Case Study
Ocean Spray’s expanding product line and move to a new facility required a creative approach to maximize storage without excessive costs. With vast inventory and growing demand, Ocean Spray needed a solution to optimize space, streamline product retrieval, and enhance overall productivity.
Ocean Spray, a leader in cranberry-based beverages and snacks, operates multiple large-scale facilities. With a new Pennsylvania site, Ocean Spray required an advanced storage system to handle high-volume distribution while minimizing storage costs and increasing efficiency.
When Ocean Spray acquired a new building, the transition required extensive racking to accommodate a high SKU volume across 250,000–988,000 sq. ft. facilities. To meet budget constraints, Ocean Spray needed an innovative partner to reduce storage costs and enhance space utilization. LD Systems provided a high-impact solution by relocating and modifying existing racking rather than installing new structures, setting the stage for substantial cost savings.
LD Systems implemented an optimized, cost-effective push-back racking system across Ocean Spray’s distribution centers. By repurposing and relocating their existing racking, LD Systems improved space utilization by 60%, enhanced productivity by 50%, and saved Ocean Spray $11 million in new racking costs.
LD Systems conducted data analysis and reviewed Ocean Spray’s operational requirements, focusing on space maximization and efficient storage to drive productivity gains.
A strategic layout was created in AutoCAD, including push-back racking to improve storage density. Pathways and racking placement were optimized to streamline product retrieval and reduce travel time within the facility.
LD Systems managed the dismantling, repair, and reinstallation of 44,000 pallets of push-back racking over 200 miles, ensuring each component was tailored to Ocean Spray’s requirements.
From planning through final installation, LD Systems coordinated each project phase, ensuring timelines and budgets were met without disrupting Ocean Spray’s operations.
LD Systems tailored an integrated pushback racking system to enhance Ocean
Spray’s storage efficiency across three facilities. This included relocating and
modifying racking to maximize space and productivity within a consolidated footprint, ideal for large-scale beverage and snack distribution.
To meet Ocean Spray’s storage needs, LD Systems implemented the following:
Push-Back Racking: Increased space efficiency by 60%, enabling high-density
storage for fast access to high-demand products.
Cooler and HVAC Modifications: Adjusted storage temperature settings to preserve product integrity.
AutoCAD Layouts: Provided precise layout designs to optimize workflows and
maximize storage.
The push-back racking system enabled efficient product flow and retrieval:
Push-Back Storage: Simplified loading and unloading, reducing travel time for order fulfillment.
Enhanced Pathways: Designed for smoother traffic and quicker access to inventory.
HVAC and Cooler Adjustments: Tailored climate control within racked areas to meet product requirements.
With LD Systems’ relocation and optimization efforts, Ocean Spray’s distribution centers now handle high SKU volumes within a compact footprint, maximizing storage space and productivity. The innovative pushback racking system provided Ocean Spray with the cost-efficient, high-capacity solution needed for sustained growth.
