Modernizing Legacy. Delivering Performance. Powering the Future.
Legacy ASRS Transformation for a Leading Cold Storage Logistics Provider in the UK
-20°C
Cold Storage Environment
16,500
Pallet Capacity
5
Storage Levels
1
Pallet Per Minute Throughput
FIFO
Best Before Expiry Management
DFDS
Leading Cold Chain Logistics Provider
United Kingdom
Project Highlights
- Migration from Legacy System
- WMS, WCS & PLC Replacement
- Siemens S7-1516 PLC Implemented
- Sensor & Infrastructure Upgrades
- Shuttle Based ASRS
- Conveyor System Modernization
- Zero Impact to Operation
Business Challenges
Aging legacy ASRS and control system with high maintenance cost
Obsolete WMS and WCS with limited functionality
Legacy PLC and sensors causing frequent downtime
Limited inventory visibility and reporting
Need for FIFO and best before expiry control
Operate in -20°C environment with high reliability requirements
Solution Delivered
Brilliant delivered a complete modernization of the warehouse by replacing legacy systems with a future-ready automation platform.
Replaced Legacy WMS with BrilliantWMS
Replaced Legacy Sensors with High Performance Sensors
Implemented New WCS for Real-time Orchestration
Modernized Conveyor & Shuttle Control Systems
Upgraded to Siemens S7-1516 PLC Architecture
Seamless Data & Inventory Migration
Technology Stack
Software
BrilliantWMS BrilliantWCS
PLC & Control
Siemens SIMATIC S7-1516 PLC Siemens ET 200SP I/O Profinet Industrial Network
Automation
Shuttle System Conveyors, Lifts, Transfer Cars Safety Systems & Interlocks
Integration
ERP Interface Barcode/RFID Real-time Dashboard & Analytics
System Architecture
Real-time Control & Monitoring
Improved Throughput & Efficiency
High Availability & Reliability
Future Ready & Scalable
ASRS Workflow
Inbound Flow
1. Pallet Receipt
2. Quality Check & Barcode Scan
3. WMS Allocation & Put away Strategy
4.Shuttle Stores Pallet
5. Inventory Updated
OUTBOUND FLOW (FIFO)
1. Order Received
2. FIFO Retrieval Request
3. Shuttle Retrieves Pallet
4. Conveyor to Dispatch Zone
5. Pallet Dispatched
Why Siemens S7-1516 PLC?
- High Performance & Speed
- Advanced Diagnostics
- Profinet Communication
- Scalability & Flexibility
- Industry 4.0 Ready
- Designed for Reliability in Harsh Environments (-20°C)
Business Results
99.9% System Availability
40% Reduction in Downtime
30% Increase in Throughput
100% FIFO Compliance
Better Inventory Visibility & Control
Lower Maintenance & Operating Cost
High Density Storage
16,500 Pallet Capacity
Shuttle Based ASRS
Fast & Reliable
Real-time Monitoring
Analytics & Reporting
Reliable Cold Storage Operations
Operates efficiently in -20°C Environment
Key Benefits
- Modernized & Future-Ready Warehouse
- Improved Operational Efficiency
- Enhanced Accuracy & Traceability
- Business Continuity Ensured
- Scalable for Future Growth
LET'S TRANSFORM YOUR WAREHOUSE
Brilliant Info Systems delivers intelligent warehouse automation, ASRS, WMS, WCS, PLC & IIoT solutions that drive performance, accuracy and operational excellence.