Safe, Smart, and Sustainable: How Moffett Automation and A-SAFE Transformed Intralogistics Operations
Key Figures at a glance:
| Location | England |
| Operational Time | 12 hours 5 days a week (inbound 12 hours per day) |
| Throughput INN | 53.5 pallets per hour |
| Throughput OUT | 53.5 pallets out per hour constant |
| Taxis | 23 |
| Building Height | 22 metres |
| VTUs | 6 |
| Inbound Locations | 6 |
| Outbound Locations | 9 |
| Specials | designs and manufactures industrial-strength polymer safety products |
Moffett Automation has delivered a transformative, future-ready intralogistics system that sets new standards in automation, safety, sustainability, and supply chain performance.
Project Overview
A-SAFE’s Halifax facility is a critical hub in its global network, housing both advanced manufacturing operations and a major warehousing and fulfilment centre. As demand for A-SAFE’s award-winning polymer safety products grew, so too did the logistical burden placed on this site.
A-SAFE faced growing operational challenges due to limited storage capacity and the restrictive nature of its manual material handling processes. With these challenges in mind, A-SAFE partnered with Moffett Automation to design and implement a fully automated intralogistics solution tailored to their needs.
Moffett Automation was presented with three key objectives:
- To enable seamless transfer of materials across separate buildings.
- To increase throughput and storage capacity while optimizing space utilization.
- To future-proof the facility with a scalable platform that can grow alongside A-SAFE’s operations.
Challenges Presented
Reimagining Intralogistics Across Divided Infrastructure
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A-SAFE’s primary challenge was its restrictive storage capacity and growing operational demands.
With manual material movement and limited space, A-SAFE needed a significant transformation to keep up with its future growth. -
A-SAFE needed to enable automated transfer of materials across separate buildings while optimizing storage density and retaining operational flexibility.
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Designing for maximum safety was a key priority, ensuring smooth, risk-free interaction between automated shuttles, warehouse personnel, and ongoing operations.
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Additionally, the facility needed seamless integration with its Warehouse Management System (WMS) to enable smooth, accurate, and adaptable inventory operations.
Storage Transformed
Moffett Automation delivered A Seamless, Scalable, and Sustainable Intralogistics Ecosystem
Moffett Taxi™
23 Taxis were deployed, delivering pallets to all four operational requirements of the warehouse.
Moffett Conveyor™
This was complemented by advanced conveyor systems that integrated seamlessly with the warehouse infrastructure.
Moffett VTU™
Vertical lift systems were introduced to optimise vertical space utilisation, enhancing overall storage capacity.
Moffett WCS™
We implemented a robust software suite that included pallet storage management, traffic control, and route scheduling, all fully integrated with Total Packaging’s existing WMS. This software not only managed the physical movement of pallets but also ensured that during peak times.
Safety measures
The project also included the installation of safety measures such as fencing and light curtains, ensuring that the solution was not only effective but also scalable and future-proof. This is combined with the fact that automated systems reduce workplace accidents by up to 70%.
Technical online support
Moffett Automation provided a 24/7 online support system staffed by their own experts to ensure continuous, uninterrupted operation and quick resolution of any issues.
Local mechanical support
The Moffett Automation system is supported by a leading local service partner who will provide preventive maintenance and rapid 24 hour onsite response if and when required.
Advanced Picking Stations
16 specialized picking gates were implemented to fulfill shop orders, greatly improving stock accuracy.
Project Results
Faster order turnaround, improved fulfilment accuracy, and greater product availability have strengthened A-SAFE’s market competitiveness.
One of the most impactful outcomes was the dramatic increase in storage density. A-SAFE’s warehouse capacity expanded to 14,186 pallet spaces. This optimization not only allowed A-SAFE to handle its growing inventory demands but also created room for future expansion, ensuring that the system remained scalable and adaptable to their evolving needs.
The automated transfer operations brought about by 23 automated shuttles and 6 high-speed VTUs greatly enhanced material flow and throughput across the site. This resulted in faster and more accurate processing, reducing lead times and improving delivery performance.
By integrating seamlessly with A-SAFE’s Warehouse Management System (WMS), the automated solution provided real-time inventory tracking and improved overall supply chain visibility. This integration allowed for better decision making and a more cohesive approach to warehouse operations.
Safety was another major area of improvement. Moffett Automation’s robust safety measures, including safety wires, automated gates, and muting sensors, minimised operational risks and kept warehouse personnel safe at all times. Additionally, the system’s energy-saving features optimised power usage during idle periods, reducing operational costs and making the warehouse more sustainable.
Feedback from A-SAFE has been overwhelmingly positive. The system’s redundancy and adaptability enable uninterrupted operations and future-proof their intralogistics. By transforming its warehouse with Moffett Automation’s solutions, A-SAFE is now well-equipped to keep up with growing demands and drive future growth.
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