A new fully automated high-bay warehouse has dramatically increased storage capacity, helping a Lancashire-based global furniture and homeware supplier facilitate growth and increase efficiency.

Global trade-only furniture and homeware supplier Coach House turned to Jungheinrich UK for its warehouse upgrade.

Coach House is a highly successful family-run business with over 40 years’ experience selling design-led furniture to retailers, interior designers and hoteliers across Europe.

The 20,000 sqft. (1,850 sqm) fully automated high-bay warehouse extension at its Lancashire base is helping Coach House face the future with confidence, following the combined challenges of 20% sales growth, a global pandemic and global supply chain issues. With a vastly increased storage capacity, the project has given the company the ability to increase its stock holding as a buffer against uncontrollable external factors.

Jungheinrich helped Coach House to help plan the project and then acted as principal contractor and onsite CDM (Construction Design and Management) coordinator. The two companies worked closely together to develop the right solution, settling on an automated storage and retrieval system (ASRS) capable of holding 10,250 pallet locations. From data analysis and feasibility studies to concept drawings, detailed designs and civil engineering, Jungheinrich consulted with Coach House to provide guidance at all stages of the project life cycle. 

Also part of the project were three Jungheinrich automated stacker cranes capable of handling two distinct pallet sizes, a clad rack structure, pallet conveyors, stretch wrappers, in-line weighing, pallet profile checks, a sprinkler system, controls and software.

Now in full operation, the high-density, high-throughput system is enabling Coach House to maximise space. At the same time, full automation (the facility requires minimal operator input) is minimising product handling and enhancing a level of efficiency already optimised by the existing Jungheinrich warehouse management system. 

Danny Bovingdon, director at Coach House, says: “Without the additional capacity, we would have needed to find new premises – which would have brought significant operational challenges and costs. This facility has secured our future growth plans.”