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Duraflow, ls2 & ergo tilt [mar 13]

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DuraFlow, LS2 and Ergo Tilt Efficient Order Picking Systems www.Flowstore.co.uk www.Flowstore.co.uk
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Page 1: Duraflow, ls2 & ergo tilt [mar 13]

DuraFlow, LS2 and Ergo TiltEfficient Order Picking Systems

www.Flowstore.co.uk

www.Flowstore.co.uk

Page 2: Duraflow, ls2 & ergo tilt [mar 13]

2

www.Flowstore.co.uk

www.Flowstore.co.uk

DuraFlow

DuraFlow Instantly converts existing pallet rackinto carton flow rack. More cartons, more configurations - in less space!DuraFlow is a modular system of pre-assembled,multi-wheel roller track sections. The densely-packed bed of wheels provides up to 90% spaceutilisation and will improve your picking efficiency.

Quick and simple to install. DuraFlow couldn’t be quicker to install. DuraFlow caneither be fitted to an existing pallet rack or supplied in acustom made framework.Re-position a beam at the loading face to create theright slope and hook on the track sections.

To change back to beam pallet rack - simply unhookand remove the track sections.

Strong and Maintenance FreeDuraFlow is virtually maintenance free and highlydurable. DuraFlow track sections have strong, self-lubricating, spring-loaded, multi-wheel axle assemblieswith reinforced wheels.

Highly VersatileInventory management could not besimpler. Track adjustments for varying

lane widths are just not necessary for new carton sizes due to the complete bed of wheels.

Excellent return on investment (ROI)With condensed pickfaces and thus fasterpicking and better FIFO inventory, the installation can pay foritself in a short time.

DURAFLOW

Space and Time Efficiency with DuraFlow Live Storage

When using DuraFlow for mixed carton widths any combination of cartons can be used without adjustments to roller tracks – saving time and effort.

With individual narrow roller tracks, everycarton size has to have track and dividersre-positioned to suit, meaning inventorychanges take longer.

If using wide rollers, space is wasted unless cartons are the same width

as the rollers.

ANY CARTON COMBINATIONEFFICIENTLY STORED

DURAFLOW

Page 3: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

DuraFlow

DuraFlow Instantly converts existing pallet rackinto carton flow rack. More cartons, more configurations - in less space!DuraFlow is a modular system of pre-assembled,multi-wheel roller track sections. The densely-packed bed of wheels provides up to 90% spaceutilisation and will improve your picking efficiency.

Quick and simple to install. DuraFlow couldn’t be quicker to install. DuraFlow caneither be fitted to an existing pallet rack or supplied in acustom made framework.Re-position a beam at the loading face to create theright slope and hook on the track sections.

To change back to beam pallet rack - simply unhookand remove the track sections.

Strong and Maintenance FreeDuraFlow is virtually maintenance free and highlydurable. DuraFlow track sections have strong, self-lubricating, spring-loaded, multi-wheel axle assemblieswith reinforced wheels.

Highly VersatileInventory management could not besimpler. Track adjustments for varying

lane widths are just not necessary for new carton sizes due to the complete bed of wheels.

Excellent return on investment (ROI)With condensed pickfaces and thus fasterpicking and better FIFO inventory, the installation can pay foritself in a short time.

DURAFLOW

Space and Time Efficiency with DuraFlow Live Storage

When using DuraFlow for mixed carton widths any combination of cartons can be used without adjustments to roller tracks – saving time and effort.

With individual narrow roller tracks, everycarton size has to have track and dividersre-positioned to suit, meaning inventorychanges take longer.

If using wide rollers, space is wasted unless cartons are the same width

as the rollers.

ANY CARTON COMBINATIONEFFICIENTLY STORED

DURAFLOW

Page 4: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

DURAFLOWDURAFLOW

Beam Adaptor Profiles are designed and manufactured from galvanised steel sheet to exactly fit the beam dimensions of your chosen rack type.

The DuraFlow track sections then sit on an internal ledge formed into the adaptor inside each rack beam.

This system provides a continuous smooth outer face to the beam for easy location labelling. The adaptors may be re-fitted onto any other beam of identical dimensions.

Fitting DuraFlow to Pallet Racks

Steel hooks formed from 8mm solid steel sections arepre-fitted at both ends of each track section. This allowsfitting to any standard rack box beams with top facewidth from 25mm up to 50mm.

This means the tracks can be moved between standard pallet racks of the same depth, even from different manufacturers.

Robust and simple, this system allows even individual track sections to be refitted into other locationswithout additional parts being required.

STEEL HOOKS

CLEAN FLUSH FACE WITH BEAM ADAPTORS

On-Load Adaptor Profile

Off-Load& Endstop Adaptor Profile

DURAFLOW

Page 5: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

DURAFLOWDURAFLOW

Beam Adaptor Profiles are designed and manufactured from galvanised steel sheet to exactly fit the beam dimensions of your chosen rack type.

The DuraFlow track sections then sit on an internal ledge formed into the adaptor inside each rack beam.

This system provides a continuous smooth outer face to the beam for easy location labelling. The adaptors may be re-fitted onto any other beam of identical dimensions.

Fitting DuraFlow to Pallet Racks

Steel hooks formed from 8mm solid steel sections arepre-fitted at both ends of each track section. This allowsfitting to any standard rack box beams with top facewidth from 25mm up to 50mm.

This means the tracks can be moved between standard pallet racks of the same depth, even from different manufacturers.

Robust and simple, this system allows even individual track sections to be refitted into other locationswithout additional parts being required.

STEEL HOOKS

CLEAN FLUSH FACE WITH BEAM ADAPTORS

On-Load Adaptor Profile

Off-Load& Endstop Adaptor Profile

DURAFLOW

Page 6: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

DuraFlow is built to a high specification to provide versatile but robust use.

Spring-loading the spindles enables simple and easy re-positioning or replacement of the axles without theneed for tools. They can also be locked in position to resist accidental dislodgement. Available axle pitchesare in 25mm increments from 50mm upwards. • The axle thickness is 8mm, and the special coatingtechnology provides a very free-running system forsmooth flow.• The supporting side channels for each track sectionsare 1.6mm galvanised steel, to minimise deflection inorder to achieve good flow characteristics. • Spacer bars 38mm x 2mm thick galvanised steel hold

the track sections together at nom 600mm -700mmcentres along each side. These have a 3 point fixing ateach end to ensure a rigid and square framework for theaxles. • Multi wheel roller track sections 305mm and 405mmwide come ready assembled for simply laying onto existing pallet rack beams. The complete bed of wheelsmeans no continual adjustments for varying lanewidths, so inventory change is easily managed.

DURAFLOW

A Bay of DuraFlow is assembled in minutes!

DURAFLOW

DuraFlow Specifications

DuraFlow Wheel Pitch

Carton Requirements

Wheel Size 49mm diameter x 25mm wideAxle 8mm dia low friction coated steelTrack Length 25mm incremental lengthWheel Centres 50mm or 75mm standardTrack Widths No. 12 - 305mm

No. 16 - 405mmSteel Guarge 1.5mm

Wheel Pitch Min Carton Length50mm 180mm75mm 250mm100mm 350mm

To ensure smooth flow of product, cartons must be freefrom distortion and have a firm flat base.

Slide the adaptor profiles into pre-positioned beams

Check & inspect a completed bay of DuraFlow

Lay in the track sections

DURAFLOW

Page 7: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

DuraFlow is built to a high specification to provide versatile but robust use.

Spring-loading the spindles enables simple and easy re-positioning or replacement of the axles without theneed for tools. They can also be locked in position to resist accidental dislodgement. Available axle pitchesare in 25mm increments from 50mm upwards. • The axle thickness is 8mm, and the special coatingtechnology provides a very free-running system forsmooth flow.• The supporting side channels for each track sectionsare 1.6mm galvanised steel, to minimise deflection inorder to achieve good flow characteristics. • Spacer bars 38mm x 2mm thick galvanised steel hold

the track sections together at nom 600mm -700mmcentres along each side. These have a 3 point fixing ateach end to ensure a rigid and square framework for theaxles. • Multi wheel roller track sections 305mm and 405mmwide come ready assembled for simply laying onto existing pallet rack beams. The complete bed of wheelsmeans no continual adjustments for varying lanewidths, so inventory change is easily managed.

DURAFLOW

A Bay of DuraFlow is assembled in minutes!

DURAFLOW

DuraFlow Specifications

DuraFlow Wheel Pitch

Carton Requirements

Wheel Size 49mm diameter x 25mm wideAxle 8mm dia low friction coated steelTrack Length 25mm incremental lengthWheel Centres 50mm or 75mm standardTrack Widths No. 12 - 305mm

No. 16 - 405mmSteel Guarge 1.5mm

Wheel Pitch Min Carton Length50mm 180mm75mm 250mm100mm 350mm

To ensure smooth flow of product, cartons must be freefrom distortion and have a firm flat base.

Slide the adaptor profiles into pre-positioned beams

Check & inspect a completed bay of DuraFlow

Lay in the track sections

DURAFLOW

Page 8: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

DURAFLOW

DuraFlow AccessoriesVery few accessories are required for DuraFlow applications, since the complete bed of rollers designeliminates the need for lane dividers, usually requiredon conventional carton flow systems, which require frequent lane re-positioning as products change.

Label holders 39mm or 50mm deep can be fitted fullwidth to load face and pick face beams, and can beused to identify locations for restocking, and to identifypicking locations

DURAFLOW

Lane indexers can be supplied in lengths of up to2000mm approximately, by special order

Lane indexers approximately 75mm high x 150mm longare available to mark locations for re-stocking products.Made of 8mm painted steel rod, these clip on to theaxles at the loading face.

DURAFLOW

Page 9: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

DURAFLOW

DuraFlow AccessoriesVery few accessories are required for DuraFlow applications, since the complete bed of rollers designeliminates the need for lane dividers, usually requiredon conventional carton flow systems, which require frequent lane re-positioning as products change.

Label holders 39mm or 50mm deep can be fitted fullwidth to load face and pick face beams, and can beused to identify locations for restocking, and to identifypicking locations

DURAFLOW

Lane indexers can be supplied in lengths of up to2000mm approximately, by special order

Lane indexers approximately 75mm high x 150mm longare available to mark locations for re-stocking products.Made of 8mm painted steel rod, these clip on to theaxles at the loading face.

DURAFLOW

Page 10: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Carton Live Storage – LS2 Flowstore LS2 is a versatile carton live storage system. LS2 uses boltless flowshelf assembly to solve your individual storage, order fulfilment, line side production and cell feed requirements.

Return on your investment: Ergonomically designed LS2 provides a fast and efficient picking system utilising FIFO storage and condensed pick faces, thereby increasing your productivity in less man hours. Cartons, bins, tote boxes, trays and unpacked individual items can be stored and handled accurately and efficiently on a first in, first out rotation.

Highly Versatile: This modular system can be easily installed and configured to suit all types and sizes of product ranges. The Flowshelves can be supplied with purpose designed supporting frames, and racks can be either static or mobile when fitted with castors. Alternatively the Flowshelves can be fitted to pallet rack structures using adaptor brackets

The benefits of Flowstore LS2 - carton live storage

• Increased picking speeds through shorter picking routes

• Easy and quick to assemble.

• Simple adjustments to shelf levels and roller tracks.

• FIFO stock rotation.

• Separate loading and picking faces.

• Stock automatically presented ‘ready to pick’

• Good return on investment (roi).

• Lower cost per pick.

• Ergonomic designs for improved manual handling.

Page 11: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

End Frames (2 leg) sLS2 has a dedicated framework, especially designed for live storage. End frames have bolted bracing, and come in a standard height of 2240mm. Heights up to 3040mm are available in 100mm increments. The bolted bracing enables versatile positioning of the bracing, and permits access to all the slots in the frame face and sides when flow shelves and accessories are fitted.Below 1840mm height frame top caps are usually fitted.

Frame Leg LS2/F/U

Frame Brace LS2/CT40

Frame End Bung LS2/F/EB

End Frames (3 leg) s 3-legged frame are constructed using a Cross Tie Connecter for frame depths of up to 3 metresA combination of 2-leg and 3-leg frames may be used to support Flowshelves up to a normal maximum of 6 metres deep.

Cross Tie Connector LS2/F/CTC

LS2

www.Flowstore.co.uk

Page 12: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Stabilising Beams sStabilising beams are normally fitted with bolts to the top of each frame leg. They are adjustable on a 25mm vertical pitch, and for increased versatility are also able to be fitted upside down.Standard connectors are 200mm long, and a light duty connector is also available 100mm long.Stabilising beams are 100mm deep or 50mm deep light duty section.

Standard Beam Profile LS2/B/P

Light duty Beam Profile LS2/B/PLD

Standard Beam Connector LS2/B/C

Light Duty Beam Connector LS2/B/CLD

Floor Fixings sMany LS2 racks are free-standing up to certain bay loads. Where advised, floor fixings are provided, together with levelling shims.

Footplate 1 bolt hole LS2/F/FP1

Floor Fix M10 x 75

Shims 2mm & 3mm Ls2/F/P1S2 & LS2/F/P1S3

Page 13: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

LS2

Mobile racks s LS2 racks can be made mobile with appropriate castors and castor footplates.Loadings are reduced accordingly, and additional care taken in design to ensure stability.Additional stabilising beams or special base cross-braces are available as required.

Castor Footplate LS2/F/FPC

Pallet Rack Adaptor Brackets s Where Flowshelves are to be fitted to pallet rack frameworks, adaptor brackets are available to fit most types of rack, subject to correct frame load specifications. Details subject to rack type.

Page 14: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Shelf Adjuster Clips A type sEndframe legs have key-hole shaped slots at 25mm vertical centres, which accept clips or bolts. Flowshelves connect to the LS2 frames by shelf clips and a spring safety clip to reduce accidental dislodgement. Type A clips are fitted at the off-load end of each flowshelf, and positively engage in slots on the bottom edge of the shelf side channels.The clips are reversible, and in combination with the frame leg hole pitch of 25mm, enable 12.5mm shelf level increments to be achieved for fine adjustment of gradient and shelf position.

Shelf Clip type A LS2/S/SACA

Locking clip LS2/S/LC

Shelf Adjuster Clips B type sShelf clip type B enables a floating position under the side channels to be realised, according to the geometry changes caused by gradient adjustments. It is also reversible, permitting 12.5mm vertical increments.

Shelf Clip Type B LS2/S/SACB

Locking Clip LS2/S/LC

Page 15: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

LS2

Bolted Flowshelves s Flowshelves may alternatively be bolted to the LS2 frames. This method is usually used on racks which are mobile, and thus subject to vibration or flexing. Holes in the side channels enable vertical fixings on 12.5mm centres to be achieved. Flowshelves are always bolted to pallet rack adaptor brackets.

Bolt M8 x20, M8 nut & washers

Cross Ties and Cross Beams sOnce side channels are fixed to upright frames, cross ties to support the roller tracks, and cross beams to house the roller track mounting clips are fitted. This is simply achieved without nuts and bolts by 6mm x 100mm pins, which also retain the safety corner caps and corner plates.

Side Channel LS2/S/SC

Cross ties 40mm LS2/CT40

Cross Ties 50mm LS2/CT50

Cross beam LS2/S/CBG

Corner Plate LS2/S/CP

Assembly Pin LS2/S/AP

Corner Cap LS2/S/CC

Page 16: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Assembly Pins and Starlock Fasteners t Shelf assembly pins are secured with a soft faced mallet, and where racks are mobile, can be retained against dislodgement by starlock fasteners if required (not shown).

Starlock fasteners LS2/S/SLF

EndstopsFlowshelves can terminate with a plain endstop, usually when whole cartons, or semi-open front cartons are being picked. The versatility of this system enables special endstop designs or other items, such as pick-to-light displays to be easily accommodated.

End Stop LS2/S/ESB

s

Page 17: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

LS2

Tilt Panels for pickingWhen picking from open top boxes or cartons, angled Tilt Panels form part of the Flowshelf.These are fitted using assembly pins, which also retain the corner caps.

Tilt Panel LS2/S/TFP

On Load PlatesAt the loading end, flat on-load panels may be fitted, for example if cartons are to be stacked before pushing into the storage lane.

On Load Plate LS2/S/ONLP

s

s

Page 18: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Track and Guide Clips sRoller tracks and lane divider guides are mounted by moulded clips. When squeezing the sides together, the clips can be engaged with slots in the cross beams, and may be laterally adjusted on 7.5mm centres.

Track Clips GS-GAP-35G

Guide Clips LS2/T/CFT

Guide Bungs sFull length lane divider guides feature push-in safety bungs at each end. Once the guide is fitted to the flowshelf, the bung is securely held in place by the crossbeams.

Guide Bung LS2/G/BR

NB An alternative type of slotted Cross Beam (Toothed beam) is available on special order when heavier duty requirements are preferred, which eliminates need for moulded track clips.

Page 19: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

LS2

Short Entry Guide sAs an alternative to full length guides, short entry guides enable easier adjustment and lower cost.Secured with standard shelf assembly pins, they are 150mm x 19mm wide yellow painted steel section, adjustable on 15mm centres.

Guide, Short Entry LS2/G/SE2

Assembly Pin LS2/S/AP

Track and guide installation sBy placing one edge of the track or guide under the retaining lip on one side of each clip, the track/guide is then rotated about 10 degrees so that the other retaining lip engages over the track/guide edge. Lateral track/guide adjustments are on a 7.5mm pitch, and must be carried out with the track/guide disengaged from the clips.

NB When using the slotted beam (toothed beam) option, clips for tracks and guides are eliminated, as they engage directly in punched slots in the cross beams.

Roller Tracks.All Flowstore roller tracks feature steel spindles, essential for long life and good rolling characteristics.

Page 20: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

Completed bay.LS2 has been proven in thousands of UK installations since 2000, and has qualities that last. Flowstore have supplied live storage systems since 1983, and pioneered the specialist use of live storage techniques for a wide range of industries and applications over nearly 30 years. When you purchase a Flowstore system, you have the assurance of a proven and reliable product, backed by experience.

Page 21: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

ERGOTILT

ErgoTilt shelf units are a unique design from Flowstore Systems. Most shelf systems feature 1000mm wide metal shelves laid flat for storage and picking of items. When picking from the shelf, it’s thus normal to have to pull the carton or container out, both to see the contents and have the space to withdraw the item.

In addition, standard shelves have a thickness often of up to 40mm. So if your shelf unit has say 6 levels you just lost 10% -15% of the useable height from the 6 shelf panels alone.

Specialists in Lean Manufacturing techniques, Flowstore aim at making efficiencies in repetitive tasks and better use of your space.

ErgoTilt ET2 shelving turns all this on its head, giving you 5 key benefits:

• Angled shelf panels only 1.5mm thick: More available height for goods.

• Picking access and visibility greatly improved.

• Vertical adjustment 12.5mm for better configuration.

• Bay widths in increments of 15mm: bettter use of space for your stock

• No rear bracing: ideal use in line-side assembly application.

There are any number of standard shelving systems available in the UK, but none that combine the unique features of ET2. ErgoTilt will pay for itself in picking efficiencies and space saving.

Page 22: Duraflow, ls2 & ergo tilt [mar 13]

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www.Flowstore.co.uk

www.Flowstore.co.uk

LS2

www.Flowstore.co.uk

Frequently, ordinary shelf systems require back bracing for stability, meaning they are unsuited to Kanban stores applications which require replenishment from the rear face for production line and assembly systems.

Full width, clear front, colour coded 30mm shelf edge labelling for picking and replenishment completes your installation.

Another feature of Ergotilt is available shelf widths up to 2200mm, meaning it’s easier to get maximum utilisation of shelf length without so many instances of cartons not filling the bay width efficiently. Proven in UK installations for over 15 years, ErgoTilt combines the adjustability of Flowstore’s LS2 live storage framework with custom-designed shelf panels. Vertical adjustability is as little as 12.5mm, and available in seven standard depths 300mm to 900mm. Adjustable shelf picking angles differ according to the depth of the bay.

Available also with castors for mobile applications.

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www.Flowstore.co.uk

www.Flowstore.co.uk www.Flowstore.co.uk

FLOWTUBE

FlowTube: A Lean Manufacturing solution for storage, assembly and materials handling.FlowTube is a simple and reusable system made up of steel tubes, quick assembly joints and accessories, which enable the design and build of a wide variety of custom designed structures.

FlowTube is an extremely versatile product, designed for continuous improvement and Lean Manufacturing applications e.g. Kaizen, 5S, Visual Management, Parts Supermarkets etc.

We offer a complete design and assembly service, or you can design and build your own solutions. FlowTube is specifically designed for ease of assembly, reconfiguration and reuse. No specialist tools are required, just a measuring tape, a way to cut the tubes, a soft faced mallet and a 5mm Allen key. We can provide training in basic design and assembly.

FlowTube supports continuous improvement in the following ways:

• Fast - FlowTube structures are quick and easy to assemble, making it ideal for shop-floor changes at point of use.

• Flexible - FlowTube can be easily modified to improve ergonomics, add or remove features, or change dimensions for different products.

• Mobile - FlowTube can be mounted on castors so that the work area can be quickly rearranged for optimal productivity.

• Reusable - In the event that equipment must be completely redesigned, FlowTube can be easily disassembled and the parts reused.

www.Flowstore.co.uk

Page 24: Duraflow, ls2 & ergo tilt [mar 13]

www.Flowstore.co.uk

www.Flowstore.co.uk

www.flowstore.co.ukFLOWSTORE SYSTEMS LTD.

Fairview Business Centre 29-31 Clayton Road, Hayes,

Middlesex , UB3 1AN, UKTEL: +44 (0) 845 270 3633 FAX: +44 (0) 845 270 3643

EMAIL: [email protected]

Specialists in Live Storage Solutions since 1983


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