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Within high-demand sectors, achieving efficient fulfilment and downstream processes is an ongoing journey. Meeting logistical demands across seasonal changes requires optimising warehouse space for maximum storage, ready to provide rapid access when needed.
In environments where accuracy, speed and accessibility are paramount, pick tunnels provide a robust and reliable solution. Within this quick guide, we break down pick tunnels, how they work, and why they’re instrumental in helping transform modern manufacturing.
What Is a Pick Tunnel?
Pick tunnels are a specialised warehouse solution, designed around a gravity-fed pallet racking system, integrated with an elevated mezzanine floor. This configuration creates a ‘tunnel’ lane, accommodating inventory picking at ground level, while reserve pallets are stored above and to the sides. Pick tunnels effectively segregate storage from picking lanes, benefitting workers in achieving more streamlined fulfilment.
These systems are renowned for their high-density storage of palletised goods, enabling manual picking that simplifies processes. Due to their capability and space-saving design, pick tunnels are commonplace in high-throughput operations, or in the storage of off-season goods, such as eCommerce, retail, cold-storage and food warehousing.
How Do Pick Tunnels Work?
Pick tunnels are specifically designed to enhance downstream efficiency. Here’s a rundown of how pick tunnels work:
Configuration: Palletised stock is stored on upper mezzanine floors as reserves, which are designed to replenish inventory ready for picking on the lanes below.
Workflow: Conventional warehouse equipment, such as forklift trucks, operates in aisles outside of the pick tunnel and rear loads goods ready for the pick lane. These lanes are often integrated with a gravity-fed system, reducing travel time for pickers and introducing efficiency for forklifts as products flow forward automatically, without having to disrupt operations. Due to this, workers on the ground floor can focus on picking inventory, improving throughput and operational flow.
Pick tunnels frequently operate on a FIFO (first-in, first-out) system, which is where the stock is loaded from behind, ensuring older products are picked first. This is particularly valuable in sectors where perishable goods are of high priority, such as food and pharmaceutical storage.
Racking systems that support FIFO, such as live pallet racking, are integrated within pick tunnels to facilitate this design. However, LIFO (last-in, first-out) is also a viable option, with the introduction of systems such as push-back racking. The choice between FIFO and LIFO is dependent on the inventory type, turnover rate, and logistical operations.
Benefits of Pick Tunnels
Pick tunnels are an invaluable storage system that offers several benefits, including:
- Facilitates faster order fulfilment
- Reduces travel time for pickers
- Maximises vertical storage space
- Increased picking accuracy
- Enhance warehouse throughput
- Efficient stock rotation
- Can accommodate FIFO or LIFO
- Can be integrated with a replenishment light system
How Do Pick Tunnels Differ From Traditional Racking?
Unlike most racking systems, pick tunnels are designed so that picking can occur at ground level. This allows staff to access stock as efficiently as possible while reducing bottlenecks.
Traditional racking setups often rely on workers manually moving up and down aisles and accessing multiple levels. For certain systems, such as narrow aisle and adjustable pallet racking, this can involve the use of forklifts or other specialised equipment. Not only does this slow down processes, but it also adds a level of concern regarding safety between machinery and pedestrians. A centralised picking zone, such as pick tunnels, mitigates these issues and ensures the lane remains clear.
Key Considerations for Pick Tunnels
There are several factors to consider when opting to integrate pick tunnels into existing operations.
SKU Velocity
Consider how rapidly a product moves through the supply chain and the frequency with which it needs to be picked.
Warehouse Layout
Pick tunnels are great for warehouses looking to maximise vertical space and store inventory separately from pick lanes.
Racking Type
Pick tunnels are dynamic, accommodating various racking types. Pick tunnels can be combined with selective, push-back and gravity-fed systems to suit unique logistic requirements.
Workplace Safety
If dealing with congestion between employees and specialised equipment, pick tunnels can be a great solution. With clear lanes dedicated for pickers, they can work without concern for forklifts.
Embrace Pick Tunnel Systems With Prodek
At Prodek, we have dedicated over three decades to designing, installing and delivering compliance-approved racking systems. From initial site audit to our ongoing maintenance with a SEMA-approved instructor, our team works tirelessly to find the perfect system for your unique needs.
We provide a vast range of solutions, accommodating both FIFO and LIFO, specialised equipment, mezzanine flooring, and full project management. To discover more about how we can transform your business logistics, enquire with our experts at Prodek today.
