Dexion’s largest insallation for P&G in Hungary
Established in Cincinnati, OH 1837, today P&G is one of the largest global powerhouses we know today. Globally P&G serves nearly 5 billion people with a broad portfolio of trusted brands.
With operations in 70 different countries, P&G has 23 multi billion-dollar brands with annual sales reaching in excess of $83 Billion.
In 2012 P&G invited Dexion to tender for their latest factory GreenPearl project in Gyöngyös/Hungary. This brand new large scale 240,000 m² factory would manufacturer Pampers nappies supplying various countries throughout Eastern Europe.
At the beginning P&G selected six possible suppliers, which was narrowed down to three during the tendering process. A 3rd pary consultancy was appointed who adivsed the remaining suppliers quality and safety was key.
Eventually P&G chose Dexion as their preferred supplier, as Dexion had previously supplied P&G in other countries and they knew that we were able to deliver a product that they could trust.
It was clear from early discussions that this installation was complex. Dexion therefore appointed a dedicated Project Manager to oversea the project. It was quickly realised that such a project required our latest technology and software, as P&G were familiar with American racking safety standards which are far more stringent than the Regional Safety Codes.
Unusually P&G also required the installation to withstand an earthquake upto a magnitude of 8 richters. P&G were very specific in the process they followed in selecting a new suppliers, and how tenders needed presenting – Dexion followed these implicitly.
Once the technical drawings were ready we were able to share these with the P&G team of specialised engineers, to ensure that calculations were correct and the plans continued to meet the clients specifications. The weight of the racking was monitored constantly as we were not just planning to install a large scale solution but the project was seismic. Understandably, as safety was a major concer P&G then cross referenced data between competitors and our own international benchmarks to ensure that the proposed solution would meet P&G’s needs.
P&G also required Dexion to provide a detailed quotation, which included information regarding the materials, delivery and installation. A projected installation raodmap was also shared.
Boker Levente – P&G Project Manager said “ Throughout this project, Dexion has shown that they are able to deliver within rigid processes, and are still able to supply a first class solution.
In order to ensure that the project remained on schedule, daily meetings and reports were updated and shared. The status had to be transparent and a 3rd party consultant checked proceedings throughout the implementation of the project.
Once the system was ready to be delivered to site a special lifting technique needed to be adopted for the very heavy frames.
Bespoke upright protectors were designed and manufactured to guide pallets and improve the loading process, and increase safety. These uprights and the reinforcement of the racking were manufactured stronger than usual so that both teams could be confident that the system could withstand an earthquake.
AutoCad drawings of the racking were rendered as 3D models for rigorous checks and testing and every component, including the torque on the nuts and screws was understandably checked and approved by a third party consultancy company.
The installation team was split into two – one which focused on the technical parameters while the other focused on safety and installation.
In total Dexion installed 450 tonnes of Drive-In racking components at Greenpearl, which took a dedicated team of 20-25, and 2 months to install.
The project completed on schedule and within budget in September 2013.
The installation was a combination of Drive-in with seismic design, static rack with seismic design and HI280 solution, providing 11.000 pallet spaces.
The total factory space is 240,000 m².