Peacock Bros RFID cuts box retrieval to one worker

Peacock Bros. has deployed an RFID tracking system for a global information management company, which is now using it across its operations in Australia and New Zealand.

The project addresses one of the toughest tasks in records storage: finding specific boxes among millions stored in large facilities. The customer provides secure document storage, digital transformation, data protection and destruction services for businesses with strict compliance and privacy requirements.

Before the system was introduced, locating files and documents required two workers and a forklift. That approach created operational strain at sites where storage racks extend to significant heights and below ground level.

The challenge was especially acute in sectors such as healthcare and legal services, where access to records can be time-sensitive. Managing inventory across multiple sites with millions of boxes added further complexity to daily operations.

System design

Peacock Bros. developed a combined hardware and software system designed to identify a tagged box in dense storage conditions, including boxes stored four deep in racking. It uses a Zebra TC21 handheld unit with a Zebra RFD90 RFID reader.

Operators scan tagged boxes with the handheld device and follow audio cues that intensify as they move closer to the target item. This has reduced the number of people needed for the task and, in many cases, removed the need for the earlier forklift-based search method.

George Pecchiar, Executive Director CTS, Peacock Bros., said the rollout was designed to meet practical retrieval needs rather than introduce technology for its own sake.

"Our goal was to develop a solution that wasn't just about leveraging technology for the sake of innovation, but truly addressing the practical needs of rapid, accurate, and safe document retrieval," said George Pecchiar, Executive Director CTS, Peacock Bros. "We proposed an integrated solution supported by the Zebra TC21 Handheld device, an Android-based unit used in conjunction with the Zebra RFD90 RFID Sled. This choice was driven by our commitment to offer a solution that was both powerful and user-friendly, enabling operators to swiftly locate tagged boxes with increasing accuracy as they move closer."

In Australian operations, the previous retrieval process delivered limited efficiency gains. With RFID-based identification, a job that once required two operators can now be completed by one worker.

Operational shift

The rollout also reflects a broader shift in warehouse and records management, as businesses adopt automatic identification tools to improve traceability across large storage footprints. In document-heavy industries, the speed and certainty of locating a single container can directly affect customer service and internal handling costs.

The RFID model was initially introduced as a premium service for selected customers. After proving effective, the client made it a standard offering across all customer engagements in Australia and New Zealand.

That suggests the deployment has moved beyond a limited pilot into core operating processes, indicating the client saw enough value to expand it across its regional business.

Peacock Bros. has a long history in labels, printing and supply chain technology in Australia and New Zealand, supplying products and systems to more than 12,000 customers in the region. Part of the Peacock Group, it also provides thermal label printers, barcode scanning tools and software for logistics and warehouse environments.

The RFID setup is intended to simplify the search process while improving safety for staff working in complex storage sites, particularly in facilities with high racks, constrained access and labour-intensive manual searches.

Practical impact

Pecchiar described the practical effect of the system in a second comment.

"Our RFID system introduces a simple yet highly effective approach, boxes filled with vital documents have RFID tags attached, which are easily scanned and located with a cutting-edge handheld device, streamlining the entire search process to just one person," said Pecchiar.