-gate system uses two counterbalanced and interconnected gates that are configured so when the first gate at the ledge is open, the second gate behind the pallet is closed. Fixed guarding on the sides—often the frame of the pallet rack in a pick module—prevents access into the side of the areas. This allows material to be loaded into the area while keeping employees a safe distance from the ledge and the material. When the rear / operator gate is opened, the ledge gate automatically closes, maintaining a barrier at the ledge while the pallet is accessed and picked. This creates what ProGMA calls a controlled-access area so there is always a barrier between the worker and the ledge.For information, ProGMA members that manufacture such solutions include Mezzanine Safeti-Gates Inc., Wildeck, and Heartland Engineered Products. Although companies still provide swing gates for pallet drop areas where a single pallet is loaded and staged, they are not an acceptable solution according to ANSI and could potentially create a situation where they are in violation of OSHA code.A self-closing swing gate, also featured in the video, should only be used when integrated with pallet flow lanes where multiple pallets are loaded into the system. The pallet flow lanes are pitched so the pallet rolls into the storage area. This allows the gate to immediately close once the pallet is loaded. By comparison, when used for a single pallet position without flow rails, the staged pallet would hold the swinging gate open, preventing it from closing.For securing multiple deep pallet flow lanes, a dual-gate system is the preferred safety method because not only does it make sure a barrier is in place all times for fall protection, but it also keeps people out of the pallet flow lanes when pallets are being loaded. The two types of incidents we see in these areas are falls from the ledges and pallets being pushed into the legs of employees who have entered the lane. Only the dual-gate system keeps people out of the lanes when the lane is being loaded. The self-closing swing gate, however, does secure the ledge for fall protection.Hand in gloveOftentimes, a safety aspect can be used to increase productivity. For example, the self-closing swinging gate on pallet flow lanes will allow pallets to be quickly loaded into the system. Any time the lift truck operator wants to load a pallet into the area, they just push the pallet through the swinging gates. The dual-gate system has the potential of the gates being in the incorrect position for loading, meaning that the ledge gate is closed when the lift truck is trying to replenish pallets into the area. So they can go to load but a barrier is in place preventing them from doing so.A user can power operate these gates for remote operation but often this isn’t feasible due to the number of areas. Manual operation can actually create a safer and faster environment. The position of the gates in a dual-gate system can be used as a signal between the picker up on the platform and the lift truck operator below. In other words, when the ledge gate is closed that means the picker is picking from the pallets or the area doesn’t need to be replenished.When the picker has finished in that bay or when they notice the pallets need to be replenished in that bay, they just manually close the gate near them, which opens up the ledge gate. Now the lift truck operator can look up and see which areas are safe and ready to be replenished. This is an example of a safety system helping communications among the different workers.In conclusion, it’s evident that, despite automation, people remain at the center of activity in and around pick modules. ProGMA and its members are a one-stop-shop for leading safety solutions, whether it be for preventing hazards associated with falling boxes, product, or workers; or structural protection of the system itself from impact. As the video serves to reiterate, even in automated systems there are still people moving around the facility, either on ground level or on the elevated levels. Even if people are not used for the picking of material, there are areas where empty pallets or totes are removed that need to be guarded.The product-centric video doesn’t feature specific brands, but free-standing pallet rack column protectors, post cushions, and bumper guards are available from ProGMA members including Adrian’s Safety Solutions, A-Safe USA, Bluff Manufacturing, Boplan, DamoTech, Folding Guard, Husky Rack & Wire, Heartland Engineered Products, Jesco, McCue, Slowstop Guarding, SpaceGuard Products, Steel King, Troax, VisiPlas, Wildeck, and WireCrafters.Costs range from inexpensive, light-duty products to more expensive, heavy-duty solutions. Importantly, talking with the manufacturer about the application will help source the right product/s for the facility. No two pick modules or applications are completely alike and that’s what the member companies of the ProGMA are here to help with.The ProGMA website—mhi.org/progma—features details of 22 member companies and hundreds of solutions to help companies with older systems find protective guarding solutions to update / upgrade their pick module system.See the latest video and others in the series at mhi.org/progma/videosShould you be using a ProGMA member to enhance the safety and productivity of your pick modules?About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at mhi.org/progma.About MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals.Contact for editorial enquiries: Ashley Skidmore, askidmore@mhi.org or 704-676-1190
Guest blog by Aaron Conway from MHI Member Company Mezzanine Safeti-Gates...
This paper is to serve a brief introduction to Vertical Reciprocating Conveyors (VRC). VRCs are vertical conveyors that efficiently move material vertically between two or more fixed elevations. They are used in commercial buildings, factories, warehouses, industrial plants and retail stores or anywhere that material or products need to move from one level to another. VRCs provide fast, convenient and safe methods for transferring material to/from mezzanines, balconies, basements, and between levels in multiple story buildings.