PM Modi to Launch High-Tech ASRS Storage at Banas Dairy’s Palanpur Plant
PM Modi inaugurates a ₹31.14 crore Automated Storage and Retrieval System at Banas Dairy's UHT plant in Palanpur to boost dairy logistics.
Prime Minister Narendra Modi is set to inaugurate a cutting-edge storage facility at Banas Dairy’s Ultra Heat Treatment (UHT) plant warehouse in Palanpur, Gujarat. This state-of-the-art Automated Storage and Retrieval System (ASRS), developed at a cost of ₹31.14 crore, is designed to revolutionize how dairy products are stored and managed, moving away from traditional manual labor toward a fully automated, data-driven ecosystem.
What is the ASRS Technology?
The Automated Storage and Retrieval System (ASRS) is a sophisticated logistical solution that employs a combination of cranes, robots, conveyors, and shuttles to handle inventory. Unlike conventional warehouses, this system uses specialized software to monitor every item in real-time, ensuring that order processing is expedited and operational precision is maximized.
The Palanpur warehouse features a unique 'mother-child' shuttle arrangement. In this setup, a 'mother' shuttle transports a 'child' shuttle to specific lanes within the racking system. The 'child' shuttle then glides into the racks to either store pallets and boxes in their assigned spots or retrieve them for dispatch. This high-tech choreography minimizes human intervention, drastically reduces the margin for error, and accelerates the speed of operations.
Infrastructure and Capacity
The new facility is built for scale and efficiency, boasting:
- Steel Racks: Extending up to 9 levels in height.
- Storage Capacity: Space for 11,000 pallets.
- Full Automation: A seamless link from the packing line to the dispatch area.
Transforming the UHT Plant Operations
The UHT plant in Palanpur, which began operations in 2015, utilizes a specialized thermal treatment process. This allows milk and dairy products to remain fresh on shelves for up to six months without the need for preservatives or refrigeration. The new ASRS warehouse will store a variety of these products, including 'Cow-Buffalo Gold', 'High Protein Lassi', 'Apple Tru', and 'Tea Special'.
The plant is a powerhouse of production, processing 5.5 lakh litres of milk every day. With an annual revenue projected at ₹1,050 crore for 2025-26, the facility currently operates at approximately 90 per cent of its peak capacity. Its reach extends far beyond Gujarat, exporting high-protein drinks, ghee, spiced buttermilk, and milk to international markets including the UAE, Singapore, Malaysia, and the Maldives.
Out with the Old: Why Automation is Necessary
For years, Banas Dairy relied on traditional warehousing where forklifts moved pallets from packing lines to storage. This method presented several bottlenecks:
- Space Constraints: Forklifts require wide aisles to maneuver, wasting valuable floor space.
- Height Limits: Manual stacking is limited in height, restricting total storage volume.
- Human Error: Locating a specific batch among thousands of pallets was time-consuming and prone to mistakes.
The ASRS eliminates these hurdles. By recording the exact location of every pallet in a computer system, the warehouse no longer requires staff to manually search for goods. Whether a batch needs a quality inspection or is ready for market dispatch, its status and location are identified instantly.
A New Era for Banas Dairy
This inauguration marks a pivotal shift in the operational philosophy of Banas Dairy. While previous automation efforts were concentrated on the processing and packing of milk, the introduction of ASRS extends this technological leap into warehousing and supply chain management.
The warehouse is no longer just a static storage space; it has evolved into an automated bridge that connects the production line directly to the consumer market, ensuring that the journey from the farm to the table is faster and more efficient than ever before.