To enable further expansion, The Weetabix Food Company decided to invest in a state of the art pallet warehouse. TGW was awarded the design and integration of this warehouse solution.

From its base in the heart of the English countryside, The Weetabix Food Company has been creating delicious breakfast cereals since 1932. The business has expanded significantly since its creation and the company now employs over 2,000 people around the world. Weetabix’ unique range of breakfast cereals isn’t just popular in the UK – they export to over 80 countries, from the Middle East and South America to Europe and South East Asia.

Objectives & Requirements

• More space required in the existing warehouse
• Reducing number of pallets held in off-site storage
• Cost effective solution
• Performance of handling approximately 200 loads per hour

TGW Solution

TGW designed a cost effective solution for Weetabix, where the pallets are conveyed and handled two pallets high, to optimise throughput and space. There are 22,000 pallet locations in the warehouse, serviced by three highly dynamic fully automatic TGW Magnus pallet handling cranes, supplying multiple pallet deep storage tubes with the TGW Muli satellite vehicles. This new solution allows for a performance of storing and retrieving approximately 200 loads per hour.

For this type of application, TGW deployed a load recovery access system, which allows safe access for qualified operators into the storage tubes to recover a failed or damaged load and can also be deployed in support of the maintenance and health and safety activity. The Magnus & Muli is used to deploy and recover the access cages into and from these storage tubes. The entire solution has been integrated into the existing facilities at the Weetabix’ headquarters in Burton Latimer.

Customer Benefits

• Cost effective concerning throughput and space
• 22,000 pallets instead of 12,000 within the same footprint
• Robust design and performance
• Maximised footprint by use of the TGW Muli system
• Minimised truck movement, reduced risk of accidents
• Solution integrated in existing Weetabix headquarters