Pharmaceutical Logistics Hub Material Handling System

Overview

National Unified Procurement Company (NUPCO) retained BNP and leading Middle East A&E firm Dar Al-Handasah for data analysis, design, engineering, and tendering services for a new pharmaceutical logistics hub. At 80,000 pallet storage positions with a footprint of 80,000 square meters, the warehouse is slated to be one of the largest in the region.

PROJECT DETAILS

Material Handling System Features

Wide Aisle Racking System

Euro 1 Wide Aisle Racking Reach Truck System consists of 75,000 pallet storage positions with a dedicated replenishment area for fast-moving goods and distribution via conveyor and put-to-light systems.

Flow Racking Case Picking Area

Flow Racking Case Picking Area with a capacity of up to 8,000 cases per hour, consisting of 45,000 case storage positions over 4,500 storage lanes, utilizing automatic distribution to the order consolidation and packing area via a sortation loop.

Piece Picking Area

Piece Picking Area with pick-to-light technology, with a capacity of up to 50,000 pieces per hour, featuring 7,500 case storage positions within 4,000 storage lanes, utilizing an automated empty tote distribution system on a mezzanine to feed the piece-picking lanes. Once picking has been completed, the conveyor system will transport the tote to the packing area and the order consolidation area via the sortation loop.

Replenishment Process

The replenishment process for the flow racking system is strategically designed to incorporate reliable put-to-light technology. This integration is pivotal for enhancing accuracy and efficiency in the replenishment operation, ensuring a streamlined and error-free workflow.

Temperature-Controlled Storage

• Cold Storage Area (2°C to 8°C) with storage up to 1,200 pallets and 67,000 cases across 9,500 case storage lanes.
• Freezer Storage Area (-15 °C to -25 °C) has a storage capacity for 5,900 cases and 3,000 storage lanes.

Specialized Storage Areas

• Hazardous Goods Storage area, with a specialized storage area for Radioactive Goods, consists of 800 pallet positions.
• Controlled Drugs Storage, including a separate 2 °C to 8°C area, with a capacity of up to 450 pallet storage positions and 32,000 cases across 4,600 storage lanes.
• Quarantine Area with segregation for ambient, cold, and freezer goods with a capacity of over 300 pallet positions and 26,000 cases.