-
- References
- Case studies
- Production optimization for vinyl records
Executive summary
Utz Poland collaborated with GZ Media, Europe’s largest vinyl record manufacturer, to design, produce, and deliver custom containers as part of their storage and logistics transformation. Through the Smart Logistics project, Utz Poland delivered 45,000 custom-designed vinyl record storage containers while collaborating with cutting-edge automation solutions. The project not only enhanced storage capacity and safety but also streamlined operations with innovative robotics and warehouse management systems. These solutions significantly increased efficiency, setting a new standard for automated material handling.
The client
GZ Media, based in the Czech Republic, is Europe’s largest producer of vinyl records, renowned for its emphasis on quality and innovation in record storage solutions. With the continued rise in vinyl sales, the company required a durable, custom-designed storage container to accommodate vinyl records and sleeves efficiently in their automated warehouse. The containers needed to be robust, feature internal dividers, and allow for safe manual handling.
The challenge
The project began with a set of predefined external and internal dimensions, alongside a requirement for internal dividers. However, the initial drawings provided by the client were insufficient, necessitating a redesign by the Utz team. Four challenges arose during the development and production process:
- Inefficient manual processes: The original plan relied heavily on manual handling for placing and removing plastic containers, which required operators to lift crates weighing 25-30 kg. This process was labor-intensive and time-consuming.
- Limited storage capacity: The warehouse was initially designed to store up to 220,000 vinyl records per day, with approximately 38,000 crates. Each container was assumed to contain 100 records, limiting overall efficiency.
- Safety concerns: Sharp edges on the handles of the storage containers posed safety risks for manual handling.
- Logistics bottlenecks: Internal transport required extensive use of cartons and labels, adding time and costs to operations.
These challenges required not only a redesign but also creative engineering solutions to ensure the containers were suitable for both automated and manual operations.
The solution
Utz engineering team collaborated closely to redesign and optimize the containers.
- Reinforced structure: Added ribbing to improve strength and eliminate wall bending.
- Safe handling: Automated robotic edge-smoothing ensured safe handles for operators.
- Optimized capacity: Containers were redesigned to hold an average of 140 records, maximizing storage efficiency.
These smart solutions allowed Utz to deliver containers that met the client’s exacting standards for both strength and safety, while also maintaining efficient production cycles.
Implementation process
The implementation process involved several key steps. After receiving the client’s initial design, the Utz team quickly realized the need for structural improvements. The design was revised to include reinforcing ribs, and a new mold was developed. Upon producing the first reference samples, the issues of wall strength and handle sharpness became apparent.
Working with a mold maker, the team implemented the necessary modifications. The robotic edge-milling solution was integrated seamlessly into the production line, ensuring precise and efficient edge smoothing. This automated approach saved time and improved safety, demonstrating the team’s commitment to smart engineering and process optimization.
The results
The optimized design and automated solutions led to impressive results:
Enhanced storage capacity
- Increased warehouse capacity to hold 43,000 crates, a 13% improvement.
- Each crate was optimized to hold 140 records, enabling the processing of up to 400,000 records per day (limited by press capacity).
Improved efficiency and safety
- Automation replaced manual handling, reducing operator strain and minimizing safety risks.
- Robotic systems streamlined sorting and transport, significantly cutting labor requirements.
Cost savings and sustainability
- Eliminated the need for cartons and labels in internal transport.
- Reduced time and costs associated with manual processes.
Utz Poland successfully delivered 45,000 custom vinyl record storage containers that not only met but exceeded GZ Media’s expectations.
The project highlights Utz Group’s ability to adapt and innovate in response to complex client requirements. The solutions developed for this project, particularly the integration of robotic technology for edge smoothing, offer scalable opportunities for future custom manufacturing projects. This case exemplifies how thoughtful design and engineering can drive efficiency and product quality.
We are pleased to share our experience of collaborating with UTZ Group, who provided us with an injection molding tool and subsequent production of containers. Despite encountering occasional challenges during the process, the collaboration was carried out successfully, resulting in a good and satisfactory outcome. We appreciate the effort and professionalism of the UTZ Group team, which contributed to the overall success of this project.
Looking for a custom solution?
Speak to our expert to discuss your individual needs, we’ll develop a solution matching your requirements.
Request consultation
