After being scanned, the totes move on this belt conveyor that leads to the push-off sorters. The computer controlled sorters send the order to one of eight designated shipping lanes based on store destination.

When Piggly Wiggly moves to its new distribution center, the conveyor equipment will be disassembled and reinstalled in that new facility.

Piggly Wiggly is a well-known supermarket chain with stores throughout the South. The company is constantly striving to streamline operations in an effort to contain operating costs, speed the flow of product to market, and offer customers a greater selection.

An example of that philosophy in action can be seen in the new conveyorized product-flow system recently installed at the Piggly Wiggly warehouse in Charleston, South Carolina.

This system is interesting for a number of reasons. For one, the entire installation-including conveyors, racks, wiring, computer programming, and so forth-was completed in just one month. For another, it was designed not only to address existing handling requirements, but also accommodate future needs. Piggly Wiggly plans to build an expanded distribution center in the Charleston area, and this conveyor operation will be an integral part of it.

The new system is installed in one of six warehouse buildings that comprise Piggly Wiggly's existing distribution complex in Charleston. This particular facility is dedicated to slow moving products as well as new and specialty items. The new installation, which features Hytrol conveyor equipment, allows Piggly Wiggly for the first time to efficiently handle these items in less-than-case load quantities.

This not only improves overall inventory management for the supermarket chain-both at the warehouse and the retail levels-but also benefits customers. "We're now able to send out less than full case loads of these items to our stores," reports Ronnie Sauls, the company's vice president of warehousing and distribution. "That means more variety for our customers." The Charleston distribution complex serves Piggly Wiggly stores throughout South Carolina and in the Savannah, Georgia area.

Needed:  A Dedicated Facility

A wide live roller conveyor merges two lines onto one. The Charleston facility now handles 1,500 of these totes a day and has the capacity to process more than 2,000.

In the past, slower moving merchandise was shipped to the retail stores in full case quantities from Piggly Wiggly's main dry grocery warehouse. The problem with this approach, however, was that the supermarkets had limited space-or "fronts"-available for these items. That meant they could handle only a relatively small number of cases of these products. In-store display and storage of these items were becoming problems.

Piggly Wiggly wanted a way of increasing the availability and variety of this merchandise without adding in-store inventory. Accomplishing this objective would bring multiple benefits-better selection for customers, improved shelf utilization, fresher code dating, and faster inventory turns.

The solution came in the form of a conveyorized product-flow system that is housed in a facility dedicated exclusively to the new and slow-moving items. It allows the stores to order a wider variety of items in the exact quantity they want.

Working closely with Conveyors & Drives Inc., a Hytrol conveyor distributor based in Atlanta, Piggly Wiggly developed an order-flow system that achieved the main objectives. It is simple and efficient, incorporating a series of live roller and horizontal belt conveyors for swift transfer of product throughout the 40,000 square-foot facility. A computer-controlled push off sorter sends the orders to the appropriate shipping lane with no manual intervention. In addition, an overhead trash conveyor helps keep the work environment clean and clear.

Straightforward and Efficient

Though relatively simple, the new system is highly efficient. Orders are received at the Charleston warehouse from a centralized order processing department and pick sheets are generated.

Operators pick from flow racks, placing the orders into totes that rest on zero pressure accumulators. These orders are picked in the exact quantity needed by the stores. And they can come in a wide range of containers-boxes, cans, jars, bags, and more. Once the order is complete, the operator places a bar code on the tote, signifying the destination shipping lane for the particular store.

Live rollers efficiently move totes from picking stations onto a perpendicular line that leads to the push-off sorters in the shipping area. The entire conveyor system will be taken down and reassembled when Piggly Wiggly moves into its new DC in April 1999.

 In the main picking area, the totes move on two main lines, both minimum pressure horizontal power conveyors (190-ACZ). These connect with another horizontal power conveyor that runs perpendicular. A third picking line is located on the other side of a wall from these two main lines. Workers pick to totes from the front of flow rack, which is supplied by Kingway. (The facility actually was an old post office, and Conveyors & Drives had to design the new system to take maximum advantage of the existing configuration.)

A live roller merger effectively combines the line from the main picking area with the separate picking line. A computerized bar code reader from Accusort scans the labels on each tote before the order moves onto a horizontal belt curve conveyor leading to the shipping area. As the tote is inducted onto the belt, a photo eye communicates to the push-off sorters. These pushers send the tote down one of eight shipping lanes, depending on the destination store. The orders are loaded on trucks and combined with the full case products from the main dry grocery warehouse.

In addition to a smooth-and-simple product flow, the system streamlines waste-removal-a key consideration where food is concerned. A trash belt (TH) conveyor from Hytrol runs above all of the picking lines. This lets the operators easily remove corrugated, plastic, and other waste material from their work areas with minimal physical effort. The waste flows to a corner of the building where it is compacted for easy disposal.

Piggly Wiggly now moves approximately 1,500 totes a day through the facility, and has the capacity to handle more than 2,000. In the short term, the company plans to add to its current staffing level of eight as store orders for the new and slow-moving items increase. In the longer term, the conveyor operation will be disassembled and reconstructed in a multi-level configuration within a brand new 500,000 square-foot distribution center in Charleston. That state-of-the-art center is scheduled to open in April 1999.

The ability to meet both current and future requirements was one of the system's main selling points, confirms Ronnie Sauls of Piggly Wiggly. He believes that it represents a win-win situation for Piggly Wiggly and its customers-both today and tomorrow.

Piggly Wiggly's Charleston Warehouse

Operators in the three picking areas pick form flow racks and assembly the orders into totes. The totes move on horizontal power conveyors on all three lines. A live roller merge combines the line coming from the main picking area with the line from the single picking area on the other side of the wall. After being scanned, the totes move onto belt conveyors and then to push-off sorters, which send the order to the right shipping land. An overhead trash conveyor above the picking lines helps keep the work areas clear and clean.