ALF Aquatic Distributors has improved warehouse capacity, stock management and picking efficiency through a Radioshuttle storage solution supplied by Toyota Material Handling UK. The project was undertaken as the company experienced increased demand for aquatic products following the COVID-19 pandemic. The rise in home fishkeeping and pond care increased pressure on ALF’s existing warehouse operation, where manual picking was time-consuming and warehouse space was becoming increasingly difficult to manage.
Stock rotation was another challenge, particularly for products such as fish food and water treatments with limited shelf lives. In addition, conveyor motors were regularly overheating and triggering the warehouse fire alarm system, causing disruption to operations. Moving to a larger facility was not considered a practical option because of the cost, operational disruption and limited availability of warehouse space in the local area. ALF instead looked for a way to increase capacity and improve picking within its existing premises.
After reviewing different storage options, ALF identified Radioshuttle technology as a potential solution and approached Toyota Material Handling UK. The two companies assessed the warehouse operation using principles from the Toyota Production System (TPS), including the identification and reduction of muda, or activities that consume time, space or resources without adding value.
Toyota recommended a pilot installation comprising nine Radioshuttle lanes. Previously, the area consisted of nine lanes of drive-in racking across three levels, with stock picked manually. Accessing products stored on the second and third levels could require additional pallet movements, adding time and manual handling.
The new installation provides nine lanes of Radioshuttle racking across two levels, with the ground level accessible using hand pallet trucks. Automated pallet movement within the racking allows stock to be brought forward for easier access and replenishment.
The system has also improved stock rotation. Older stock can be presented first, giving warehouse staff greater control over replenishment and reducing the risk of products approaching expiry. Improved accessibility has also enabled the purchasing team to order higher volumes where required.
The Radioshuttle system has reduced the need for workers to manually move pallets to reach targeted products. This has accelerated pick-face replenishment while reducing manual handling. The new racking configuration has also increased back-stock capacity and made better use of the existing warehouse footprint. At the same time, removing the overheating conveyor motors has eliminated a recurring source of operational disruption.
ALF chose to begin with a pilot rather than undertake a complete warehouse redesign. The approach allowed the company to test the system under live operating conditions and assess its benefits before making further investments. Following the successful pilot, ALF plans to work with Toyota Material Handling UK to introduce additional Radioshuttle and racking systems across the warehouse. ALF Aquatic Distributors Ltd is a leading wholesale partner serving the aquatic and pet industry, connecting global manufacturers with independent retailers and specialist stores across the United Kingdom and beyond.
Founded with a passion for aquatic life and a strong commitment to customer service, ALF has evolved from a specialist distributor into a trusted supplier to the industry. The company represents a portfolio of established brands across aquatics, ponds, reptiles and pet care, providing retailers with innovative products, industry expertise and dependable distribution services.
