Client Project

Case Study: High-Density Warehousing for Oriental Kopi

Oriental Kopi is Malaysia’s premier Nanyang-style cafe chain, managing an extensive line of retail products including instant coffee, curry pastes, and frozen goods. To support their rapid nationwide expansion, we designed a high-performance warehousing system for their Central Kitchen and Distribution Center (DC).

1. Challenges & Pain Points

The original warehouse faced several operational hurdles: Insufficient space utilization as the warehouse height was underutilized; SKU complexity ranging from bulk raw materials to small retail packs; and FIFO (First-In, First-Out) pressure, which is non-negotiable in the food industry to prevent stock expiration.

2. The Hybrid Solution

We implemented a multi-tiered racking strategy to balance accessibility with high-density storage:

• Selective Pallet Racking: Provides 100% accessibility for immediate picking of diverse SKUs.
• 2-Way Radio Shuttle Racking System: An automated system that utilizes semi-automated shuttles to move pallets within deep lanes, increasing storage density by up to 50%.
• Environmental Protection: High-strength Powder Coated steel and Hot-dip Galvanized coating were used for moisture-prone zones to prevent rust.

3. Results & Impact

The transformation delivered significant operational gains:

• Capacity Growth: Successfully increased pallet positions from 500 to 1,200 units within the same footprint.
• Operational Velocity: The Radio Shuttle system reduced loading and unloading times by approximately 40%.
• Regulatory Compliance: The system is fully aligned with food safety management standards (HACCP/ISO).

4. Technical & Support Value

Our solution included heavy-duty performance supporting up to 1,500kg per level. We executed the installation in phases to ensure zero-disruption to Oriental Kopi’s daily logistics. Furthermore, we provide Annual Safety Audits (RSI) and an extended warranty to ensure long-term structural integrity.