Zebra Technologies

With a rich history of innovation, Zebra is recognized as an industry leader in enterprise mobile computing, barcode scanning, specialty printing, RFID readers and more.

Recently, they were looking to make the maintenance of multiple production lines easier and more efficient. The production line area was tight and adding extra people for maintenance, with the current setup, was a detriment to production and working conditions.

Zebra Industries reached out to The Mezzanine Company to provide a solution. Several challenges would need to be overcome for a successful project:

1.     The production area, where the mezzanine was needed, was in an extremely tight area

2.     Production lines could not be shut down, so any work would have to be done outside of the normal business hours

3.     No “hot work” would be allowed due to a restriction on any sparks in the building

Working closely with Zebra Technologies, we came up with a design for a 1,700 square foot mezzanine that would meet their needs. To accommodate the tight area, the mezzanine was custom designed with precise column locations to work around the existing equipment below. Additionally, the mezzanine had several cutouts to allow for existing equipment and building columns to pass through (see photos).

For employee access, the mezzanine included an IBC staircase with an intermediate landing.

Once the proposal was accepted, approval drawings were generated, and our team made a site visit to make the finishing design adjustments. Additionally, we provided PE stamped drawings for the State of New Jersey to be used for permitting.

Once the mezzanine production was complete, we arranged for a prompt delivery and coordinated together the best installation schedule. To work around their installation timing requirements, the install was done over two weekends. Additionally, to avoid any “hot work”, special tools were used.

In the end, Zebra Technologies ended up with the required storage space needed, with minimal interruption to business.

Rob Reilly, from Zebra Technologies, had this to say about our service, "Your crew worked quickly and safely.  This was a very complicated installation, with 800-pound beams getting lifted over two $4,000.000 process lines. You committed to a very tight timeline, and you were able to honor it, stick with it, and make it happen.. Your crew was willing to work off-hours and long days. They were collaborative and cooperative when issues, or potential issues came up that required “field huddles”. "