PPG Paints & Silk Contract Logistics Melbourne Hub

Project Overview

As part of their operational strategy to optimise distribution, PPG transitioned their Sydney Distribution Centre to Melbourne. With the Sydney lease due to expire, the team required an efficient and high-quality program to deliver their new Melbourne-based hub on time. PPG had once again partnered with Silk Contract Logistics as their third-party logistics provider to not only establish their new facility, but to run the site, and the two parties were working closely to ensure the project ran smoothly.

Safer Storage Systems worked under significant time pressure while coordinating with multiple stakeholders. This included Simon Robinson at PPG Paints, Duane Dean at Silk Contract Logistics, Fraser McDonald at CBRE, the landlord, as well as the team at Hamilton Fire to ensure the project met fire engineering requirements and safety codes.

The Solution

Safer Storage Systems played a key role in delivering a tailored pallet racking and warehouse solution that met PPG’s criteria. Once the design was finalised in close collaboration with PPG and other stakeholders, the SSS team commenced material manufacturing and commenced works within 5 weeks, delivering the overall solution early, in line with the published go-live dates.

SSS designed a comprehensive warehouse solution which accommodated PPG’s specific storage needs, as well as addressing critical safety requirements for dangerous goods and site traffic management to create a safe and highly efficient facility.

Locally Produced Racking

This project utilised our Australian-made Silverline® Racking. This not only allowed PPG and Silk to meet critical lead times, it also offered a more heavy duty and sustainable solution. Its durability in high-traffic environments ensures long-term functionality, reducing maintenance needs and further contributing to operational efficiency.

Another benefit of SSS’s local manufacturing capabilities, was the ability to produce continuous, site spectific10.3-metre-high uprights to suit the height clearance of the new facility, without delays to material deadlines.

A total of 16,500 pallet spaces were installed. This included additional bays installed in the outdoor area under the canopy which further optimised the operational flow. Silverline® Pallet racking is the ideal choice for both indoor and outdoor areas, due to its galvansied finish.

Upright Protection

In high-traffic environments like this, upright protection is essential to extend the longevity of the racking system and minimise repair costs. A damaged upright guard is far more economical to replace compared to an upright, in terms of materials and downtime associated with repairs.

The SSS heavy duty upright protection system is installed independently to the uprights, which means any impact is deflected away from the racking and transferred to the concrete floor. It offers a robust and effective way to protect the pallet racking investment and improve warehouse safety.

PPG opted for front and rear guarding throughout the warehouse storage system, further enhancing the quality of the overall solution.

Dangerous Goods Compliance

Working closely with Hamilton Fire, SSS engineered a complete fire safe solution for the storage of flammable goods. The solution included a 16.5m high, floor-to-ceiling dangerous goods cage, complete with locally engineered fire baffles, fire sprinklers and automatic sliding gates, which were linked to the fire indicating panel (FIP) in case of emergency.

Fire Safety

The fire safety strategy incorporated comprehensive sprinkler coverage across all storage zones, ensuring compliance with Australian fire regulations and maintaining safety for flammable and non-flammable goods alike.

Traffic Management and Safety

In a busy warehouse like this one, which has areas to be accessed by both material handling equipment and pedestrians, traffic management is an important consideration to ensure operational flow and to keep people safe. SSS provided a complete traffic management system, including Armco railing and line marking, always ensuring clear and safe navigation throughout the warehouse.

Battery charging zones were also marked with epoxy resin, which will aid in containing and protecting the concrete floor should there be any oil spills by material handling equipment.

Small Parts Shelving

To accommodate smaller items, such as product sample swatches, custom shelving was added near the front of the warehouse. This allowed for efficient access to these items as required.

Certification Requirements

As part of Safer Storage Systems’ complete, end-to-end solutions, the team takes care of all certification and permit requirements. For PPG, this included the building permit application process, which was broken down into three stages to coordinate with the move from Sydney to Melbourne without disruption.

Project Management

A key factor in the successful delivery of this project was the efficient and effective project management. Jazmyn Wray, the SSS project manager leading this project, played a pivotal role in ensuring that timelines were met, and all stakeholders were kept informed throughout the process. Her proactive approach, including regular progress updates and quick resolution of any issues, helped to maintain momentum and prevent delays.

Jazmyn coordinated seamlessly between all stakeholders, ensuring that each phase of the project progressed smoothly. Her hands-on involvement, along with meticulous planning and attention to detail, was instrumental in completing the project on time and to a high standard.

Results

This project showcases the importance of strategic collaboration and meticulous project management in delivering a successful warehouse solution. Despite the tight deadlines and complex requirements, the combined efforts of PPG, Silk Contract Logistics, and SSS resulted in a high-performance warehouse that is fully compliant with safety regulations and ready to support future growth.

The project stands as a testament to the value of working with local suppliers and partners who are capable of meeting the unique demands of modern warehousing.