Gestamp Tallent: VNA Racking

Challenge: Meeting Growing Storage Demands for Automotive Pressings

Gestamp Tallent, a global leader in automotive chassis and suspension components, expanded its Aycliffe plant with a new 45,500 sq. ft. press hall. To support 15% projected growth over seven years and optimise storage for pressings and fasteners, the company required a high-density racking system that could safely withstand press vibrations while maximising the available footprint.

Approach: Custom VNA Racking

Link51 collaborated with Gestamp Tallent to design a custom Very Narrow Aisle (VNA) racking system, considering the site's weight constraints and vibration challenges. Key design elements included:

• 9 runs of VNA racking with P&D stations for 4,500 stillage locations.
• Reinforced top-tying for stability against press vibrations.
• Collaboration with Linde to optimise materials handling, including wire-guided trucks for safe navigation in narrow aisles.

Safety was prioritised with extra-heavy-duty anti-collapse mesh and a robust structure to handle significant stillage weights.

Solution: High-Density, Safe & Scalable Racking System

The installation included:

• 4,500 stillage locations within a compact footprint.
• Wire-guided trucks for precise, safe operations in the VNA aisles.
• A pick-face system for smaller pressings with tote boxes for efficient manual handling.
• Additional safety measures, including anti-collapse mesh and top-tying for vibration resistance.

The system delivered an efficient, future-proof solution to support production growth.

Key Features

• VNA racking with 4,500 stillage locations.
• Advanced safety features for press vibration resistance.
• Wire-guided trucks for precise aisle navigation.
• Scalable design for future capacity expansion.