ALF Aquatic Distributors Streamline Operations and Eliminate Waste with Toyota Material Handling UK
ALF Aquatic Distributors partnered with Toyota Material Handling UK to improve warehouse efficiency, increase storage capacity and reduce waste without expanding their existing footprint. By introducing Radioshuttle technology, the business streamlined picking, improved stock rotation and created a strong platform for future growth.
About ALF Aquatic Distributors
Founded in 1988 and based in Bedford, ALF Aquatic Distributors Ltd has become one of the UK’s leading wholesalers of aquatic products. The company supplies retailers nationwide and further afield with everything from fish food and water treatments to pond equipment and accessories.
Over nearly four decades, ALF has built its reputation on two things: a comprehensive product range and a commitment to outstanding customer service. As the business has grown, so too has the importance of running an efficient warehouse operation capable of supporting that service.
The Challenge: Making Room for Growth
During the COVID-19 pandemic, interest in home aquatics increased significantly as more people turned to fishkeeping and pond care as hobbies. For ALF, this surge in demand created an exciting opportunity for growth. However, it also exposed limitations within the company’s existing warehouse operation.
Picking stock is labour-intensive and time-consuming, creating busy working days for employees. Valuable warehouse space was not being used as effectively as it could be. Managing stock rotation was increasingly difficult, particularly for products such as fish food and water treatments with finite shelf lives. At the same time, overheating conveyor motors were regularly triggering the fire alarm system, causing avoidable disruption.
Relocating to a larger premises wasn’t an option for ALF, due to the significant cost, operational upheaval, and scarcity of warehouse spacing in the local area.
Instead, ALF wanted to find a smarter way to increase capacity and improve efficiency within its existing footprint. They were keen to understand how their current picking processes could not only be made faster, but more accurate
Searching for a Better Solution
After researching a range of storage options, the ALF team identified Radioshuttle technology as a potential solution. To explore the concept further, they approached Toyota Material Handling UK.
Working closely together, the two companies assessed ALF’s operational challenges and identified opportunities to remove waste from the warehouse.
The project was guided by the principles of the Toyota Production System (TPS), particularly the concept of muda - activities that consume time, space or resources without adding value.
The Solution: A Radioshuttle Pilot Project
Following a detailed review of ALF’s operation, Toyota Material Handling UK recommended a pilot installation consisting of nine radioshuttle lanes.
Before the project, this section of the warehouse featured:
- Nine lanes of drive-in racking across three levels
- Manual picking processes
- Limited visibility and control over stock rotation
- Conveyor systems prone to overheating
- Time consuming access to products in the second or third levels of the racking
Toyota replaced this with:
- Nine lanes of radioshuttle racking across two levels, with the ground level being accessible via hand pallet trucks
- Automated pallet movement within the racking, allowing faster access to pallets to put away and take out
- A First-In, Last-Out (FILO) stock management system
While the number of pallet locations remained broadly the same, the new system transformed how stock was accessed, managed and replenished.
Immediate Operational Benefits
Better Stock Rotation and Less Waste
For ALF, effective stock rotation is essential. Products such as aquatic food and water treatments can lose value if they approach their expiry dates.
The new system ensures that older stock is always presented first, letting workers have better control over stock replenishment, and higher volume to be ordered by the purchasing team due to increased accessibility. This has helped ALF reduce the risk of unnecessary write-offs and protect profit margins.
Faster, Easier Picking
Previously, workers spent valuable time manually moving pallets to access stock, sometimes needing to move extra pallets just to move the targeted product – wasting time and effort.
With the Radioshuttle system, pallets are automatically brought to the front of the racking, making products immediately accessible. This has expedited the pick face replenishing process and reduced the amount of manual handling required.
Improved Use of Space
The new racking system has increased back-stock capacity and improved access to inventory, enabling ALF to make better use of its existing warehouse.
As a result, the business has been able to support continued growth without the cost and disruption of moving premises.
Reduced Downtime
By removing the conveyor motors that had been overheating, ALF has eliminated a recurring source of operational disruption.
The warehouse now runs more reliably, with fewer interruptions to daily activity.
A Low-Risk Approach to Change
Rather than committing to a full warehouse redesign from the outset, ALF chose to begin with a pilot project.
This phased approach allowed the business to test the solution in a live environment, confirm the operational benefits and build confidence among the warehouse team, all while keeping risk to a minimum.
The pilot quickly demonstrated its value, and feedback from the ALF team has been overwhelmingly positive.
Looking Ahead
Following the success of the initial installation, ALF plans to continue working with Toyota Material Handling UK to introduce additional Radioshuttle and racking systems across the warehouse.
The pilot has provided a clear roadmap for future improvements and created a strong foundation for continued growth.
By partnering with Toyota Material Handling UK, ALF Aquatic Distributors has transformed a key part of its warehouse operation without increasing its footprint.
Using the principles of the Toyota Production System, the business has reduced waste, improved stock control, increased operational efficiency and freed up its team to focus on delivering excellent service to customers.
The project demonstrates how the right combination of warehouse design, automation and operational expertise can help growing businesses unlock more capacity and prepare confidently for the future.