Related Case Studies
Industry: C-Store
Technology: Sortation System, Multi-Level Pick Module, WCS, Shrink Wrap, Auto Baling
Unique challenges and constraints of the convenience store market
Convenience store distributors face unique product challenges that many other retailers do not. Most convenience stores lack a back room and have complex replenishment cycles, making just-in-time delivery critically important. In addition, convenience stores are more physically constrained than any retail chain, which means each product must be the right fit for the market — culturally and geographically.
To ensure that all products are delivered where they need to be, on time, and in proper condition, the distribution center must:
- Store, pick, and ship products at the right temperature, whether ambient or frozen.
- Understand and be equipped to handle the cumbersome processing of cigarettes.
- Handle hazardous automotive products safely.
- Efficiently process, pick, pack, and distribute labor-intensive products, such as fresh and prepared foods and baked goods. Often these require special storage and transportation efforts to ensure speed of delivery and consistent quality.
“TriFactor has good people who are industry experts and put the time in to perform the right analysis. Their team works to solve our biggest challenges in distribution center design including right size picking solutions and the overall design of the systems.”
– Dan Bennett, Sheetz
Services Provided
- Needs Analysis
- Functional Design & Budgeting
- Architect & GC Coordination
- Final Engineering
- System Implementation
- Acceptance Testing
- On Schedule Go-Live
Solution Technologies
- (2) Multi-Level Pick Modules
- Real-Time System Messaging
- Cigarette Carton High-Speed Sorter
- Inline Case Cutter
- High Speed Carton Stamper
- Zero Pressure Accumulation
- Barcode Label Scan Tunnel
- Inline Case Shrink Wrapper
- Timing Belt 90-Degree Sort System
- Shipping Put Module
- Waste Compactor
Staying relevant and meeting consumer demand
For more than 60 years, the mission at Sheetz has been to meet the needs of customers on the go. The privately held company contacted TriFactor while designing a new distribution center in North Carolina, hoping to optimize picking processes, sorting technology, and storage solutions.
The top priority for Sheetz was a distribution center design that would allow for growth as the chain opened new stores in multiple states. The design needed to improve throughout and make the picking, sorting, and packing process - a unique pain point for convenience store distribution - more efficient. It also needed to help Sheetz speed up delivery of freshly prepared foods, a major component of Sheetz's business.
Optimized Picking
Fast and efficient processing is a must, with TriFactor’s custom design incorporating space-saving, multi-level picking modules that can be expanded, torn down, or re-configured as needed. The mezzanine-style pick modules also feature stairwells and lighting to make it easier for distribution center staff to navigate the layout, select cartons, and place them in totes headed for sorting. A new, state-of-the-art central conveyor system ensures the totes move from Point A to Point B as efficiently as possible. While the previous system moved just 9 totes per minute, the new system moves 20 totes per minute.
Customized Sorting & Packing
In addition to improving the picking area, TriFactor worked with an equipment vendor to create customized sorting equipment designed specifically for cigarette cartons. The new sorting equipment separates cartons of cigarettes, scans barcodes, stamps, sorts, and divides them among three packing stations -- at the impressive rate of about 90 cartons per minute.
Create a Supply Chain That Ensures The Daily Delivery of Fresh Foods
To keep up with the growing demand for fresh, ready-to-eat, and made-to-order foods, Sheetz has begun producing baked goods like cookies, donuts, and bread in-house (the new Sheetz distribution center has a full bakery. TriFactor worked with Sheetz to provide racking and conveyor systems to help design a blend of customized racking and conveyors to reduce labor, increase efficiency, and ensure that baked goods are delivered with an eye to consistent quality and speed.
Ensure Room For Growth
The equipment in the new distribution center — from the mezzanine-style picking modules to the sorting and scanning equipment — is scalable, which means Sheetz can easily expand, shift, or remove equipment as needed.