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Spaceways fits out new distribution centre

When it came to choosing a company with innovative designs, fast response times and attention to detail for its distribution centre at its new headquarters in Ryde, Isle of Wight, Liz Earle Beauty Co, manufacturers and distributions of the fast expanding Liz Earle Naturally Active Skincare, turned to the Spaceway Group. Now Romsey based Spaceway, a leading UK provider of integrated interior space solutions, has completed the fit-out of the distribution centre, which encompasses 196 square metres of warehousing and a 102 square metre picking and production area.

Britain's largest independent beauty brand, Liz Earle Naturally Active Skincare has experienced year on year growth since it was founded in 1995. The UK growth in the business along with the launch of the range into the USA, Germany and Australia last year necessitated Liz Earle Beauty Co expanding into new premises in Ryde Business Park. Looking for a company that had the credentials to fit out the hi-tech central distribution centre, Liz Earle Beauty Co selected the Spaceway Group.

“We had worked with Spaceway on other projects and knew that they had the design and technical ability to provide us with a complete turnkey operation for the three areas needed in the distribution centre”, said Simon Hastain, Fulfilment Manager at Liz Earle. “Spaceway worked with us on this project for over 12 months to ensure that when we took possession of the building it could provide us with a fast turnaround which enabled us to continue to fulfil and distribute our own products and to deliver an exceptional service to our customers”.
Comprising of high bay pallet and carton live racking, shelving containers and work stations, the warehouse section of the distribution centre has been designed by Spaceway to provide the maximum number of pallet locations. In order to segregate the order picking from the forklift operations, Spaceway utilised a BITO pallet live picking tunnel with carton live storage below.

A total of 200 pallet locations have been fitted into the confined area. These comprise of 85 static single depth locations, 100 pallet locations over the picking tunnel and 15 picking pallets feeding into the picking tunnel which has 80 carton live pick faces. The configuration has been designed in order that a standard reach truck can be utilised and to guarantee first-in first-out stock rotation of date sensitive product.

When it came to designing the picking and production area, Spaceway decided that BITO carton live would provide Liz Earle with a short picking route, take up less space and aid stock rotation.

Liz Earle Beauty Co's existing picking system comprised of single box depth with multiple locations for the same product which resulting in long picking aisles making it difficult to rotate stock. The new system incorporates BITO carton live shelving for 140 of the fast moving product lines each four cartons deep. The system in contained within a picking aisle of just 12 metres long with 560 carton worth of stock immediately available.

“One of the main issues of Liz Earle's old site was the travel distances involved when order picking”, said Charlie Jeary, Sales Manager, Storage Division. “Previously the stock required a picking route of 48 metres. Now we have reduced the travel distance by 75%”.

To cater for slower moving stock, Spaceway also installed single box depth locations. In total the system can now store 976 cartons in a total of 496 locations.

To complete the installation, Spaceway designed in conjunction with Liz Earle Beauty Co four types of specialist workstations to suit the different applications. In total Spaceway has supplied a total of 50 workbenches with further orders to follow.

“Once again Spaceway pulled out all the stops to ensure the project went without a hitch”, concluded Simon
Hastain. “Everything has been designed to meet the latest Building Regulations and was skilfully carried out by the Spaceway management team”.

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