Automated Intralogistics for A-SAFE’s Manufacturing and Fulfilment Operations
Key Figures at a glance:
| Location | England |
| Operational Time | 12 hours per day, 5 days per week (inbound 12 hours per day) |
| Throughput IN | 53.5 pallets per hour |
| Throughput OUT | 53.5 pallets per hour outbound, constant |
| Taxis | 23 Moffett Automation Taxi pallet shuttles |
| Building Height | 22 metres |
| VTUs | 6 Moffett Automation VTUs |
| Inbound Locations | 6 |
| Outbound Locations | 9 |
| Special features | Automated material transfer across separate buildings, 16 specialised picking gates and WMS integration |
Moffett Automation delivered an automated intralogistics system for A-SAFE’s Halifax facility, improving pallet flow, storage capacity, picking accuracy, safety and WMS-connected warehouse control.
Project Overview
A-SAFE’s Halifax facility is a critical hub within its global operation, combining advanced manufacturing, warehousing and fulfilment for industrial-strength polymer safety products. As demand increased, the site needed to manage higher inventory volumes, faster material movement and more complex fulfilment requirements.
A-SAFE partnered with Moffett Automation to design and implement an automated intralogistics solution that increased pallet capacity, improved throughput and enabled automated material transfer across separate buildings. The system combined 23 Moffett Automation Taxi pallet shuttles, 6 Moffett Automation VTUs, conveyor integration, WMS connectivity, safety infrastructure and 16 specialised picking gates.
The result was a scalable warehouse automation platform designed to improve material flow, support manufacturing output and strengthen fulfilment performance.
Project objectives
- Enable seamless material transfer across separate buildings
- Increase throughput and storage capacity within the existing facility
- Improve storage density and space utilisation
- Integrate with A-SAFE’s WMS for accurate inventory control
- Create a scalable platform to support future operational growth
Challenges Presented
Connecting Manufacturing, Storage and Fulfilment Across Separate Buildings
A-SAFE’s main challenge was managing rising operational demand across separate buildings with restrictive storage capacity and manual material movement. The business needed to increase warehouse capacity and improve flow without creating new bottlenecks between manufacturing, storage and fulfilment areas.
The solution also needed to balance throughput, safety and flexibility. Automated shuttles, conveyors and warehouse personnel would be operating around live warehouse processes, so safety infrastructure and traffic control were essential. WMS integration was also required to support accurate inventory visibility, route scheduling and adaptable material movement.
Storage Transformed
A Scalable Automated Intralogistics System
Moffett Automation Taxi pallet shuttles
23 Moffett Automation Taxi pallet shuttles were deployed to move pallets efficiently across the warehouse’s operational requirements.
Moffett Automation Conveyor
Advanced conveyor systems were integrated with the warehouse infrastructure to support controlled pallet movement between storage, transfer and fulfilment areas.
Moffett Automation VTU
6 Moffett Automation VTUs were introduced to support vertical pallet movement and optimise use of the 22-metre building height.
Moffett Automation WCS
Moffett Automation implemented warehouse control software to manage pallet storage, traffic control and route scheduling. The software was integrated with A-SAFE’s existing WMS to support real-time inventory visibility, accurate stock movement and operational coordination during peak periods.
Safety measures
The project included fencing, light curtains, safety wires, automated gates and muting sensors to support safe interaction between people, equipment and automated pallet movement.
Technical online support
Moffett Automation provides 24/7 remote technical support from its in-house team to help maintain system availability and respond quickly to operational issues.
Local mechanical support
The Moffett Automation system is supported by a local service partner providing preventative maintenance and rapid 24-hour on-site response when required.
Advanced picking gates
16 specialised picking gates were implemented to improve stock accuracy, support order fulfilment and reduce manual handling complexity.
Project Results
Faster order turnaround, improved fulfilment accuracy, and greater product availability have strengthened A-SAFE’s market competitiveness.
The Moffett Automation system helped A-SAFE transform warehouse flow across its Halifax facility, creating a scalable automated intralogistics platform with 14,186 pallet spaces and improved movement between manufacturing, storage and fulfilment operations.
The automated transfer operation, powered by 23 Moffett Automation Taxi pallet shuttles and 6 Moffett Automation VTUs, improved material flow and supported consistent throughput of 53.5 pallets per hour inbound and 53.5 pallets per hour outbound. This helped reduce lead times, improve fulfilment performance and increase product availability.
Integration with A-SAFE’s Warehouse Management System improved inventory visibility, stock control and decision-making. The 16 specialised picking gates improved picking accuracy and supported faster order processing, while safety infrastructure including fencing, safety wires, automated gates and muting sensors helped create a more controlled working environment.
The system’s redundancy, scalability and support structure gives A-SAFE a future-ready platform designed to keep pace with growing demand and continued operational expansion.
Assess Your Manufacturing Warehouse Automation Opportunity
Speak to Moffett Automation’s engineering team to review your warehouse layout, pallet profile, throughput targets and site constraints. We can identify where automated intralogistics, pallet shuttle systems and WMS-connected storage could improve capacity, safety, flow and fulfilment performance.
