Mezzanines offer a quick fix for companies seeking to expand their warehouse capacity. But special temperature control may be needed, for the sake of both workers and product.
Martha Spizziri has been a writer and editor for more than 30 years. She spent 11 years at Logistics Management and was web editor at Modern Materials Handling magazine for five years, starting with the website's launch in 1996. She has long experience in developing and managing Web-based products.
For companies that are running short on warehouse or DC space, mezzanines can be an attractive solution. For one thing, installing a mezzanine can eliminate the need to relocate. For another, it can avoid the expense and hassle of building an addition.
But mezzanines also have a downside: Heat rises, and because the mezzanine is up high, close to heat-emitting light fixtures, the temperature could run as much as 20 or even 30 degrees higher than temps on the floor. That makes things uncomfortable for workers and could result in heat stress. It also raises the risk of product spoilage or packaging failure due to moisture from condensation.
Too-high temperatures can also keep an operation from running at peak efficiency. When people are fatigued from the heat, order accuracy can suffer, warns Brian Neuwirth, vice president of sales and marketing at warehouse equipment company Unex Manufacturing Inc. in Lakewood, N.J.
FINDING YOUR COMFORT LEVEL
When DCs go to tackle the worker comfort problem, the first impulse is often to put in fans, but fans alone might not be the best solution. (In fact, they probably aren't.) "If it's 20 degrees hotter at the ceiling and you just put in a fan, then it's going to be roughly 10 degrees hotter than at the floor," says Christian Taber, senior applications engineer at the fan company Big Ass Solutions. "That is not necessarily the best scenario."
That's because temperature isn't the only factor that contributes to workers' perception of how hot they are, or to their safety, says Taber. He points to standards from the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE), which identify six factors that help determine how comfortable a person feels: air temperature; radiant heat (heat emitted by warm objects such as lighting fixtures, machinery, and people); air speed; humidity; clothing insulation level; and metabolic heat, which increases with activity.
"All six of those together really drive whether or not a person's comfortable, or whether or not they're going to have heat stress," says Taber. "For example, if you have to wear two full layers of clothing for safety reasons and you're doing high-activity-level work, then the temperature at which you're going to go into heat stress is going to be dramatically lower than if you're wearing shorts and a T-shirt and you're engaged in light activity and there's a nice breeze blowing. So, temperature alone doesn't really define it. It's a combination."
Studies show that productivity starts to drop when the perceived temperature rises above 77 degrees Fahrenheit, says Taber. Heat stress—heat-induced physical problems that can include cramps, heat exhaustion, and heat stroke—can become a problem when temperatures reach the mid-80s.
FIND THE ROOT CAUSE
Although DCs often look first to fans, a better approach to remediating heat issues is to step back and try to determine the root cause of the problem, Taber says. His company usually looks first at the ventilation or exhaust system when evaluating a client's facility, he reports. "If the building does not have sufficient exhaust that takes the hottest air off the ceiling, the other solutions really don't work as well," he explains. "If you're not bringing fresh air in low (and) you're not exhausting hot air up high, then that heat tends to build up (near the ceiling)."
Other possible root causes include poor roof insulation and lighting that emits too much heat—or even the number of workers in a space or the clothing they're wearing. Focus on the changes that will give you the biggest return, advises Neuwirth.
Neuwirth recommends starting by asking yourself what's putting off the most heat. Often, the answer is an internal heat source, such as lighting or motors from conveyors or other equipment. Solutions could include replacing motor-driven conveyors with nonmotored gravity units or replacing old-fashioned metal halide lights with light-emitting diode (LED) or fluorescent lights, which give off less heat.
Sometimes, it's necessary to isolate the source of heat from the rest of the building. Taber cites a project where a large oven was throwing off a huge amount of heat. "Rather than exhausting air out of the whole building, we isolated the oven and put it essentially in a closed space, and then exhausted that heat directly out of the building," he recalls. "That kept that heat from being spread throughout the building and overheating everyone."
BRING IN THE FANS
Once you've dealt with the major problems, the next step is to circulate the air to equalize the temperature from floor to ceiling. This is where fans come in.
But the answer might not be traditional ceiling-mounted fans. Those might not work over a mezzanine, because safety regulations may require a minimum distance between the mezzanine floor and an overhead fan.
That might mean companies have to get creative with their fan placement. "Generally speaking, when we're dealing in mezzanines, we're looking at either mounting directional fans off a mezzanine blowing in, or mounting them around the interior of the mezzanine," says Taber. A fan mounted to the side can pull the hottest air from the ceiling level and push it down toward the floor, creating a more uniform temperature from floor to ceiling.
Fans mounted on poles, beams, or walls can be used in cases where a ceiling fan would be too close to workers' heads. (Photos courtesy of Rite-Hite Inc.)
High-volume, low-speed (or HLVS) fans are usually used to mix hot and cold air, according to Dan Anderson, product manager for Milwaukee, Wis.-based Rite-Hite Inc. Once the air is circulating, additional fans can be used to boost air speed so occupants feel cooler. A high-volume, high-speed (HVHS) fan is usually used for that purpose.
As for fan positioning, some companies place fans on tall posts on the lower floor, which is more stable than a mezzanine, and adjust them so that they blow across the platform. An alternate approach is to place fans at one side of the mezzanine to blow air across and another series of fans on the opposite side to pull air over the platform, says Bradley A. Lehman, regional sales manager for Wildeck Inc. in Waukesha, Wis.
An automated fan-control system is optimal. For one thing, says Taber, automated controls free up the workers to focus on the task at hand. "For another, you know it's going to do the right thing, rather than have user interaction muddle things up," he says. "We've seen fans spinning in the wrong direction, or off when they should be running to help increase comfort. By using an automated controller to take that over ... (you can help ensure) the fans are going to run appropriately whatever the conditions."
WINTER WOES
Even in colder weather, heat can be a problem. "A traditional heating system might have a discharge air temperature that's 100, maybe 125, degrees Fahrenheit," Taber says. That air will rise toward the ceiling, with the result that, in a DC where the floor-level temperature is 65 degrees, the temperature could be as high as 75 or 85 degrees at the ceiling. "When you're dressed for the winter and it's 85 degrees at the ceiling, that can be problematic," he notes.
Summer or winter, hot air rises to the ceiling and stays there, while colder air remains at floor level. Adding a fan near the ceiling mixes and circulates air to create a more uniform temperature. (Photo courtesy of Rite-Hite Inc.)
During colder months, dampness from condensation can create problems too, says Anderson. That's because doors and windows are usually kept closed, so there's less ventilation. The resultant moisture can wreak havoc with products—particularly when products are stored on top of mezzanines, where it's likely to be warmer, even if the air is circulating. "Condensation and cardboard or produce or other items can cause different problems, whether it's breakdown in cardboard or ruining raw materials or spoiling produce," he notes. Gentle air movement from an HVLS fan can help in that situation.
A HOLISTIC APPROACH
There's no single solution to tackling a heat problem effectively, Anderson says. "It's not a one size fits all. You don't want to buy these things out of a catalog, because they all need to interact with each other." He suggests bringing in consultants and having them work with an end user from the client company who understands the work processes. The knowledge a DC employee brings to the table can really make a difference in coming up with the best solution for a particular operation.
"The one thing that I always try to stress is, these applications, they're more of an art than a science," says Anderson. "You have to look at the space as a whole and really find out what's happening and where it's critical to get the air moving. ... There's not one solution."
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.