Manual handling…in the cold

Industrial Automation Ltd has helped 3663 First for Foodservice solve a materials handling problem at its two Regional Distribution Centres at Royton and Banbury by inventing a machine that transfers a pallet-full of trays on to a set of dolleys. The machine was needed for a particular contract handling fresh chicken for KFC. KFC has been so impressed with 3663’s approach to the contract and in particular the innovations that were being implemented (of which the new machine is part) that it awarded 3663 ‘Best New Supplier’ early in 2006.  The particular challenge for IAL was that the machines are operating in a chilled part of the RDC where temperatures are kept between –2oC and +2oC; this presents problems with condensation and the performance of lubricants for moving parts.

In 2004, 3663 won the contract for KFC which includes the movement of fresh chicken to the RDCs in 1.5kg trays containing a minimum of 25kg of chicken. Each tray can potentially weigh up to 30kg, which is in excess of the 25kg that regulations recommend as a maximum weight for manual handling. The contract involves each RDC handling between 2,000 and 3,500 trays a day, which are transported on wooden pallets. They will then be de-palletised onto dolleys in stacks of six. Most of KFC’s restaurants take delivery of several stacks of six trays on dolleys, but need the flexibility to take part stacks of less than six. This contract would require eight 3663 RDC staff to perform the operation over the course of an 8.5 hour shift.