Tobacco Flow Smart Warehouse: Stacker AS/RS Builds New Pillars for Efficient Tobacco Circulation

A key domestic tobacco commercial enterprise, responsible for cigarette warehousing, sorting, and distribution, serving tens of thousands of retail terminals. It needs high-density intelligent warehousing to support the efficient circulation of the entire "tobacco leaf - cigarette" chain.

Project Background

Traditional flat warehouses had <35% space utilization, low efficiency in full-pallet cigarette storage and sorting, struggling to meet peak order demand; plus excessive manual operations brought high compliance and loss risks, demanding a stacker AS/RS upgrade.

Solution

High-Density Storage: Built a stacker AS/RS with 20,000 positions, boosting space utilization to 85%.
Automated Operations: Stackers + conveyors enabled automatic access, sorting, and inventory of cigarettes at 800 pallets/hour.
Intelligent Control: WMS linked with stackers to achieve precise management of cigarette batches/locations, complying with tobacco industry regulations.

Project Difficulties

Strict Industry Compliance: Must meet special safety and regulatory norms for tobacco monopoly and warehousing.
Multi-Spec Adaptation: Diverse cigarette packaging demanded stable and precise access for stackers.
Peak Scheduling: 2x order surge during holidays required efficient and stable system operation for stackers.

Project Value

Space Efficiency: Storage capacity increased by 2.4x, supporting business expansion without new warehouse construction.
Fulfillment Upgrade: Sorting efficiency increased by 220%, with 99.9% on-time fulfillment rate.
Cost Optimization: Labor costs cut by 70%, saving over 3.5 million yuan in annual warehousing operations.

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