Toolbank (Ireland) Interfloor fulfilment centre
Toolbank, Regional Branch in Dublin. Previously trading as Tucks O’Brien Ltd.
Toolbank are one of Europe’s leading specialist distributors of hand and power tools, in association with many of the leading independent DIY retailers and the world’s leading manufacturers. CSL have worked with Toolbank at 6 of their distribution centres over the last 10 years.
The Brief
Under Toolbank’s continuous expansion programme, it was decided that due to the ever-increasing amount of business emanating from Ireland necessitating large shipments from the UK, they needed to invest in a permanent branch but needed an established and highly reputable business in a good location so Tucks O’Brien was ideal with their long experience of the Irish market and a 35,000 sq. ft warehouse.
The site, which had an existing two floor mezzanine, was to feature an automated multi floor order picking/sorting conveyor system to service over 16,000 product lines. The system needed to deal with a wide range of order sizes ranging from single totes up to multiple tote orders, along with separating work streams for B2C packing.
The system also had to be capable of reversing for stock replenishment up to all floors and allow for future expansion.
The Solution
CSL and Toolbank collaborated to create a space-saving multi-level spiral conveyor system, designed to move products between floors for picking and order consolidation. The system features two stacked spiral conveyors, allowing products to be transported between the ground, first, and second floors, with direction reversal at any level. Picked orders are moved between floors, manually sorted, and then conveyed to a roller system for palletizing. An HMI touchscreen controls the system, enabling reverse flow to replenish stock. Toolbank praised the solution for streamlining operations and handling higher demands while saving space.
