Hello, my dear logistical beings! Welcome to another video lesson. Today, I'm here in Vinhedo, in the interior of São Paulo, near Campinas, at the invitation of Solística, together with Decra.
This website is wonderful! The video was incredible and there is a lot of innovation. For example, have you ever seen a logistics operation with PCP?
Here, item turnover is quite high, due to the constant dynamic of new products entering. Have you ever witnessed a logistics operation with 1. 5 million cubic meters of cold monitored 24 hours a day inside a Bunker?
I didn't imagine finding an ice factory around here! Just look at this order cycle wall. Here, inside the control tower cell, we can monitor everything that happens.
Let's look at four types of operations. In dry operation, we are talking about 22,000 pallet positions. What is flammable is very interesting; I hadn't seen this technology yet.
Regarding refrigerated and frozen foods, when the seal is placed, we have two hours to complete the shipment. How is the packaging done? Here, products include many high-value- added vaccines for both animals and humans, and this requires strict control of shelf life, order cycle and temperature, as well as customer service.
We show a lot of content! Let's see if we can include everything in this video, but it's very important that you leave your like here. This video took all day to produce, and I understand that the content is very different.
We have never published anything like this. For those who may be coming to the channel for the first time, my name is Carlos Mexique, I have been a specialist in the logistics field for 23 years and I work as a consultant. Many things I saw here were new to me, especially in this operation.
Come on, let's start our video! We are arriving at Decra to ship the products. I'm looking forward to learning a little more about this factory.
To give you an idea, access control is entirely through biometrics. Now, we are entering the packaging area; Obviously, we can't get in, so the team will come here to give us access. We are waiting for the release.
[Music] We arrive at the packing area. We are using this garment because the product is already inside the packaging. In the production area, where we actually deal with the bacteria that goes into the product, we would need to completely change our clothes.
Typically, this process takes about 10 minutes. To give you an idea, people who work in the production area cannot leave there. When they go out, all the clothes they wear are not thrown away for washing.
So, for lunch, they change and put on new clothes to access the production area. Here, control and hygiene are essential. This product, lept, comes from the production area through a small hole in the wall, via a conveyor belt.
The employees here will inspect it to check whether it is well sealed, whether the screen printing is clear and, mainly, the issue of the expiration date and the batch. These are crucial points in the evaluation of the product, which is done here before starting the packaging, which will be carried out next. You have seen that, for example, packaging and labels are consumed here.
The way to supply the unit is through a small lock. Note that it can only be opened if the other door is closed. Here, the green part indicates that the raw material and packaging will be passed through this tunnel.
On the other side, the person places the packages and normally uses alcohol to sanitize them. This alcohol is used to disinfect the packaging on the outside before placing it inside. It's a totally different supply process.
Note that the quantities are also small, because there are no large batches of packaging coming here; These are only small quantities due to the high added value of the product. We arrived here and the product is ready. We are on the border between packaging and shipping.
Our logistical being will open the door for us. He cannot cross to the other side, as this would change the hygiene protocol. So he opens the border gate, takes the pallet there, Leave the pallet at the border and come back.
He cannot go beyond that door; it's just to collect and then close the door for the team to take the product to the cold room. Now, let's change our clothes and head to the other side, where we will carry out the expedition using a refrigerated, isothermal truck, etc. The truck is plugged into the socket to ensure vehicle cooling.
It will come out of an area of 15ºC, which is where we are now. You can see the logistician bringing the pallet. From this 15ºC area, it will come to the expedition and board the truck.
Here, we have a leveling dock that makes the process easier. The dock allows for continuous flow due to its application. Well, then the truck is refrigerated because, in this case, there is no ice inside the boxes, so there is no need for ice, right?
Note that the floor has a lane; it has a very deep ray so that air can circulate above and below. So, do you see here? This is where it is releasing cold, cold air.
[Music] Here we will learn about the active part. Look, don't tell anyone! Come here, let's see the administrative part of Solística.
I thought it was really cool to show this due to the size of the team that is working here. This is perhaps one of the hearts of the operation, where all Solística customers make money, which is precisely in managing the order cycle. Let's show this now.
Certainly, this is the competitive advantage that the logistics operator offers to its 44 different CNPJs in this operation. Inside the control tower cell, we can monitor what happens. The big advantage is that this operation does not work in D0, but in D1.
There is a cutoff that takes place at noon, and all orders are consolidated for 24 hours so that these 85 to 90% of the vaccine cold chain market share are together and can be consolidated at the time of dispatch. The business intelligence is in the PCP and the routing part, which takes these orders. The PCP analyzes what can be shipped by air and what can be shipped by road, depending on delivery lead times.
This goes to routing, which groups all 24-hour orders, consolidates and generates a great competitive advantage, as they manage to group several different customers going to the same destination, for the same CNPJ, generating a cost advantage in transportation and distribution, which is a representative part of the cost. So, here it is very important to understand what advantage the logistics operator offers the customer. Let's see the operation!
I'm arriving at the dry area, one of the areas available in this large complex. There are more than 120,000 m² in total. On this ship, we are talking about 22,000 pallet positions, with 13,000 m² of area and 27 docks, which we can see here on my right side.
On the left side are the pallet racks. We are going to Rua S, where Decra products are located. The structure of the logistics operator is interesting.
The products we will see here are from the dry line. This warehouse, being dry, allows up to 30ºC; with a temperature of 28ºC, it activates a circulation device to lower the temperature. In other words, it ensures that the temperature never reaches 30ºC in the critical area, which is the ceiling.
The sensors are up there, glued to the ceiling. Today is a relatively hot day, but it's super pleasant here. Let's see sales support products, such as marketing products, inside a dry warehouse.
Here we will even have pens for veterinarians, folders, flyers and items to support product launches. There is a very large turnover of items, as new products are always coming in and others leaving, when they no longer make sense. Here it is a traditional storage and separation process, with closed pallet racks at the top and a picking area at the bottom.
There is some access control, as you can see. Keyed, we have gold pendants and cool pens for vets. There are products with high added value that are protected here, guaranteeing a certain access control.
But the great idea is to have the sales support product, the merchandising product and the marketing product together, because, at the time of distribution, the flyers go together with the merchandise on the same truck on their way to the customer. Like this, the final destination is the same, which generates savings on freight, always optimizing costs. Our mission here is to always optimize, especially the shipping cost, which is a high cost.
The air-conditioned warehouse, in this case, varies from 15 to 25ºC. It is interesting to note that the temperature control acts both downwards and upwards, as it cannot exceed these limits: it cannot go below 15ºC or rise above 25ºC. You must already be hearing the noise of the evaporators, which are strategically positioned.
In the bunker, they virtually control the temperature of all Solística refrigerated warehouses in Brazil. We are now in the Decra corridor, which is corridor G. Here, we can already see Decra products .
In this configuration, it is important to understand that the area is segregated for the client. These corridors are dedicated to Decra's operation, and the operator here is trained specifically for this operation, knowing Decra's products well. Remembering that the operation here is always full case; 95% of what happens here is full case separation.
We can clearly identify the Decra corridor signage. Another practice that I like to highlight is that shifts and key users are trained for the operations that take place here. Let me show you some typical products of yours.
This one is a product from the Pet line, aimed at puppies. Please note that all these products, both for meat animals and pets such as dogs, cats, horses and pigs, are valid for 24 months. However, as tests are carried out during three months of these 24 months of validity, this means that three months have already been lost, making validity a critical aspect for control, especially as they are products aimed at the pet and animal consumption line.
Therefore, there is great concern regarding the quality of the processes. When we talk about temperature, validity and batch control, all products here have batch control and are inspected by several responsible bodies. To give you an idea, there are eight bodies that monitor these products and ensure that they comply with market regulations and standards, often even following European standards.
This demonstrates the relevance of the service provided by Solística and the peace of mind it offers to those who hire it, as is the case with Decra. Now, let's go to the refrigerated area. This area has a very big peculiarity regarding the temperature, which must be between 2 and 8 degrees.
Therefore, I need to use specific PPE to protect myself. This area is monitored 24 hours a day by a person in the bunker. Remember I mentioned the bunker where the security part is?
There, a person monitors all the thermal sensors to check that everything is in order. If there is any contingency, in addition to the electronic devices, a person is there controlling everything. It's interesting that working here also has its peculiarities.
At 1:40, the product spends 20 minutes in thermal recovery in a container next to it, allowing the team to have a cup of coffee and relax a little, while the body recovers the appropriate temperature. This operation is quite peculiar and the procedures here are very strict. For example, if the temperature reaches 88ºC, this is the maximum temperature allowed.
If it reaches 7. 5ºC, an alarm goes off, warning staff to close the doors in order to maintain the temperature. I want to show you Decra products, which obviously come from the factory in this white styrofoam.
There are two sizes: a 50-liter and a smaller one, but most sales are made on the larger device. The separation is done in boxes, because the operation is full case, and this needs to be placed on the production line where the ice will be applied. I will show you the products.
Just to give you an idea, this one is a livestock vaccine, which arrives in bulk. They need to take the product, bag it, place a bag with the product and add the ice. There are two types of ice: gel ice and flake ice, which I will show you on the production line.
Let me show you the best-selling product here: this vaccine, Excel 10, for livestock. It suits almost all types of animals, such as cattle, sheep, pigs and so on. Here We can now see the plastic bag, which is used to prevent ice from coming into contact with the merchandise.
This is important, because in PCP (Production Planning and Control) they need to know the distance from the customer. If delivery is within 48 hours, they can ship it by road transport. If it takes more than 48 hours, shipping must be done by air, as the ice will not withstand the temperature.
There are six states in the federation that are within a 48- hour service radius. So, they can ship it by road directly from here with the ice. For longer distances, delivery needs to be done by air, and it is the PCP that determines this.
Now, let's see what the ice production line looks like. I didn't imagine finding an ice factory here; they produce 19 tons of flake ice. Look here, a wall of ice!
This is to serve all refrigerated customers, not just Decra. This ice is of the scale type and is not intended for consumption as drinking water, which is why there is a plastic bag to isolate the product from the ice. It is very interesting to note the economic value that this operation generates.
This entire operation is supported by generators, in case of energy supply problems, which is a fundamental contingency for operation here. The separation process is traditional: the SKUs are separated, one SKU per box. After separation, the process of adding ice and ice cubes begins.
In this case, we are talking about gel ice. This 50-liter box can fit eight units. Here is the product.
To avoid humidity, this is on top, two more on this side and four on top. If I learned well, let's see here: TRS and the last one that closed. I added the ice, watch.
I'll pass it on to Wandel now to seal it. When it seals, we have two hours to complete the shipment. If, eventually, I don't know, the truck doesn't show up and it takes more than two hours, what will we have to do ?
Take that box again and put the ice back in, because it needs to stay for two hours before it can be shipped. Otherwise, we reprocess the ice for quality and control reasons again. Very interesting!
I thought it was really cool, thanks guys. Now let's go to the last deposit, which is the flammable deposit, which I'm going to show you. We arrived at the operation's flammable warehouse.
Of course it's not the same size as the other areas, but it's very peculiar. The peculiarity begins, I believe, with the sprinklers. You can see, especially in the image you are seeing, that all levels, all pallet addresses and all stringers have sprinklers installed.
Here, why? Because this is a dangerous place, with the risk of catching fire, like acid, and so on. As if the sprinkler wasn't enough, note that the positions of the pallets are isolated from each other, because, if it catches fire here, the fire will not spread directly to the next part, as there is a steel plate that provides insulation.
Another very important point: did you notice a little yellow mark here? The pallet cannot exceed this to guarantee space. This free space is to ensure that the sprinkler can spread the water and put out the fire.
Another interesting detail, which you can see well, is the containment basin we have here. See this grid? If there is any acid or liquid that drips and spills onto the floor, it tends to be captured by the containment basin, preventing it from spreading.
So, it's all these concerns. And the icing on the cake is this: in this area here, look up there, the air area. The air is pushed downwards and exits through the intake here, changing the air throughout the warehouse three times an hour, preventing any gas or vapors from accumulating, ensuring the safety of operators and ensuring that the air is being renewed.
Very interesting! I had not yet seen this air exchange technology inside a flammable warehouse. Very cool!
Comment if you liked this information. Thank you very much for making it to the end of our video. I think this was one of the most complete videos we were able to show, with several different operations.
I would like to express my gratitude to the staff at Solística, who welcomed us very well, opened all the doors and showed all the operations, including things that were not even within the scope of this video. We were able to meet, enjoy and learn from the Solística team. Many, many thanks to the people at Decra, Alexandre and the entire factory team who welcomed us and invited us to put together a project like this, a video that makes a lot of difference, as we understand how it can help you, which is logistical, to see other perspectives and different visions of logistics that you might not have even imagined, such as, for example, the cold chain, which is a very peculiar operation, complex in terms of control.
This shows Solística’s excellence in solving this type of problem. So, guys, please, at this moment, it's your turn to reciprocate: like, subscribe to the channel here and share this content so that more and more logistics professionals have the privilege of learning about this type of operation. That was it for today!
A big kiss and see you in the next video. It cost!
