Automated Pallet Storage for a Growing Farming Machinery Manufacturer
Key Figures at a glance:
| Location | Ireland |
| Operational Time | 12 hours 5 days a week (inbound 12 hours per day) |
| Throughput IN | 30 pallets per hour |
| Throughput OUT | 15 pallets out per hour constant |
| Taxis | 5 |
| Building Height | 12.2 metres |
| VTUs | 2 |
| Inbound Locations | 1 |
| Outbound Locations | 1 |
| Specials | Hazardous goods warehouse and picking tunnels |
The Moffett Automation Taxi system helped Irish Farming Machinery transform warehouse storage and operational efficiency, delivering increased pallet density, advanced picking capability, improved safety and scalable capacity for future growth
Project Overview
Based in Dunleer, Ireland, Irish Farming Machinery is a leading manufacturer and supplier of farming machinery. As the business grew, its existing warehouse setup became increasingly constrained, limiting storage capacity, picking efficiency and the ability to manage rising inventory volumes.
Irish Farming Machinery partnered with Moffett Automation to design and implement a fully automated pallet storage system tailored to its operational requirements. The project focused on improving warehouse layout, integrating advanced automation and delivering a scalable solution to increase storage density, support picking operations and maintain high safety standards.
Moffett Automation was presented with a number of key objectives:
- Redesign the warehouse layout to support growth
- Introduce automated pallet storage and retrieval
- Improve storage density, picking performance and safety
- Integrate with the customer’s Warehouse Management System
- Create a scalable platform for future throughput increases
Challenges Presented
IFM faced several critical challenges in fulfilling their warehousing
operations:
Irish Farming Machinery faced several operational challenges. The warehouse had only 1,000 pallet spaces, which was no longer sufficient for rising inventory levels. The business also needed to support four different operations within one facility, including a mezzanine-level picking area for daily shop orders.
The project also required careful safety planning due to increased interaction between people, equipment and automated systems. Seamless integration with the customer’s Warehouse Management System was essential to support accurate inventory control and efficient movement across the warehouse.
Storage Transformed
Moffett Automation delivered a bespoke automated pallet storage solution designed around Irish Farming Machinery’s storage, picking and safety requirements.
Moffett Automation Tax
Five Moffett Automation Taxis were deployed to move pallets efficiently between storage and the warehouse’s four operational areas.
Moffett Automation Conveyor
The conveyor system was integrated with specialised fire safety doors and existing warehouse infrastructure to support safe and controlled pallet movement.
Moffett Automation VTU
Vertical transfer units were introduced to optimise use of height within the building and improve access to multi-level storage.
Moffett Automation WCS
Moffett Automation implemented warehouse control software to manage pallet storage, traffic control and route scheduling. The system was integrated with Irish Farming Machinery’s Warehouse Management System to support live stock visibility and efficient pallet movement.
Safety measures
The project included fencing, light curtains, safety wires and magnetic locks to help protect personnel and support safe operation around the automated system.
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 on-site response when required.
Advanced picking stations
Sixty-seven specialised picking stations were implemented to support shop orders, improve stock accuracy and make picking more efficient.
Project Results
The implementation of the Moffett
Automation System at Irish Farming
Machinery resulted in significant
enhancements to their warehouse
operations, delivering measurable
improvements.
One of the most impactful outcomes was the dramatic increase in storage density. IFM’s warehouse capacity expanded from 1,000 pallet spaces to 6,209. This optimization not only allowed IFM 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 streamlined picking operations brought about by the 67 specialized picking stations greatly enhanced order fulfillment processes. These stations improved the speed and accuracy of picking tasks, reducing processing times and ensuring that orders could be completed more efficiently.
By integrating seamlessly with IFM’s Warehouse Management System (WMS), the automated storage 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 management.
Safety was another major area of improvement. Moffett Automation’s robust safety measures, safety wires, and magnetic locks, minimized operational risks and ensured a secure working environment for warehouse staff. Additionally, the system’s automated energy-saving features reduced operational costs by optimizing power usage during idle periods, making the warehouse not only safer but also more cost-effective.
Feedback from IFM has been overwhelmingly positive. The system’s reliability and redundancy features ensured uninterrupted operations. By transforming its warehouse with Moffett Automation’s solutions, IFM is now better equipped to meet its operational goals and drive future growth.
Request more info
Get in touch and our team of engineers will identify how efficient your current storage system is and detail the benefits of automated storage solutions to save floor space and time, reduce costs, increase operational speed and return on investment.
