From Four Walls To Full Service: A Historical Perspective Illustrating the Progression of Our Industry

Transcription

1 From Four Walls To Full Service: A Historical Perspective Illustrating the Progression of Our Industry F. Brooks Royster III, President broyster@mtccold.com (410)

2 INTRODUCTION I will attempt over the next few slides to outline from where this industry has evolved, to where our industry has progressed. This discussion will begin with industry practices of over a century ago on the lakes and rivers of America, and end up in portcentric international refrigerated DC s.

3 Ice was scored, using a horse-drawn scorer s ICE HARVESTING Men would cut along the score lines in the ice, creating long rectangles of ice.

4 CONVEYOR LIFTING ICE TO THE ICE HOUSE Harvesting ice at Wolf Lake, Indiana, in 1889, showing the conveyor belts used to lift the product into the ice house.

5 1920 s FACILITY DESIGN Cold storage facility in Washington, DC: Ice was delivered by rail directly into the building Multi-level storage facility Elevators Ability to handle truck and rail shipments

6 1920 s FACILITY DESIGN Cold storage facility in Washington, DC: Ability to load and unload cars and trucks for local deliveries.

7 1920 s FACILITY DESIGN Cold storage facility in Washington, DC: Truck dock doors with the ability to load trailers for increased product fulfillment.

8 1950 s FACILITY DESIGN Modernized facility in Baltimore, Maryland: Conveniently located outside of city limits for easier access. Entire operation is on one floor, eliminating elevator bottlenecks Architectural Drawing of Merchants Terminal Corporation Baltimore, Maryland Facility Large freezer and cooler space.

9 Modernized facility in Baltimore, Maryland: Truck parking off the street. Spacious loading dock to handle more trailers. Extra lighting for trailer and product condition inspections. Increased truck turn times. Shippers and distributors participate in Pool Car deliveries s FACILITY DESIGN

10 1950 s FACILITY DESIGN Modernized facility in Baltimore, Maryland: Freon 12 as refrigerant. Large freezer and cooler storage rooms. Ability to store 15 million lbs. of product. Adequate lighting for identifying product during placement and removal.

11 2014 FACILITY DESIGN Port of Baltimore Location: State-of-theart traditional refrigerated DC. Note the solar panels.

12 2014 FACILITY DESIGN Port of Baltimore Location: Located with accessibility by highway, rail, and port. Decrease in drayage costs to customers. Timely delivery and receipt from the pier. Max loading capability.

13 AS/RS

14 2014 FACILITY DESIGN ENCLOSED REFRIGERATED DOCK, RACKING, USDA INSPECTION ROOM, TRAILER RESTRAINT SYSTEM

15 REFRIGERATION - AMMONIA Ammonia was first used as a refrigerant in the 1850s in France and was applied in the United States in the 1860s for artificial ice production. The first patents for ammonia refrigeration machines were filed in the 1870s. By the 1900s, ammonia refrigeration machines were being commercially installed in block ice, food processing, and chemical production facilities.

16 REFRIGERATION - AMMONIA Typical 1920 s Engine Room Typical 1950 s Engine Room

17 REFRIGERATION - AMMONIA Central ammonia has been the workhorse in the industry, but has come under scrutiny due to the perceived volatility and danger of ammonia. OSHA regulations are becoming more and more stringent. Typical 2014 Engine Room

18 REFRIGERATION CO2/NH3 (Cascade) systems have grown in popularity in the states and have proven cost effective when running temps below -20F. Low charge ammonia systems are being introduced he in the states due to the increased regulations and public opinion, but are mainly popular in Europe. STAR and NXTCold are two manufacturers.

19 REFRIGERATION ELECTRICAL CONTROLS Typical 1950 s Electrical Control Panel Typical 2014 Electrical Control Panel

20 DOCK DOORS 1953 manual opening Modern Bi-fold Automatic Doors

21 Old school lights were the yellow high pressure sodium and whiter metal halide lights which ran at 440 Watts each. LIGHTS Replacement lights were fluorescent high bays with motion sensors for instant on and instant off (but did not work as well in temps below 40F). They run about 240 to 350 watts each. Newer school for cold storage are LED lights with instant on and off as well as computer controls for each individual light. They run about 110 to 150 watts each and excel in cold temps. Payback can be in range of 1 to 7 years depending on use and fixture being replaced.

22 DOCK LEVELERS Dock plates were used most frequently on open air docks and were manually placed on the dock into the trailer floor. Old school pit style levelers leaked a lot of air.

23 DOCK LEVELERS New Vertical Pits are easier to clean around and save over 50% of the energy.

24 BLAST TUNNEL Blast freezing tunnels with capacity of 120,000 lbs. every 24 hours. Blast Tunnel MTC Logistics, Baltimore, MD 1952

25 BLAST CELL Conventional blast cell systems typically blast froze 24 to 48 pallets in a room at a time and ran temps at or near -40º F while using drive in racking and basically fixed pallet sizes.

26 QUICK FREEZE

27 1915 MATERIAL HANDLING EQUIPMENT

28 1924 MATERIAL HANDLING EQUIPMENT 1924: The World's First Forklift First shipment of a Duat (Clark) with an optional tiering attachment. This modified Duat became the world's first internal combustion fork lift truck.

29 1960 MATERIAL HANDLING EQUIPMENT By the late 1950s and early 1960s, forklift manufacturers began to offer options for load backrests and operator cages. These items eventually became standard.

30 Stand Up Narrow Aisle Reach Truck: Able to reach high racks Safety guard to protect employees Pantograph attachment for reach-in pallet placement MATERIAL HANDLING EQUIPMENT

31 WAREHOUSE MANAGEMENT SYSTEMS Earlier years: Order process performed by either fax or verbal techniques. Product information was recorded manually. Information manually inputted into the WMS. Printed on multi-part paper and mailed or faxed.

32 WAREHOUSE MANAGEMENT SYSTEMS More modern WMS systems: Consist of hand-held barcode scanners and forklift mounted equipment that enable the capture of real-time electronic inventory management. Capture more product information. Provide improved inventory accuracy. Improve the efficiency of operational staff by identifying product locations within the storage locations. Track product more efficiently for traceability and recall purposes.

33 INFORMATION TECHNOLOGY 1960 s: Incoming telephone calls were answered and transferred by a switchboard operator s 1980 s: Use of more modern telephones, typewriters, and Xerox machines were introduced to better serve the customer.

34 INFORMATION TECHNOLOGY Customer orders are typically ed. Data transmitted electronically, EDI. Customers can simply log onto our website and access: Inventory history Receipts Orders Other relevant data 24 hours a day, 7 days a week and view real-time updates. Wherever they have internet access

35 INFORMATION TECHNOLOGY Web accessible inventory/order management tool: MVision TM can automatically e- mail event notifications to notify customers when carriers trucks are unloaded, inventory levels get low, or other activity involving their product. MVision TM has the ability to send data in a preformatted Excel spreadsheet that customers can quickly and easily use for their documentation or reports, or import into their own proprietary system.

36 COST OF DOING BUSINESS A standard ambient warehouse costs on the average $25 - $40/sq. ft. to build while a traditional refrigerated DC can cost upwards of $ /sq. ft. A standard ambient warehouse s electrical bill may run less than $.50/sq. ft. (month), a refrigerated D/C s electrical consumption can be as much as $2 - $3/sq. ft. A standard ambient warehouse does not typically have a trained plant engineer, a refrigeration technician, and multiple shifts to pay for the investment, while a refrigerated DC must do all of these things. So, what am I alluding to? The owning and operation of a refrigerated DC is not for the faint of heart!

37 IN CONCLUSION Cold storages have evolved into refrigerated distribution centers. Services have evolved from room rental to full logistical support. Buildings have evolved from labor intensive, less than energy efficient multi-floor buildings to rack supported fully automated structures. And, more is to come: low oxygen fire suppression, automated truck/container loading and unloading, AGV pallet movers, etc.

38 Thank you! F. Brooks Royster III, President (410)