Trinchero Family Estates Napa Valley Winery
⭐Key Features
- •PowerStore robotic storage and retrieval system
- •4 million case capacity (60,000+ pallets)
- •9-level high storage equivalent to 7-story building
- •27-minute order staging time
- •14-cart loop system feeding 4 vertical lifts
- •84 rows deep with 12 pallet spots per row
📊Results & Benefits
- ✓100% inventory accuracy confirmed by physical count
- ✓22 million cases shipped annually
- ✓27-minute order staging capability
- ✓Consolidated two distribution centers into one
- ✓Increased speed of product movement into storage and shipping
🎯Challenges & Solutions
Transitioning employees from manual systems to advanced automation technology
Comprehensive team partnership approach and training program
Handling high volume and velocity from three high-speed bottling lines
Implemented PowerStore system with efficient loop and vertical lift design
📝Project Overview
Project Overview
Trinchero Family Estates, founded in 1948 and now the second largest family-owned wine company in the US and top 10 globally, undertook a major automation project to centralize its bottling and distribution operations. The company, known for its family-focused culture and strong employee partnerships, hired over 130 local people to sustain and grow this groundbreaking facility.
The 2013 project was driven by the need to increase the speed at which products moved into storage and were shipped, while consolidating inventory from two distribution centers into one high-density location. The facility represents a complete end-to-end winery operation, crushing over 100,000 tons of grapes annually and processing wine through three high-speed bottling lines with capacity for a fourth.
Swisslog was brought in to ensure efficient handling of the massive volume coming off the high-speed production lines, creating a revolutionary approach to warehouse operations.
Technical Solution
PowerStore Robotic Storage System
The facility features Swisslog's PowerStore automated storage and retrieval system with a massive capacity of 4 million cases (over 60,000 pallets). The system stands nine levels high, equivalent to a seven-story building, providing exceptional storage density in a compact footprint.
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Key Features
The PowerStore system's 4 million case capacity represents one of the largest automated wine storage facilities in the world. The 27-minute order staging capability provides exceptional responsiveness for shipping operations, enabling rapid order fulfillment.
The 14-cart loop system with four vertical lifts creates a continuous flow of products into and out of storage, handling the high volume from three high-speed bottling lines. The system's intelligent storage algorithms optimize space utilization while maintaining accessibility.
Results & Benefits
The automated warehouse achieved remarkable 100% inventory accuracy, confirmed by a full physical count after over a year and a half of operation. The facility successfully handles 22 million cases shipped annually, demonstrating the system's capacity and reliability.
Order staging time was reduced to just 27 minutes, providing exceptional speed in product movement from storage to shipping. The consolidation of two distribution centers into one high-density location streamlined operations and reduced complexity.
The system enables products to be brought into inventory and out of inventory at the fastest possible speed for the wine industry, setting new standards for operational efficiency.
Challenges & Solutions
The primary challenge was transitioning employees from traditional manual systems at previous facilities in Green Island Road and American Canyon to advanced automation technology they had never encountered before. The solution involved creating a close partnership between Trinchero and Swisslog, forming a unified warehouse startup team that worked collaboratively through the transition.
Another challenge was handling the enormous volume and velocity of products coming from the high-speed bottling lines. This was addressed through the PowerStore system's efficient loop and vertical lift design, which can accommodate the rapid flow of 22 million cases annually while maintaining precise inventory control.
System Integrator
Swisslog provided comprehensive automation solutions and maintained an outstanding partnership with Trinchero Family Estates throughout the project. Their openness to changes and ideas fostered a strong, productive relationship that extended beyond typical vendor-client dynamics.
The Swisslog team demonstrated exceptional commitment, being consistently available throughout the implementation and operational phases. This trust-based partnership ensured the facility operates with the precision and reliability of a "Swiss watch," establishing a benchmark for automated wine storage and distribution.
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