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CEF National e-commerce Fulfilment Centre

Find out how CSL Automation designed and implemented an efficient eCommerce fulfilment system for CEF’s new distribution centre to help enhance throughput and meet customer demand. 

The Client

City Electrical Factors – specifically their eCommerce National Distribution Centre

The Brief

City Electrical Factors Limited (CEF), who were formed in 1951, are the UK’s leading Electrical Wholesale Network, and currently boast twice as many distribution outlets than their nearest competitor.

In order to provide the best possible service CEF has developed a highly responsive and motivated organisation that can adapt readily to each individual customer’s needs and requirements.

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Clicking the button below will download a copy of
this case study in PDF format

The Client

City Electrical Factors
eCommerce National Distribution Centre

The Brief

City Electrical Factors Limited (CEF), who were formed in 1951, are now the UK’s leading Electrical Wholesale Network, and currently boast to having twice as many distribution outlets than their nearest competitor.

In order to provide the best possible service CEF have developed a highly responsive and motivated organisation that can adapt readily to each individual customer’s needs and requirements.

Key Solutions Used

Due to its projected growth and need to maintain a continued professional service level, CEF recognised that they needed to move from their existing distribution warehouse to a larger purpose built distribution centre (DC). 

This resulted in a 100,000 sq ft purpose built and specially designed distribution centre being commissioned.  Along with a 2 level mezzanine structure, the total floor space equalled 160,000 sq ft.

As part of the infrastructure to the new DC, a solution was required to enhance the process from order placement through to despatch and provide increased throughputs. One requirement was to incorporate the processes of order picking, packing and despatch solutions along with an inboundreplenishment function, which could all be controlled with an easy-to-use in-house developed IT system

Following initial investigations and discussions with various potential suppliers, CEF turned to CSL Automation as the preferred partner to work with on this project.

During the tender process CSL Automation demonstrated an understanding of the project values, and conducted a pro-active assessment of the project. CSL Automation worked closely with CEF and developed a partnership which ensured both CEF and CSL Automation were the right fit for each other.

Our Solution

The design team at CSL Automation needed to ensure the system layout maintained the functionality and was space efficient. Using 2D and 3D modelling software CSL Automation developed a conveyor system which fulfilled all of the requirements.

CSL Automation employed the use of the Interroll 24v motorised roller conveyor which provides non-contact accumulation and zonal control for the entire system. All of the peripheral devices are 24v controlled also.

A web based WCS/SCADA was implemented by CSL Automation to interface to the WMS system, enabling the conveyor system routing to be controlled and amended in live time. The WCS provided all historical data as well as over-arching control of the entire conveyor solution. The client has the ability to dial into the WCS from a PC or tablet in any location that has an internet connection.

The scope was defined in very specific detail. For example, inbound-replenishment stock was to be conveyed in a grey tote, order picking in red totes (not coincidental that they matched CEF corporate colours) and despatched items in cartons. All totes had dedicated barcodes incorporated onto them for easy identification and tracking. 

With both inbound-replenishment and order picking totes sharing the same conveyor, which provided a dual function, wherever a tote was offloaded, the operator could instantly recognise it as an order pick requirement or replenishment stock given its colour-coded tote. 

The first challenge was linking up the inbound-replenishment stock, which arrived at the opposite end of the building, to the mezzanine storage/picking area. Stock was booked in and then scanned into a tote, which was immediately elevated to high level via an AmbaFlex spiral. It was then conveyed all at a high level using specially designed hangers that utilised the building columns at 7m centres, ensuring no supports occupied ground floor space. The replenishment roller conveyor entered the 1st floor level and merged into the main conveyor system.

New orders were assigned to totes, which were inducted into the system at ground floor level and elevated via an AmbaFlex spiral onto the 1st floor mezzanine area, combining the replenishment element into one common roller conveyor.

The replenishment and order picking functions take place over two mezzanine floor areas with each floor having four offload transfers, each of which has a bi-directional transfer and spur conveyor. This provides eight locations per floor.

The routing of the totes is dictated by the client’s WMS, and the offloading is controlled via the WCS.  At each transfer point, a SICK barcode reader is employed for confirmation reading and/or triggering. 

If an order needs consolidating from another location or cannot access the required offload location, it will continue to visit all other required locations, then elevate up to the 2nd floor mezzanine via an AmbaFlex spiral located on the 1st floor mezzanine. The process is replicated on the 2nd floor.

All completed order picks or empty replenishment totes are lowered to the ground floor via the 4th AmbaFlex spiral in the system and delivered to one of 40 pack benches using a two-tiered conveyor system.

Any item that could not be offloaded to its required destination is re-circulated through the system and is WCS controlled.

The dual sided pack benches share a common incline conveyor belt, onto which they load the packed and completed items.  All despatch items merge onto the top tier of this two-tier conveyor. At the end of the line, a 4way SICK scanning array is employed, examining the front, two sides and top of the carton for a despatch courier label. Items are then sorted via one of two Interroll High Performance Diverters to one of four despatch lanes.

Craig Marks, Divisional Manager for CEF online said “I have found working with CSL Automation to be the ideal partnership. They understood the brief and worked closely with CEF to ensure the design met all of the criteria. The support from start to finish was excellent. The project ran smoothly from start to finish. The conveyor system has made our new warehouse very efficient and allowed us to increase our throughput”.

How CSL Automation Can Help Your Business

At CSL Automation , we offer a range of conveyor system solutions to ensure your warehouse is working at its optimum. Whether you have an inefficient fulfilment centre, are looking to streamline your sortation centre or need to upgrade your national distribution centre, we can help! We specialise in areas such as order picking, product sortaton and returns to transform your order processing. 

Get in touch with our team today and experience efficiency like no other.

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Business Automation FAQs

What type of conveyor system could you design for a warehouse or national distribution centre?

With over 25 years of experience, our team at Conveyor Systems have designed an array of conveyor systems to match the needs of various businesses across a range of industries. From order fulfilment for a major meal kit provider to spiral conveyor systems for fashion eCommerce businesses, we can create a tailored conveyor system to meet your requirements. For more information on our services, take a look at our conveyor system solutions today. 

What conveyor system maintenance services do you offer?

We don’t believe in ending our relationship with our customers after a project has been completed. That’s why we offer a range of maintenance solutions to keep your new and improved facilities running smoothly. From mechanical servicing to spare parts and conveyor modifications, we can get your conveyor systems working as efficiently as the day you got it. 

Creating relationships that last

We are proud to have completed installations for many major organisations, forging strong relationships and continuing to provide automation solutions through ongoing maintenance or follow-on projects due to expansion and our customers’ trust in CSL to meet and exceed their needs.