Installing an Efficient Pallet Racking Process at Apollo Tyres: The Nilkamal Success Story

In 2017, the Nilkamal sales team in Ahmedabad sold a custom-made pallet racking system to one of the most well-known companies based in Baroda. This company is a leading tyre manufacturing company dealing with the production of a wide range of automotive tyres for ultra and high-speed passenger cars.

Although it has a worldwide presence and recognition as the seventh-largest tyre manufacturer in the world, it earns 69% of its revenue from India alone. With over 2500 exclusive outlets in India, the company has four manufacturing units in Ind Further to an inquiry and a layout drawing we received from the IP salesperson in February 2017, our first meeting with the company was held in March 2017 with our project person Mr. Nitin Mehta. Prior to this meeting, we had noticed that cage pallets had inverted angles, which could damage the beams of the racking systems. Moreover, in the existing racking system, the self-stacking of the pallets was not safe beyond four levels as the operator would have to make judgments about placing the pallets at these heights, and any misses in the same could damage the pallet and cause major accidents. We also observed that the key safety features would need to be incorporated into the system to ensure the overall safety of operators and other staff members.

After having carefully studied the client’s specific requirements, we proposed the following options: a. Utilizing the existing storage system in a new warehouse to reduce the overall cost b. Installing an entirely new system from scratch with new materials.

 

Nilkamal Storage System Case Study

Additionally, we suggested erecting the pallet support bars to prevent any beam damage caused due to the inverted angles of the cage pallets. We also discussed various other safety measures for the proposed racking systems, including back-stoppers, column guards, and raw guards. Soon after, we carried out some other changes to the layout to increase the pallet locations and add some underpass bays. Accordingly, we agreed to carry out changes to the existing process to address these material handling issues and increase the overall workplace productivity.

The new pallet racking system that Nilkamal installed in the company’s warehouse ensures that pallets may be placed in the racks for a total of 8 levels per elevation, which considerably increases the storage capacity of the system. Such an efficient process also eliminates any chances of mishaps and accidents. It also increases the speed of the storage and retrieval of the pallets, thus increasing the overall efficiency levels at the warehouse.

After having carefully studied the client’s specific requirements, we proposed the following options: a. Utilizing the existing storage system in a new warehouse to reduce the overall cost b. Installing an entirely new system from scratch with new materials

Nilkamal Storage System Case Study

Additionally, we suggested erecting pallet support bars to prevent any beam damage caused due to the inverted angles of the cage pallets. We also discussed various other safety measures for the proposed racking systems, including back-stoppers, column guards and raw guards. Soon after, we carried out some other changes to the layout to increase the pallet locations and add some underpass bays. Accordingly, we agreed upon carrying out changes to the existing process to address these material handling issues and increase the overall workplace productivity. The new pallet racking system that Nilkamal installed in the Apollo Tyres warehouse ensures that pallets may be placed in the racks for a total of 8 levels per elevation, which considerably
increases the storage capacity of the system. Such an efficient process also eliminates any chances of mishaps and accidents. It also increases the speed of storage and retrieval of the pallets, thus increasing the overall efficiency levels at the warehouse.