001 revista bp en

1r Quarter - Year 2016 - No. 1

Cases StudiesBenco Dental / DAFSA / DHL / Gioseppo / Havi LogisticsHayat Kimya / Hemosa / Hepco Motion / Iron Mountain / Luis SimõesMGA / Nufri / PAVI-Groupauto / Takeda / Ypê / Zbyszko

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7979Index13 HAYAT KIMYAOne of the tallest warehouses in Europe in an earthquake prone zone in Turkey.

29 GIOSEPPOAutomated clad‐rack warehouse with a capacity of two million pairs of shoes.

41 YPÊHigh‐rise warehouse with massive picking area for the Brazilian company Ypê.

49 TAKEDAAlmacén automático llave en mano para el gigante farmacéutico japonés Takeda.

59 NUFRIRacks on Movirack mobile bases for their headquarters in Catalonia.

63 MGAEfficient automated miniload warehouse with conventional racks.

71 LUIS SIMÕESThe operator equips their installations with a Pallet Shuttle system combined with conventional racks.

79 DHLNew logistics centre for DHL on the outskirts of Madrid.

87 PAVI-GROUPAUTOConveyors on several floors the axis of a picking installation.

95 HEMOSAMecalux equips the processing plant for Hemosa located in Madrid.

103 ZbYSZKOThe Polish manufacturer Zbyszko Company entrusts Mecalux with the connection of theproduction area with a new automated warehouse.

111 DAFSAA singular warehouse in choice surroundings.

127 HAVI LOGISTICSThe logistics services business relies on mobile bases to keep growing.

131 HEPCO MOTIONA special mobile racks with cantilevers solution installed in the United Kingdom.

135 IRON MONTAINEarthquake‐proof racks in the Belt of Fire in the Pacific.

139 bENCO DENTALInterlake Mecalux speeds up the picking at Benco Dental.

146 OUR ExPERTS- Logistics software, the cloud is the

future.- Clad‐rack warehouses: when the racks

also support the building.- How to calculate the structure of

conventional pallet racking.

News I Mecalux

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Safety in the warehouse is the foundation on which to develop an installation’s day-to-day work operations in an efficient and risk-free way. Therefore, Mecalux invests a signi-ficant part of its R&D resources to improve the security devices of all its products.

The latest innovation in this respect is the incorporation of a new junction system between uprights and beams in Mecalux pallet racks. This involves a connector with a locking system, developed to provide greater safety on the whole.

Its most outstanding contribution is the in-tegration of a safety locking mechanism in the actual connector, which results in two key advantages: on the one hand, it is im-possible for the safety device not to work or to lose it accidentally; while on the other

hand, once it is assembled it is not possible to remove it without the disassembly of the entire beam. This prevents accidental or deliberate manipulation of the connector – with a blow by a forklift, for example – thus avoiding the beam displacement and its possible consequences, such as the collapse of the load.

After successfully introducing this new locking system into installations set up in the United States, where Mecalux is a lea-der in the pallet racking market, it is now integrating it into all their projects within Europe.

They are the only manufacturer on the European continent to develop and incor-porate this breakthrough device into their storage solutions.

Keeping with its commitment to innovation and new technologies, Mecalux has com-pletely updated its e-commerce portal for Spain, offering a new design, new content and a better user experience.

The new Mecalux Shop specialises in the di-rect sale of metal shelving and related pro-ducts to warehouses, workshops, offices, archives, change rooms, etc., building on the extensive knowledge and experience of Mecalux within the sector.

Among the newly inte-grated enhancements are the following:

• New categories and advanced search filters which allow you to easily find any product.

• More information on each product: description of main product features, with more detailed technical information and more pictures.

• Making a purchase is streamlined and speedy with a user friendly design.

• Optimised design for smartphones and tablets.

• More advantages for registered users: custom offers, easy personal data admin, order tracking, purchase history access, etc.

Another of the key points of Mecalux Shop is its Customer Service, with professionals who know the product and its applica-

Safe and sound: Mecalux introduces an innovative safety locking mechanism

Mecalux Shop: a new look, new clickable content

tions and that, if necessary, can help the user to choose between different storage solutions.

With this rejuvenation and the inclusion of better features and navigability, Mecalux has updated its online sales gateway witn the steady flow of technological breakthroughs in the field of e-commerce and in the shifts in user enthusiasm. The end user will benefit from the esase of use.

News I Mecalux

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As one of the leading companies in storage solutions for more than 50 years, Mecalux invests significant resources in the develop-ment of new products and the continuous improvement of those which are already part of their catalogue. It always aims to in-corporate the latest in technological inno-vations to deliver better profitability.

So, one of the solutions that has experien-ced the greatest amount of development is the semi-automated Pallet Shuttle. This compact system uses an electric shuttle instead of forklifts to handle pallets inside the storage channels (that can reach 40 m in depth), considerably reducing manoeu-vring times and helping to streamline stora-ge processes for all kinds of companies.

Among the new add-on innovations what stands out is the adoption of Wi-Fi techno-

Maxi-innovation for Mecalux’s semi-automated compact storage

logy, which mul-tiplies the system benefits: the forklift operator communi-cates the storage and removal orders to the shuttle using a control tablet with Wi-Fi connection, with an intuitive, user friendly interface.

Different key features:

• Input and removal of pallets: conti-nuous or partial.

• Inventory functionality. • High speed: 90 m/min without load and

lifting time of 2 s. • Lithium batteries that provide up to

10 h of autonomous use, with a quick connect battery compartment that elimi-nates the need for cables.

• Pallet type selector (the shuttle sup-ports various sizes).

• LIFO/FIFO setup to select the load ma-nagement strategy.

• Position camera that facilitates the ope-rator in centralising the pallet on the rails (optional).

• Security scanner: controls access to the rails while the shuttle is operating (optional).

• Additional lock system that increases the clamping of the electric shuttle to the forklift blades.

• Compatibility with Mecalux Easy WMS software, or other generic WMS used by the customer.

• The lifting platform can receive pallets with buckling of up to 25 mm.

• Tiltmeter: detects the incorrect position of the shuttle within the channel

• Rescue: recovers the damaged shuttle from within the channel

The result is a new generation of Pallet Shuttle, which capitalises new technolo-gies to enhance the warehouse performan-ce and its profitability. It is an ideal solution for companies with a large volume of pallets per SKU and high loading and unloading activity.

News I Mecalux

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Mecalux has had a significant presence in Mexico for many years, with 8 sales offices. Being local, together with the experience of its team of professionals, has led nume-rous Mexican companies to rely on the Easy WMS Mecalux software, as a means to ma-nage and capitalise their storage processes.

Among the rollout Easy WMS projects sig-ned in Mexico in the past few months, the following stand out:

• Grupo Acuícola Mexicano (GB-PO). With Easy WMS they can au-tomate the management of one of its freezing chambers, controlling the entries from the production li-ne, and correct load management using FIFO and expeditions. • Distribución Hugo’ss. Within its improved processes, they ha-ve chosen the Easy WMS, which communicates with their SAP ERP, to speed up and streamline their picking processes, elimina-ting customer service errors.

• Polioles. ELeader in the petrochemical industry. Its main objectives are the reduc-tion of costs and storage errors, to control warehouse operations, product traceabili-ty and cross-docking management.

• Diseños Labor. With Easy WMS they can reconfigure their warehouse layout, the improved inventory visibility, handles

information real time via bar codes and radio frequency controls and, in general, automate warehouse processes.

• Grupo Comrap. They use Easy WMS in two warehouses, designed and built by Mecalux, in Mexico DF to manage large scale picking and fulfil their commitment to offer excellent service to their customers.

Furthermore, two prestigious univer-sities, the Autonomous University of Queretaro (UTEQ) and the Auto-nomous University of the State of Mexico (UAEM) have acquired the field license for Easy WMS Basic for academic use in the Logistics degree professorship.

The three university courses delivered in 2015, within the framework of the Mecalux UPC classroom, were created through the collaborative agreement between the UPC (Universitat Politècnica de Catalunya), the ETSEIB (Escola Tècnica Superior d’Enginyeria Industrial) of Barcelona and Mecalux, all being extremely reputable parties.

Due to success, this new training modules will be taught throughout 2016, which will give new students the opportunity to dee-pen their understanding of subjects such as the development of structures, robotics and the automation of storage facilities.

The objective of the UPC Mecalux Aula is to train up tomorrow’s professionals and provide them with the tools necessary to make advances in R&D&I within the logis-tics industry. To this end, Mecalux offers scholarships covering course fees for UPC master’s students, which fulfil the entry

Success, innovation & automation: the Mecalux UPC classroom offers new courses in breakthrough logistics systems in 2016

requirements, in addition to putting the Mecalux technological centres at their dis-posal and offering them the possibility of starting their career in the company.

New courses are scheduled to start in March of 2016, with 30 lecture hours, at the Mecalux UPC classroom premises.

Mecalux and the UPCAs a company that bases its leadership on technological innovation, Mecalux has for years been committed to fostering this company-University relationship, collabo- rating with the UPC and in particular with the ETSEIB, since 1979. All this through the Department of Material Resistance (LERMA), with which it has developed an Experimental Analysis of Characterisa-tions program and another of Research and Development.

Along these lines, the two entities have promoted the creation the Mecalux UPC

Aula, as a means of consolidating long-term collaboration in R&D&I activities and the transfer of research results and scien-tific dissemination within integral logistics related topics.

For more information and to register contact: http://aulamecalux.upc.edu/E-mail: [email protected]

Mecalux Easy Warehouse Management Software: a blockbuster in Mexico

Visit the Mecalux Mexico stand in the upcoming industry fairs at: Logistic Summit & Expo, México DF, on April 6th and 7th, 2016.Expopack, México DF, from May 17th to 20th, 2016.

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News I Our customers

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In recent months, the markets of Argenti-na and Peru have opted for the compact storage system Pallet Shuttle by Mecalux. This solution incorporates numerous inno-vations to streamline the processes of the entry and exit of goods in the warehouse. It also provides great storage capacity, thanks to an electric shuttle that loads and unloads pallets in the interior of the racks, moving autonomously along rails.

Among the projects recently carried out in these countries, two constructions, in parti-cular, stand out that have combined the be-nefits of clad-rack warehouses with those containing Pallet Shuttle racks.

In Argentina, Granja Tres Arroyos, one of the major producers and exporters of fro-zen chicken, has chosen this solution when building their new frozen cold-storage. The combination of a clad-rack warehouse with the Pallet Shuttle system is particularly re-commended in cold-storage, although, the building is not of great height. In addition to lowering manoeuvring times, it offers a high storage capacity that reduces the vo-lumetric area to be kept cool, resulting in energy cost savings.

On the other hand, the Mecalux Peru team has completed the construction of another clad-rack warehouse with Pallet Shuttle for Medifarma, one of the top 5 pharmaceuti-cal laboratories in Peru. In this project, gi-ven the diversity of the products marketed, the versatility of the system proved essen-tial, while also increasing the number of cy-cles per hour compared to a conventional system.

In both cases, it is worth noting that although these clad-rack warehouses are not very tall, they have also been the most profitable option for both companies. This is because the storage channels were cons-tructed to the depth which was strictly ne-

Logistics chain innovation in Argentina and Peru: clad-rack warehouses with Pallet Shuttle to be built

cessary, calculated according to their requi-red functionality.

The goal is to put new technologies and approaches within reach all kinds of com-panies, to multiply the productivity and pro-fitability of storage installations, achieving maximum performance within the logistics chain.

Mecalux, in their effort to provide up clo-se and personal service to its customers, are present in Argentina with two sales offices in Buenos Aires and a 21,000 m2 production centre, while there is also a delegation in Lima, Peru. Overall, the strength of the cus-tomer support is second to none.

Close up of the Granja Tres Arroyos warehouse in Argentina

Close up of the Mediafarma warehouse

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All in the family: Mecalux expands the Familia Group warehouse in Colombia

Familia Group, a company specialising in personal care and hygiene products, will expand its current clad-rack warehouse to reach a capacity of more than 16,000 pallets.

In 2011, Mecalux erected Family Group one of the first automated warehouses within Co-lombia. The installation, with a capacity for 7,416 pallets and 31.2 m high, is managed by three stacker cranes.

A few years later, the company has again cho-sen Mecalux to execute the Cájica warehouse expansion. The objective: to reach 34.4 m in height, increase capacity to include another 9,480 pallets, and install an additional three stacker cranes. Moreover, recirculation is set up that allows both the management of inputs from outside sources and internal production, and also direct dispatch from the warehouse. The warehouse management system, Easy WMS software, implemented by Mecalux will also be supplied.

With this expansion, the Family Group ware-house will achieve greater inputs and outputs, bringing it to the forefront of logistics within the tissue and the personal hygiene sector.

Çaykur’s, the biggest producer of Turkish tea, new clad-rack warehouse in Iyidere (Turkey) will be more than 40 m high and almost 160 m long.

Mecalux will provide a large, single aisle, automated warehouse served by three single-column stacker cranes and aided by Pallet Shuttle that are responsible for transporting 800 x 1200 x 2600 mm sized pallets with a maximum weight of 600 kg each.

In order to optimize accessibility to loca-tions, Mecalux has developed a control system and safe passageways that allow the stacker cranes to enter the annex zones. This is all controlled by the ware-house management system Easy WMS and the Galileo control software.

Mecalux will build Çaykur a clad-rack warehouse with a capacity for more than 29,000 pallets

In addition, input of goods will be done at the side the warehouse via three raised overpasses that connect the warehouse with the docking area. The elevated over-passes allow for workspace savings so that the ground floor remains completely available.

Çaykur, which opened its first tea factory in 1947, produces 133,000 tons of tea an-nually in 46 different factories, making it the largest tea producer in Turkey and one of the most important worldwide. This massive solution could only be properly set up using Mecalux’s extensive know-how.

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This company, specialised in the manu-facture and marketing of caps and clo-sures, will incorporate an automated and asymmetrical, four tiered ware-house into its Wiltz (Luxembourg) plant.

The warehouse, with a capacity for more than 5,000 pallets, will be managed by two stacker cranes and a Pallet Shuttle that will work with two types of pallets: 800 x 1,200 x 2,200 mm and 800 x 1,200 x 2,700 mm. The warehouse management system, Easy WMS, will also be supplied, tasked with managing all the centre’s own ope-rations. For the first time in its history, Easy WMS will be permanently connected to Axapta (Microsoft Dynamics AX), the ERP system that the client uses.

United Caps is a leader in the design and pro-duction of plastic caps and closures. With their headquarters in Luxembourg, this family business offers its innovative so-lutions throughout the world and has its own production plants in France, Belgium, Germany, Hungary, Ireland, Luxembourg and Spain. The company, which had an an-nual turnover of 122.000.000 € in 2015, employs more than 530 workers.

United Caps seals the deal: Mecalux to automate new warehouse

The very popular Brazilian company, specialised in the production of pre-cooked, frozen potato products, has entrusted Mecalux to design, ins-tall and launch a clad-rack automa-ted warehouse. This warehouse has the capacity of storing more than 33,000 pallets, 1,000 x 1,200 mm in size and each with a maximum weight of 1,120 kg.

The warehouse, which is more than 25 m high, has three twin-mast stacker cranes with Pallet Shuttle that allow for an input or output of 105 pallets/hour. Thus, the company’s required throughputs are

Bem Brasil is keeping cool with clad-rack: Mecalux sets up automated storage in Brazil

attained. The stacker cranes, when work-ing in deep lanes, are supported by a Pallet Shuttle that is responsible for mo-ving the pallet up to the location designa-ted by the Mecalux Easy WMS software.

Additionally, in order to ensure the per-fect condition of the goods, Bem Brasil’s clad-rack frozen storage is expected to work at a temperature of -30 ºC.

Founded in 2006, Bem Brasil produces more than 100,000 tons of pre-cooked frozen fries a year. It has become the na-tional leader within the sector, and one of the most consumed brands within Brazil.

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The French company, dedicated to the technological agribusiness sector, will have an automated mainland ware-house for boxes – with a capacity of more than 10,000 boxes – built.

The miniload warehouse is comprised of two double depth aisles where a stacker crane will circulate and be tasked with executing the in-put and output of 400 x 600 mm sized boxes, each weighing a maximum of 50 kg. In the

Agrarian giant Gregoire Besson announces new automated miniload warehouse in France by Mecalux

header of the automated warehouse, three P&D stations are set up to prepare orders of smaller products. In addition, the installation will be equipped with six conventional pallet rack aisles with a capacity for 4,440 pallets and a cantilever rack for over-sized products.

Thanks to the different storage solutions provided by Mecalux, Gregoire Besson will optimise space and, at the same time, streamline order preparation.

Gregoire Besson, with almost 200 years’ ex-perience, is a leading French company in the manufacture of agricultural machines and in the implementation of technological so-lutions designed to optimise land produced resources. With a large representation worldwide, their ploughing machines are innovative, effi-cient, robust and adaptable to the characte-ristics of any type of arable land.

Home decor’s largest warehouse: Mecalux will equip Maisons du Monde with new installation

The new conventional pallet rack ware-house, of the French company speciali-sed in home decor, will be built within a 96,000 m² logistical centre located in Saint-Martin-de-Crau, a town in the south of France.

Distrimag, the company responsible for dis-tributing products to customers of Maisons du Monde, has once again commissioned Mecalux with supplying a warehouse for pallets. Since 2007, Mecalux has built them

10 warehouses that are divided into 4 lo-gistics centres (Saint Martin, Fos Distriport, Feuillanne and Boussard) and that allow the storage of a total of 304,000 pallets. In this way, Distrimag commands 477,600 m2 of storage in strategic locations in the south of France, extending its firm grip on the de-coration market.

Founded in 1990 by Xavier Marie, Maisons du Monde has 260 shops spread throughout France, Italy, Spain, Luxembourg, Switzer-land, Germany and Belgium, and which em-ploy more than 4,500 workers. The Group has more than 40,000 high-quality pro-ducts, making it one of the leading compa-nies in home decor in France.

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The new automated warehouse, to be built in the Polish town of Zary can store more than 20,000 pallets, or 2.9 million square meters of finished product.

Kronopol, one of the world’s leading pro-ducers in wooden material manufacturing, has commissioned Mecalux to construct its new automated warehouse for pallets, where the floor panels fabricated by the

company will be depo-sited. The warehouse, composed of four aisles with double depth racks, measures 30.3 m high, 32.9 m wide and 89.3 m long. In each aisle a stac-ker crane will circulate that is able to move 840 x 1,410 x 1,200 mm pallets, with a maximum weight of 1,075 kg each.

This installation, which is scheduled for comple-tion in the third quarter

Kronopol goes automated: Mecalux constructs custom warehouse for timber products

of 2016, was the Kronopol organisation’s most substantial investment in 2015. Its construction, apart from increasing storage capacity by maximising available space, will give the company a series of advantages. Among these are complete automation, an increase in the loading and unloading speeds of vehicles, and the preclusion of damaged goods caused by forklift usage. In addition, the warehouse is also distinguis-hed by being environmentally friendly be-cause the solutions used will work via elec-tricity, which will eliminate the emission of gases.

The Polish company Kronopol, present in more than 50 countries, has been part of the Swiss Krono Group holding company since 1994. Throughout this process, the firm has become a worldwide leader in their sector, thanks to the quality and va-riety of their timber products earmarked for the manufacture of interior finishings and furniture.

This renowned Spanish food and be-verage company has entrusted Meca-lux in the semi-automation of trans-port and delivery processes of Leche Pascual, one of its leading brands, in its packaging centre located in Gurb (Barcelona).

After a thorough study, the technical team at Mecalux opted for the installation of two automatic conveyor circuits, one on each floor of the facility, and a lift which connects the two levels. Therefore, they get the strea-mlining of product throughput and the best use of available space on the warehouse’s first floor.

The ground floor conveyor circuits will move pallets from the end of the production area

to three possible destinations: the drive-in racks situated on the same floor, the dis-patch area, or the storage-ready area on the first floor.

On the other hand, the conveyor circuit de-signed for this upper floor will be reversible, so that it can be used for both inputs and outputs of pallets. The maximisation of this space will make it possible for the Catalan Pascual plant to dispense with external ware-houses, with subsequent cost and time sa-vings in the transport of goods between dis-tant warehouses.

In addition to the lift which connects the two levels of the warehouse, they complement the equipment with a pallet stacker and a pa-llet unstacker.

All movements of the equipment will be monitored by the Mecalux Galileo con-trol software, which is in communication with the warehouse management soft-ware currently used by the company in this installation.

To sum up, the project that Mecalux will set up in the upcoming months in the Gurb packaging centre will provide Qualidad Pascual with greater agility and accuracy in product throughput and dispatches. This is all part of the group’s commitment to offer-ing excellent quality service, and the con-tinuous improvement of both its products and processes.

Throughput conveyed and supersized: Quality Pascual and Mecalux collaborate on new conveyor system in Barcelona

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Founded in 1983 by Jesus Gasca, STUA in one of the most internationally recog-nized Spanish contemporary furniture design companies. Recently, its opera-tions moved to a new facility in Astiga-rraga (Guipúzcoa) in order to boost con-tinuous growth.

After assessing various options for the imple-mentation of a storage system that best re- solved their needs, STUA finally chose the project submitted by Mecalux, due to the confidence that being made in Spain and their extensive experience conveys.

STUA’s objectives are to gain perfect con-trol of both their products and deliveries to any part of the world, in addition to maximi-se storage capacity. To fulfil these require-ments, Mecalux has planned out a solution consisting of an automated clad-rack ware-house annex to the production building that stands out for its slenderness, since it has had to adapt to some unusual measurements: 80 m long, 25 m high and only 9 m wide.

The automatic warehouse is made up of an aisle where a single-mast stacker crane circulates, which serves the double depth racks located on both sides. The racking has 10 levels of different heights in order to locate various sized load units – some larger than usual – given the characteristics of the product. The inputs and outputs of the automated warehouse have been dealt with a circuit of conveyors.

Last but not least, to manage all warehouse processes, Mecalux will implement its Easy WMS warehouse management software, which will allow the full control STUA stock and real-time inventory, while also optimi-sing and coordinating product throughput, from its entry into the warehouse to its dis-patch to the end customer.

The new automated clad-rack warehouse will provide STUA with better efficiency and pro-fitability in their logistics operations. This will, in turn, give them a competitive advantage in their job of innovating and promoting Spanish design, which was recognized in 2008 with the National Prize for Innovation and Design.

Design and efficiency go hand in hand: a new automated clad-rack warehouse designed by Mecalux for STUA

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Case study: Hayat Kimya

Tallest warehouse in Europe constructed: earthquake prone area in Turkey not an issue for Mecalux and its partner Hayat Kimya

Location: Turkey

Hayat Kimya is the leading chemical company in the Turkish and Eurasian market in the manufacture of cleaning and hygiene products. They entrusted Mecalux in the construction of a spectacular 12,500 m2, 46 m tall automated logistics centre in the city of Izmit (Turkey).

They were supplied with a plan that included the warehouse management system Mecalux Easy WMS, responsible for ma-naging all the centre’s activities.

The solution implemented for Hayat Kimya has become a global benchmark for auto-mated clad-rack warehouses, showcasing Mecalux’s professional fortitude and skill.

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Case Study I Hayat Kimya

Who is Hayat Kimya?Founded in 1937, Hayat Kimya is the lead-ing chemical company in the Turkish, Asian and Middle Eastern market for cleaning and hygiene products.

The needs of Hayat KimyaThe huge growth experienced by Hayat had obliged them to distribute goods be-tween several warehouses located near di-fferent production centres, which involv-ed high logistical costs that could increase over the years.

Faced with this situation and seeking to re-duce production costs, Hayat Kimya de-cided to build a single warehouse with a minimum storage capacity of 150,000 pal-lets and in which to undertake picking functions.

In addition, and in order to save on trans-port costs, they thought of putting it in a space available in their largest facility, equal distance from three of their most im-portant plants and near a fourth high pro-duction site.

In the two images on this page the warehouse’s location in relation to the factories and to the connecting overpasses can be seen:

1. Logistics centre

2. Tissue factory 1

3. Tissue factory 2

4. Hygiene factory 1

5. Hygiene factory

6. Detergent factory

7. Tissue input overpass 2

8. Tissue input overpass 1

9. Hygiene input overpass

The company has twelve brands distributed in three sectors: household care, hygiene products and tissues

At present, Hayat Kimya is the seventh largest manufacturer in Europe in its sector, having more than 5,200 employees and reaching all its consumers through an export network which covers 101 countries.

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2

3 4

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The solution

Taking into account the above premises and the data provided by Hayat Kimya, Mecalux worked from the outset in the de-sign and construction of a warehouse with the following features:

- Automated clad-rack warehouse with a capacity for 161,000 pallets.

- Four raised overpasses above the la-nes inside the installation that connect the factories and the main conveyor cir-cuit.

- A ground floor dedicated almost exclu-sively to dispatches, with the exception of two multipurpose docks and a dock fitted with an automated unloading sys-tem intended for the receipt of merchan-dise from other factories.

- First floor used exclusively for offices and other services.

- Second floor reserved entirely for pick-ing.

- On the third floor is where all inputs take place in the warehouse from the factories that are located in the complex, as well as the outputs intended for pic-king areas.

- Wide manoeuvring area and loading/unloading of trucks, with 21 docks.

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For the design of the whole package that makes up the logistics centre, operative details were meticulously taken care of, trying to achieve not only the goals in the initial specifications of required flows, but that were also the best

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Map data ©2015 Google

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The warehouseThe size of the warehouse is 120 m long x 105 m wide and 46 m tall, with a total ca-pacity that exceeds 161,000 pallets that are 800 x 1200 mm in size and weigh a maximum 700 kg each.

The construction system is self-support-ing, that is to say the racks, in addition to storing goods, have additional structures on which sheet clad panels are attached to that make up the building. This forms a complete unit that is the warehouse.

The racks must support their own weight, the pallets stored, the wind pressure, han-dling equipment, the seismic activity on the basis of the coefficient indicated at the construction site and the weight of snow that conforms to the regulations.

The Hayat Kimya warehouse consists of 15 aisles with double-depth racks placed on both sides and is 24 load levels high. In each aisle a 45 m high stacker crane was set up that is responsible for the move-ments within the warehouse, from the re-ception area to product locations.

Each stacker crane is equipped with a double cradle that allows two pallets to be moved at a time and with single-mast construction, something unusual for a warehouse of this height. The main-tenance of the stacker cranes is carried out on the side that coincides with the conve-yor circuit.

It is interesting to point out that in each of the 24 load levels that integrate rack bays, three pallets in the first position and three other pallets in the second are stor-ed. This is very difficult to achieve in a tall warehouse which is located, as explained below, in an area with such a high rate of seismic activity.

In this image the loading docks and the offices located on the bottom floor of the warehouse can be seen.

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The final solution was the construction of a huge 12.500 m2 logistics centre, with a 46 m tall, clad-rack warehouse, readied

to house up to 161,000 pallets

The warehouse itself is an enclosed box in which all passages between the inside and the outside connection floor are done through airlocks that help maintain the atmosphere required by the fire protection system.

This system (inerting) works by reducing the oxygen in the interior’s air, to an atmospheric level of 14%, at which point combustion is no longer possible. A piece of equipment controls the oxygen levels in the air and adds nitrogen until reaching the percentage that has been previously programmed.

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Major construction challenge:its location The city of Izmit is located at the beginning of the Northern Anatolian fault line, which runs along the upper zone of the peninsu-la and which makes up the greater part of Turkey’s territory. This stretch, parallel to the Black Sea, also coincides with the fault line that crosses the Sea of Marmara and the Bosphorus Strait.

To build a warehouse of these dimensions in a place with such a high rate of earth-quakes, with a height of more than 45 m and with stacker cranes prepared to move two pallets at a time and operate in double-depth racks, was a challenge never before surpassed by Mecalux. Furthermore, the warehouse was built in an area exposed

Izmit

Anatolia

African Plate

Arabian Plate

Eurasian Plate

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to the wind and where snowfall, although not frequent, can be abundant when it does occur.

With all these constraints, only one com-pany with the experience and quality of Mecalux was able to build a warehouse on this scale.

By its particularities, this logistics centre could not be built with the traditional cold-formed profiles. Nor was it possible to do so with a structure of standard hot rolled profiles, due to the accuracy of as-sembly that this installation required was extremely high.

The solution provided by Mecalux’s tech-nical team was to combine the two con-

The main difficulty Mecalux faced was the existence of a major earthquake zone right

where Hayat Kimya wanted to build its upcoming central warehouse

structive options. The first to conform all racks, and the second to complete the construction of a vertical reticulate struc-ture coupled to the racks.

The objective was to absorb all the hori-zontal dynamic forces, mainly those of a longitudinal direction, which is the least rigid part of the racks.

The weight of this additional structure was more than 1,900 t (for the whole structure 10,000 t was used).

Both the dimensions and mode of opera-tion, as the building’s location, represent-ed a challenge for the Mecalux’s Structural Engineering department that had to deal with some extreme determinants.

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20 Best Practices

Upper floor: inputsAll warehouse inputs from the factories that are located on-premises take place on the third floor of Hayat Kimya’s logistics centre. The accumulative automatic roller conveyors have been set up in the four overpasses connecting the warehouse to the factories.

All the factories have a conveyor circuit that is tasked with the input of the pal-lets into the system after checking both its size and its weight. Only then will they ensure that the pallets that arrive to the warehouse do so in good condition.

In each overpass two lifts were placed, one in each factory’s entry points and an other at the end of each overpass, allowing goods to be lifted to transport height and subsequently to the third floor. At the same time, this floor has a triple electrified mo-norail circuit running both the external and internal movements of the warehouse.

On the third floor, alongside inputs, out-puts of goods that are lowered to the de-signated picking floor are also done via the elevators.

Every day an average of 6,500 pallets come into the warehouse, peaking at 400 pallets per hour

This image shows the upper floor where inputs into the warehouse are performed.

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Plant intended for the picking operationsThe second floor of Hayat Kimya’s ware-house has been reserved for picking func-tions, dividing it into two areas:

Zone A: 118 live channels, each three pal-lets deep, are grouped into four blocks. Each block is serviced by a shuttle that automatically feeds the channels with the goods from the lifts.

This area is intended for A type products (high demand).

This image displays the floor set up for picking.

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Zone B: 174 pallet racking bays with 2 or 4 levels for pallets, including the ground floor, grouped into four double and two single rack alignments.

It has a total capacity of 500 pallets for picking placed directly on the floor and 1,050 reserve pallets on upper levels. This second area is allocated for the picking of B type products (medium demand).

In addition, the same racks were set up for levels of live box picking to give access to C type products (low demand).

The feeding of the pallet racks is perform-ed using front loading reach trucks that take the pallets from the warehouse in a specific exit, where one of the lifts has pre-viously deposited the pallets destined for this zone.

Picking is done manually by the opera-tors, aided by order fulfilment machines and a computer terminal that works via radio frequency.

When the orders are completed, they are taken to the baling area and, via two lifts, are sent to the ground floor to be dispatched

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Lower floor: dispatchesAll outputs designated for the dispatch area are carried out on the ground floor by electrified monorails. These automated transport units take the pallets from the conveyor output inside the warehouse, and the lifts that descend from the picking floor, and classify them into preloads.

The preloads are composed of 17 triple-channel groupings, which have a capacity to deep-store 11 pallets.

Each triple-channel group has a total capa-city of 33 pallets each that correspond to an order, route or an out-sourced means of transport (truck or sea container). This re-quest is prepared before loading the truck to avoid waiting time in goods being dis-patched from the warehouse.

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Every day an average of 7,000 pallets leave the warehouse, in other words, more than 200 truckloads

Depending on the means of transport used, and the agreements with company’s individual customers, the merchandise is shipped on pallets (usually by truck) or in single, stacked boxes (sea container). For loading trucks generally light, front loading forklifts are used, since they are very agile and thus the most suitable.

The dispatch area has 17 docks only for loading, allowing the preparation of 17 transport vehicles at a time.

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Automatic unloadingIn addition, on the lower floor merchandise inputs from the detergent factory (located 2 km away) is also done.

The inputs take place on the ground floor via three reception docks, one of which is readied to automatically run unloading.

From here, the pallets pass, one by one, through the checkpoint and continue via the electrified monorails to the input stations located inside the warehouse that is found on this floor.

The automatic unloads accumulation device can receive all the pallets of a full truckload (trucks are set up with similar equipment)

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Easy WMS: the nerve centre of the logistics centreAll the operations of the logistics centre are governed by the warehouse management system Mecalux Easy WMS and its Galileo control software; tasked with controlling the computers that run the transport and the storage of goods tasks.

Easy WMS is also responsible for:- Management of goods input from its re-

ception at the docks.- Locate pallets in the warehouse using

rules previously parameterised, under the criteria of streamlining and maximum productivity.

- Manages the stock and the warehouse

layout (what and where the goods are).- Manages the warehouse outputs to the

picking and/or dispatch areas.- Manages and controls the picking opera-

tions through radio frequency terminals, guiding the operator in the tasks to be performed and the order to follow to op-timise routes.

- Allows the checking of the status of diffe-rent parts of the logistics centre, and the various equipment that operate in it, via query and reporting tools.

The Easy WMS (Warehouse Management Software) is in permanent and bi-direc-tional connection with Hayat Kimya’s SAP ERP system.

ERPSAP

of Hayat

Mecalux Easy WMS

Electrified monorails and airlocksAll movements from the stations to the inside of the warehouse, both on the third floor and on the ground floor, are carried out by autonomous shuttles hung from electrified monorail that works at a speed of 100 meters per minute.

There are more than 900 meters of elec-trified monorail and 55 autonomous shut-tles in the entire installation that are able to move more than 850 pallets per hour

The warehouse should be as airtight as possible to avoid the entry of air currents

with a higher percentage of oxygen. This means that all the merchandise that enters and exits via the electrified monorails passes through a sealed area with double doors or airlocks that can never be opened at the same time.

These spots are often bottlenecks in an unattended installation – consequently in this case, which work via electrified mo-norails and where there are also very high flow rates – it was necessary to design se-veral accesses with triple inner shuttle ca-pacity. In other words, the shuttles of the electrified monorails pass three at a time.

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Advantages for Hayat Kimya

- High storage capacity: 161,000 pallets, 800 x 1200 mm in size and each weighing a maximum of 700 kg can be warehoused, in a surface area of 12,500 m2.

- Production cost savings: they have built four overpasses connecting the factories and the front of the warehouse. Each day an average of 6,500 pallets come into the warehouse, peaking at 400 pallets per hour.

- Total control of the automated warehouse: thanks to the Mecalux Easy WMS (Warehouse Management Software), Hayat Kimya controls all the processes and operations that take place inside the warehouse, from the moment the product leaves packaging lines until it is delivered.

- Remote support, remote maintenance: Mecalux is available to give technical support to Hayat Kimya 24 hours a day, seven days a week.

Technical data

Length of the warehouse 120 m

Width of the warehouse 105 m

Height of the warehouse 46 m

Storage capacity 161,000 pallets

No. of storage aisles 15

No. of docks 24

No. of double cradle stacker cranes 15

Extraction system double-depth

Total electrified monorails > 900 linear metres

No. of shuttles in the installation 55

Total in overpasses > 420 linear metres

Total number of lifts 12

Total number of shuttles 4

Live channels for picking 118

Live preloads 17

Total live preload channels 51

Automatic unloading platform 1

Pallet input per day 6,500

Maximum pallet input per hour 400

Pallet output per day 7,000

Maximum pallet output per hour 450

Average truckloads issued per day > 200

Weight of the warehouse structure 10,000 t

For further information about this and other success stories look at our web www.mecalux.com/success-stories

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Case study: Gioseppo

Two million pairs of shoes: Mecalux builds Gioseppo a clad-rack solution for footwear

Location: Spain

The installation that Gioseppo has in Elche (Spain) is composed of an automated clad-rack warehouse for pallets, with live racks and a specific area for picking. The warehouse management system Mecalux Easy WMS was supplied, which is responsible for managing all the centre’s processes.

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Case Study I Gioseppo

3

2

1

Who is Gioseppo?Founded in 1991, Gioseppo is a family busi ness from the Elx region, dedicated to designing and marketing medium to high-end shoes for men, women and child.

After almost 25 years, Gioseppo is cur-rently a well-established brand whose products are marketed in more than 60 countries worldwide.

Its growth and track record has led Gioseppo to be included in the prestigious ‘Forum for Renowned Spanish Brand’s’, an alliance made up of companies and leading brands from their respective sectors.

Logistical needsThe objectives presented by Gioseppo to Mecalux were very specific: build a ware-house to increase its storage capacity to lo-cate all products coming from production, and automate the internal transport of goods with the purpose of managing a greater number of SKUs in the most effi-cient way possible.

With this, the company would take a quali-tative leap forward on a logistical level that could reduce production costs, while im-proving warehouse productivity

Based on these requirements, Mecalux de-signed an integrated solution in which au-tomated storage processes were more pro-fitable for Gioseppo.

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2

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Construction needsAnother premise that Mecalux had to keep in mind was to pay careful attention to the public image of the company. It was of ut-most importance to limit the impact con-structing a clad-rack warehouse would have on the landscape of the Gioseppo “Love Work Place” logistics centre, an environmentally friendly space near the Mediterranean Sea.

Accordingly, the dimensions of the logistics centre could not exceed a certain height. So, it was necessary to find a solution that offered high storage capacity, while at the same time reducing the installation’s size.

It was paramount to reduce the impact constructing a clad-rack warehouse had on the landscape of Gioseppo’s ‘Love Work Place’ logistics centre

Map data ©2015* Google

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A clad-rack warehouse as a solution This 18.5 m high, 79 m long and 21.5 m wide clad-rack warehouse is composed of three aisles with double-deep racks on both sides, offering a storage capacity of 5,844 pallets, weighing 500 kg each. To be clad-rack means that the structure of the building is formed by the racks themselves, and that the outer cladding is supported and attached to them.

For structural calculations of clad-rack warehouses the following are taken into account: its own weight; the weight of the goods stored; the wind pressure both push and suction depending where it is built; the weight of the snow as indicated by the re-gulations; ramming by stacker cranes; and finally, the seismicity corresponding to the territory in which it is located.

Its purpose, as explained above, was two-fold: to optimise height in order to a chieve the largest possible storage capacity, and reduce landscape impact to preserve Gioseppo’s public image.

In each aisle a stacker crane circulates, hand ling the movements of the pallets from the conveyors at the end of the aisle to its designated location.

The use of stacker cranes helps increase productivity, at the same time decreasing the resources required to manipulate the goods.

Gioseppo’s clad-rack warehouse is distinctive because they excavated

a 6 meter deep trench where a large portion of the warehouse was

installed

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Inputs and outputsThe inputs and outputs of palletised goods are done via a double shuttle that con-nects the main circuit of conveyors with the stor age aisles. The goods input area has an entry checkpoint, which is respon-sible for verifying that the size, weight, and condition of the pallets comply with the installation’s specifications.

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Picking functionsThis same transfer car is tasked with transferring the pallets from the aisles to the P&D stations. The picking area is organised starting with six independent stations where operators take the boxes they need from the pallet and deposit them onto the box conveyor with the order sorter located on the back.

In addition, and in order to facilitate work, each picking station has a lift table so that the pallets are kept at the ideal height for each operator, improving its ergonomic position.

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The picking area has six independent

stations that are set up with a lift table

to improve ergonomic design

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Live racks for orders completed and consumer productsA block of 36 live rack channels has been installed both for storing orders prepared, as well as the stacks of idle pallets.

This 8 m high, 9.5 m long and 11 m deep warehouse has a storage capacity of 324 pallets 800 x 1,200 x 1,900 mm in size, each with a maximum weight of 400 kg. Each channel receives nine pallets.

The live racks are a compact storage sys-tem that allows maximum use of space and that are composed of roller channels on a slight incline. The pallets are inserted into the highest part of the rack and move via gravity to the lower end, being available to the operator. The pallet travel speed is con-trolled by roller brakes.

Therefore, this storage system is ideal for lowering handling times and exped-ites picking, increasing the installation’s productivity.

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Easy WMS: the nerve centre of the installationIn Gioseppo’s new warehouse the ware-house management system Mecalux Easy WMS was implemented to manage and coordinate the different automated oper-ations that take place within the installa-tion: the input and output of goods, stor-age, picking and dispatches.

This powerful management software has been customised to Gioseppo’s demands, being able to: locate pallets in the racks based on algorithms or parametrisable rules, manage outputs on the basis of tra-ceability and FIFO criteria, check the stock, run standard and custom labelling of con-tainers, group output orders in different modalities, etc.

Easy WMS (warehouse management soft-ware) provides a competitive advant age to Gioseppo, since it involves cost sav-ings, an improvement in service quality and consequently, maximising warehouse profitability.

In addition, Easy WMS is in perman-ent communication with the SAP ERP, Gioseppo’s main management system, ex-changing orders and the information that is essential for its overall management.

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Advantages for Gioseppo

- Increased storage capacity in a small space: Gioseppo’s clad-rack warehouse receives 5,844 pallets in a surface area of 1,700 m2, quadrupling the capacity of the previous warehouse.

- Limiting environmental impact: a 6 meter deep hole was excavated to obtain height and stor-age capacity, while the impact on the area’s landscape was minimised.

- Cost savings: the automation of the clad-rack warehouse allows Gioseppo to increase efficiency and reduce personnel and logistics costs.

- Complete control: the Mecalux Easy WMS controls all the processes and operations that take place inside the warehouse.

Technical data

Automated Warehouse


Maximum weight per pallet 500 kg

Warehouse height 18.5 m

No. of stacker cranes 3

Type of stacker crane twin-mast

Fork type double-deep

Construction system self-supporting

Live racks

Storage capacity 324 pallets

Pallet size 800 x 1,200 mm


Warehouse height 8 m

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Case study: Ypê

Wide prep area for orders: a key Mecalux design feature for Ypê warehouse in São Paulo

Location: Brazil

Ypê, a company dedicated to the development of cleaning products for the household and personal hygiene, has hired Mecalux to install a 29.5 m high automated clad-rack warehouse with a 24,168 pallet storage capacity in its logistical support centre in Amparo (São Paulo).

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Case study I Ypê

Analysing the needs The main production centre of Ypê is loca-ted in Amparo, a town close to the city of São Paulo. The growing needs of the com-pany required the construction of a large lo-gistics centre next to the production plants, from which they could offer comprehensive service, and at the same time reduce costs.

Mecalux installed the racks and structu-res of the warehouse, the automatic inter-nal handling equipment, the construction of a picking area and Mecalux Easy WMS software deployment, the warehouse management system which governs and controls the operations of the logistics centre.

The collaboration of Mecalux with Ypê has been very close from the development phase of the project to its execution

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Case study I Ypê

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Case study I Ypê

Solution adopted: clad-rack warehouseThe most striking part of the project de-veloped by Mecalux is the installation of a self-supporting construction ware-house with a total capacity of 24,168 pallets, 1000 x 1200 mm in size, each with a weight of 1,300 kg.

Being clad-racked, the racks are a funda-mental part of the structure of the building and cladding is placed on them. In addition to its own weight, it must withstand the pallets stored, the force of the wind on the basis of the site characteristics, the pressure of the handling equipment and the seismic risk that corresponds to the zone in accordance with the country’s regulations.

The traditionally constructed buildings are adjacent to Ypê’s logistics centre, just be-sides the automated warehouse, where available space has been set aside for futu-re expansion.

At present, this 29.5 m high, 107.5 m long and 49.5 m wide warehouse has a total

of eight storage aisles, with racks on both sides, of which five are double-depth and three single-depth.

Each aisle is set up with a twin-mast stac-ker crane that automatically performs the movements between locations and the main conveyor circuit, placed at the header of the warehouse.

Warehouse area reserved to expand the storage capacity of Ypê

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Case study I Ypê

The warehouse is distributed into the following areas, as can be seen in the layout:

A. Warehouse

B. Input stations

C. Main conveyor circuit

D. Direct outputs station

E. Picking channels

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Case study I Ypê

The input of the pallets that go into the warehouse takes place via three stations readied with a gauge control and input checkpoint equipment. This space is locat-ed in the reception dock area for incoming goods, occupying one of the sides of the warehouse.

A conveyor with accumulation capacity transports them to the header, where the main conveyor circuits are placed.

A large percentage of the pallets that leave the warehouse do so designated for the picking area.

As of now, there are five groups of live channels outfitted and one for pallets placed on the floor of the warehouse.

Group of picking channels

47Best Practices

Case study I Ypê

Each grouping contains 66 channels with a three pallet capacity. The feeding is per-formed via transfer cars that automatically move from specific positions of the hea-der to the live channels. The slight tilt with which channels are mounted allows the pallet to move by gravity to the closest free position in work aisles.

Among the five groups, there is a total of 330 channels with a capacity for 990 pallets; each channel is intended for a single SKU. Apart from that, there are 138 posi-tions for pallets placed on the floor, which are directly supplied by forklifts.

The consolidation of orders, once the pal-lets have already passed by the balers, is carried out in the area allocated to pre-loads close to the loading docks.

The logistics centre of Ypê also features live racks to store consumer products that do not enter into the automated warehouse. This area, next to the docks, works as cross-docking, the live racks acting as a buffer.

Easy WMS: the nerve centre of the logistics centreEasy WMS is a powerful warehouse ma-nagement system developed by Mecalux with which you can manage all the ware-house needs, stepping in from when the goods are received till the order has been dispatched.

Among all the functions that Easy WMS is capable of performing, the most impor-tant are: the receipt and registration of the pallets that enter into the warehouse, the management of the locations on the basis of rules or parametrable algorithms, control of outputs in accordance with FIFO criteria and traceability, order preparation, consolidation, label issuing, documenta-tion prior to delivery, etc.

All of this with the major advantage of re-ducing the errors arising from manual ma-nagement to a minimum.

Furthermore, the Mecalux Easy WMS warehouse management software is con-tinuously and directly connected to the ERP of Ypê, from which it receives the back- ground information and that reports the outputs executed.

The installation that Ypê has in São Paulo, with a 24,168 pallet capacity, is expected to achieve a total flow of 200 pallets/hour in inputs and outputs

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Case study I Ypê

Advantages for Ypê

- High storage capacity: the clad-rack warehouse of Ypê enables them to locate 24,168 pallets, 1,000 x 1,200 mm in size each with a weight of 1,300 kg, in a 5,200 m² area.

- Cost savings: automation of the different storage processes helps Ypê to boost efficiency while redu-cing operational costs.

- Flexibility for future growth: an area to the side of the automated warehouse has been prepared in order to expand storage capacity based on the future needs of the company.

- Complete control: thanks to the Mecalux Easy WMS, Ypê controls all the processes and operations that take place inside the warehouse.

Technical data


Dimensions of the pallet 1,000 x 1,200 mm

Maximum weight per pallet 1,300 kg



Fork type single and double-depth

Live picking channels 330

Pallets in picking positions 1,128 pallets

No. of transfer cars 5

Preload on the floor

49Best Practices

Case study: Takeda

Turnkey pharmaceutics: automated warehouse by Mecalux for Japanese partner Takeda

Location: Poland

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Case Study I Takeda

A clad-rack warehouse as a solution When Takeda moved forward with the ex-pansion of its production centre, it was very clear that the warehouse should be auto-mated. This would allow for perfect con-trol of stored goods, in addition to being able to achieve the maximum permissible height, given that the space available for warehouse construction was limited.

The solution proposed by Mecalux was the construction of a 32.5 m high clad-rack warehouse located next to the manufac-t uring facilities and the bay assigned to delivery preloading. In this type of cons-

Who is Takeda?Takeda Pharmaceutical Company Limited, with its headquarters in Osaka (Japan), is a global company specialising in the inves-t igation of pharmaceutical products. In the mid-twentieth century, it experienced massive growth, making it a world leader in the pharmaceutical industry and the larg est of its kind in Japan.

The company has a commercial pre sence in more than 70 countries, most signifi-cantly those in Asia, North America and Europe and emerging markets such as Latin America, Russia and China.

truction, the racks themselves make up the structure of the warehouse.

The installation consists of two aisles, in which two automatic stacker cranes move independently, handling the pallets stored in double-deep racks (two pallets in depth on each level). Thanks to the optimal space utilisation, the Takeda warehouse has a storage capacity of more than 6,500 pal-lets in a surface area of only 950 m2.

The warehouse was equipped with a HVAC system (Heating Ventilation Air Conditioning) which keeps the tempera-ture between 16 and 24 °C and prevents the humidity level from exceeding 70%, which is something that could affect goods stored.

3D computer graphic of the Takeda clad-rack warehouse

Takeda, one of the most important pharmaceutical companies in the world, has entrusted Mecalux to build a turnkey warehouse in its new Lyszkowice production plant, near the Polish city of Lowicz.

The solution was to construct a temperature controlled, 32.5 m high clad-rack warehouse with a capacity to store more than 6,500 pallets. It is equipped with a cold storage system and an ‘oxygen reduction system’ for fire prevention. They were also supplied with a warehouse management system, the Mecalux Easy WMS, which is responsible for managing all the centre’s processes.

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Case Study I Takeda

Warehouse aisle

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Case Study I Takeda

Outside view of the warehouse

14,505 mm

32,3

82 m

m

An innovative fire protection system (inerting) has also been used, which reduces the amount of oxygen in the atmosphere to 15% to avoid fires.

The pipes of the air’s humidity and temper-ature control system have been installed above, targeting the aisles and placed in the free space between trusses in the fa-cility.

For structural calculations of clad-rack warehouses the following are taken into account: its own weight; the weight of the goods stored; the wind pressure both push and suction where it is built; the weight of the snow as indicated by the regulations; thrusts by stacker cranes; and finally, the seismicity corresponding to the territory where it is located.

Due to the slenderness of the building (14.5 m wide and 32.4 m high), a highly re-inforced structure was built. Also, many large sized anchorages have been placed with the aim of absorbing maximum wind pressure.

This 32.5 meter high clad-rack warehouse has a storage capacity of 6,584 pallets, 800 x 1200 mm in size, with a maximum weight of 800 kg

Layout: elevation, floor and profile of the Takeda warehouse

85,657 mm

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Case Study I Takeda

Cooling tube Reinforced racks

Twin-mast stacker crane

19,8

00

mm

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Case Study I Takeda

Inputs and outputs are practically unified and are constructed very simply, they are suitable for forklifts and stackers use. The entry conveyor has a checkpoint, which ensures top condition of all the pallets that are put into the automated warehouse.

The connection with the inside of the warehouse is done using a double convey- or circuit (inputs and outputs) that pas-ses through doors with double vertical screens.

The space between the two screens amounts to what is needed for a single pa-llet, being that the system sends alterna-ting open and close signals, limiting tem-perature changes inside.

In order to avoid capacity loss, a superior platform was set up for doing secure main-tenance with one access per aisle.

Entry and exit of the warehouse

Main conveyor circuit

The stacker cranes are double-mast and incorporate a maintenance cabin, which is located on the lifting cradle itself

Entry and exit of the warehouse

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Case Study I Takeda

Easy WMS: The management, synchronisation and control of the entire warehouse, includ-ing parts that interact with the mainte-nance equipment, work thanks to the Mecalux Easy WMS (Warehouse Manage-ment Software).

The main functions of Easy WMS are:

- Receiving and recording the pallets that come into the warehouse.

- Pallet location in the racks based on algo-rithms or parametrical rules.

- Management of outputs based on FIFO criteria and traceability.

- Via the Galileo software, all movements of the mechanical parts run and optimi-sed the internal routes.

- Connection to the warehouse door control program so that it acts automatically.

In addition, Easy WMS is in constant com-munication with the SAP ERP, Takeda’s main management system, exchanging orders and information that is essential to its overall management.

Plant’s maintenance access

Maintenance access

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Case Study I Takeda

Turnkey warehouseTakeda wanted all development and cons-truction phases of the warehouse, inclu-ding the supply of the software needed to properly manage all internal operations, carried out by a single company.

That is why Mecalux was commissioned to run the turnkey project from beginning to end.

Stages of warehouse implementation:

- Land preparation via pilings: due to the low bearing capacity of the soil, and the large static demands, a deep founda-tion was made on pilings.

- Installation of a reinforced concrete foundation slab: first a reinforced top and bottom was built with steel rods, and subsequently the ground was filled with concrete.

- Finish: the foundation was finished and hardened with the objective of obtaining dust free paving.

- Rack assembly: regarding clad-rack warehouse, the racks themselves make up the actual structure.

- Assembly of warehouse cladding: in clad-rack warehouses wall panelling and ‘sandwich type’ roofs are fastened directly to the rack structure. In Takeda’s case, and having used an inerting system, it was necessary for the outside cladding to be as watertight as possible.

- Introduction of maintenance teams: conveyors and stacker cranes were assembled inside the warehouse.

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Case Study I Takeda

- Installation of the inerting system: implementation of a fire protection sys-tem that allows you to inject nitrogen in-to the warehouse so that the oxygen con-centration is reduced to less than 15%.

- Installing the HVAC air conditioning system: it controls the temperature that should be maintained between 16 and 24 ºC.

- Assembly of the electrical and light-ning protection systems.

- Assembly of the drainage system.

- Airlock construction: the separation of the portion of the warehouse equipped with the inerting system to the adjoining building that work under normal envi-ronmental conditions.

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Case Study I Takeda

Advantages for Takeda

- High storage capacity in a small space: the clad-rack warehouse enables you to place 6,584, 800 x 1,200 mm sized pallets each weighing 800 kg in a surface area of 980 m2.

- Product security: pharmaceutical products stored by Takeda are protected and isolated thanks to the automatic warehouse installation. Only authorised people can access the warehouse.

- Turnkey warehouse: Mecalux was responsible for the development phases, the construction of the warehouse, the supply of storage, cooling, and fire safety systems, as well as the implementation of the WMS (Warehouse Management Software).

- Complete control: thanks to Mecalux Easy WMS, Takeda controls all the processes and operations that take place inside the warehouse, from the time the product leaves the packaging lines to its delivery.

Technical data

Warehouse capacity 6,584 pallets




Fork type double-deep


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Case study: Nufri

Nufri has put its confidence in Mecalux yet again by installing Movirack mobile pallet racking in its headquarters in Catalonia

Location: Spain

Needs and the proposed solutionNufri handles around 400 million tons of fresh and processed materials, selling to more than 40 countries worldwide. To guarantee quality, personalized service, Nufri needed a warehouse in which it could access all its stored products in a straightforward manner, all the while maximizing surface area and the volume of the installations.

In response, Mecalux opted to install Movirack mobile pallet racks of 12 m high, converting it into one of the tallest solu-tions of this kind and perfectly adapting it to the needs presented by Nufri.

The warehouse is divided into two well-marked areas: the first, which is small-er in size, is set up to store products and packag ing at ambient temperature, while the remainder of the area is cold storage used to store extracts, juices and purees.

Mecalux supplied and installed a Movirack mobile racking system in Nufri, business leader in processing fresh fruits and vegetables with more than 40 years’ experience in the sector. This new warehouse in its logistics centre in Mollerussa (Lleida) allows the storage of more than 6,100 pallets.

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Case Study I Nufri

Ambient temperature areaIt is set up to supply production areas, from cylindrical containers of enormous dimen-sions, including the products necessary to complete its range of processing.

This area, with a storage capacity of 1,200 pallets that are 1,200 x 1,200 mm in size and have a maximum weight of 2,100 kg each, is available with seven mo-bile bases and two non-moving racks.

BLOCK 3BLOCK 1

BLOCK 2

Being located beside the cold storage allows combined supply, removal and sto-rage of processed goods, significantly opt-imising the internal movements inside the installation.

Providing for the future needs of the com-pany, an area has been set up where five more mobile pallet racks can be installed. To that end, the floor has been fitted from the beginning to facilitate possible pro-gressive growth.

Block 3: ambient temperature area

The utilization of Movirack mobile pallet racking provides the maximum installation streamlining

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Case Study I Nufri

Cold storageThere are a total of 31 double mobile ba-ses and four non-moving racks which give a storage capacity of 4,930 pallets 1,200 x 1,200 mm in size, and have a maximum weight of 2,100 kg each, which conser-ves processed materials at a controlled temperature.

The racks are arranged in two large blocks separated by a main gangway. Each block has a wide work aisle that opens up be-tween racks. To automatically open it, the operator must only push a button via the remote control.

For the purpose of ensuring the security of its operators and the installation in gene-ral, the Movirack system has the following devices: external optical safety barriers, longitudinal photocells placed on both sides of the bases, proximity sensors, pre-programmed activation protocols and emergency stop and reset buttons.

The forklifts that are used in the refrigerat-ed storage area are the retractable type that makes it possible to work in an aisle less than 3 m high. The last load level is plac ed at 10.6 m high, and the maximum load height would reach 12 m high.

The racks have mesh shelves in them for low strength pallets or those that are not standard size

Blocks 1 and 2: cold storage unit

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Case Study I Nufri

Technical data


Pallet size 1,200 x 1,200 mm

Maximum weigth per pallet 2,100 kg

No. of mobile bases 38

Rack height 10.6 m

Total height with load 12 m

Work aisle length 23 m

Warehouse temperature ambient / refrigerated

Advantages for the customer

- Storage capacity is increased using a Movirack mobile pallet rack system.

- Direct access to any pallet: the aisle opens up exactly where the goods are located.

- Products are maintained in optimal condition facilitated by the parking function, which keeps the racks slightly apart maintaining better air circulation.

- Flexibility for future expansion.

63Best Practices

Case study: MGA

MGA has an efficient automated miniload warehouse coupled with conventional pallet racking

Location: France

For the new logistics center located in Saint-Quentin Fallavier, a town close to the city of Lyon, MGA chose Mecalux as provider of all management and storage systems, including an automated miniload warehouse with a capacity of 15,872 boxes.

MGA is an important spare parts distributor with regional warehouses in different cities within France. The priority of the company is to offer express delivery to its customers, generally automobile replacement part wholesalers.

In this logistics center, Mecalux has in stalled an automated miniload warehouse with a

specific picking area and a warehouse for pallets placed on conventional type racks. It has also included the implementation of a Mecalux Easy WMS (warehouse management software), tasked with handling all operations, from the entry of goods till dispatch, previously passing through the storage and picking phases.

64 Best Practices

Case Study I MGA

Warehouse interior

Connection between the warehouse and the picking area

Warehouse for pallets: ‘A’ and bulky type product picking

Conventional pallet racksThe conventional pallet rack warehouse is intended for bulkier products and items with greater turnover (A type) placed upon pallets. Racks have two inferior levels to conduct direct picking from the pallets, while reserves are placed on superior levels.

This storage system is characterised by its simplicity and capacity to adapt itself to the needs of the company. In addition, conventional pallet racks make it possible to directly access each pallet, storing the maximum number of unit loads in a safe and organised way.

The miniload warehouseA miniload warehouse with four aisles, and two doubledeep racks (one per side), was installed, allowing storage of a total of 15,872 plastic euroboxes, 600 x 400 x 320 mm in size. The height of the racks is 12.3 m and the total admissible weight per box is 50 kg.

All medium and small sized products are located in the miniload warehouse, generally B and C type items. These products are handled by four stacker cranes, three picking stations and a replenishment station.

65Best Practices

Case Study I MGA

Four stacker cranes

The construction of the miniload warehouse was done in two phases, in accordance with the needs of MGA. The first included three storage aisles with three stacker cranes and three picking stations, while in the second they installed four aisles, set up a new stacker crane and completed the replenishment station.

If we analyse the parts that the installation is composed of, represented by the images on this page, you will see the following:A. An automated warehouseB. Automated warehouse conveyors C. Three picking stationsD. A replenishment station

The MGA miniload warehouse can store 15,872 plastic euroboxes

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Case Study I MGA

Two box extractions

Miniload with conveyors inside the warehouse

Doublemast stacker cranes were installed; the extraction system placed in the cradle is a double box and doubledeep, being capable of handling two boxes at a time.

The extractor is formed by a fork and two independently moving belts that allow them to interchangeably pick boxes from one or another side, first moving to the contrary side where you are going to make the second extraction.

The conveyor system has been sized to move great quantities of boxes that may coincide with times of higher demand, while the travel speed, and mainly the stacker crane’s lifting speed, were adjusted to the characteristics of this warehouse.

67Best Practices

Case Study I MGA

Access doors to the stacker cranes

Interior of the stacker crane aisle

Cantilevered storage levels Rear area of the warehouse

In addition, a cantilevered structure has been made above the loading and unloading stations, managing to increase capacity by 320 more boxes.

In the rear, equipped with a large maintenance area, there are reference devices for the position of the stacker crane. The whole space is enclosed with mesh panels and safety doors that will individually disconnect the machines in case they are opened.

Thanks to the four stacker cranes and the high number of boxes that they operate with, MGA ensures the liquidity of the flow of movements

68 Best Practices

Case Study I MGA

Main picking area circuit

Control computers and picking stations

Picking stationsThe enclosure where the main warehouse is located is independent of other buildings and, in particular, from the picking station, which was installed on the side of the warehouse.

The picking stations, in the shape of a “U”, are located terraced perpendicularly to the main conveyors.

These conveyors are comprised of a double circuit that allows both the recirculation of boxes, as well as the connection to the warehouse and the replenishment station. Moving boxes to either of the two main conveyors is direct, thus avoiding unnecessary movements.

Each station, with capacity for three boxes on hold plus the one which is being processed, is run by an operator, who in turn is able to prepare waves of six orders at the same time. To that end, there is a computer connected to the Mecalux Easy WMS (warehouse management software) and different support devices for picking. For example, put to light devices placed on top of the containers of each order, indicating

to the operator which order each item corresponds to.

On the pallets/containers of each order, the item location in the pallet racks has been previously introduced, that is to say, this same zone serves as an order consolidation area. In this way, fast and agile order preparation has been achieved.

Three picking stations, a replenishment station

and the consolidation area were set up

throughout the facility

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Case Study I MGA

Put to light device

Conveyors in the picking station

Easy WMSThe Mecalux Easy WMS is the nerve center that manages all the necessary functions for the general operations of any type of warehouse, regardless of its complexity.

Easy WMS (Warehouse Management System) controls: all the inbound proces

ses, the warehouse locations, stocks, location rules, storage and extraction, the pallets that have to go to picking stations, the picking itself, returns to the warehouse, etc. It is also able to analyze the state of distinct parts or areas via query and reporting tools, as well as the devices that operate in it.

Easy WMS is in bidirectional and permanent connection with the customer’s SAP ERP

70 Best Practices

Case Study I MGA

Technical data

Storage capacity 15,872 boxes

Maximum weight per box 50 kg


Type of stacker crane double-mast

Extraction system double-deep,two boxes

Advantages for MGA

- Improved storage capacity: the MGA miniload warehouse offers a storage capacity of 15,872 boxes.

- Increased productivity: thanks to the high level of warehouse automatization, the speed of order preparation has increased.

- Perfect stock control: thanks to the Mecalux Easy WMS, the company MGA can manage all movements, processes and operations that take place within their warehouse.

Miniload warehouse height 12.3 m

Picking stations 3

Replenishment stations 1

Pallet capacity 1,480 pallets


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Case study: Luís Simões

Mecalux equips Luís Simões’ new installations in Portugal with Pallet Shuttle and conventional pallet racking

What is Luís Simões: what are its needs?Luís Simões is a comprehensive transport and logistics services operator that began operating in 1948 in the portuguese city of Loures.

The firm has operated in Spain for over 25 years, and is currently the market leader in trade flows between the two countries, with a fleet of 2,000 vehicles (owned and outsourced) and over 1,500 employees.

According to its storage facilities expansion and modernisation plan, the company commissioned Mecalux to equip two large, newly built sites, with almost 10,000 m2 of surface area each.

Luís Simões needed to speed up the flow of incoming and outgoing pallets in the warehouse while, at the same time, increasing storage capacity. This was needed to efficiently meet the demands of both existing and potential customers.

Location: Portugal

This warehouse, separated into two distinct areas and built under the “multi-client” concept, covers a surface area of 17,500 square metres and can supply more than 33,000 pallets.

Luís Simões performs all of its business-related activities from this installation, including storage and picking, mass and capillary distribution.

72 Best Practices

Case Study I Luís Simões

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Seven double and one single conventional pallet racks were installed, along with two compact racking units with the Pallet Shuttle system. They feature six load levels and the capacity to deepstore 15 pallets per level.

The lower level of the conventional pallet racking was prepared to perform picking functions, because a high percentage of Luís Simões’s orders require it. Moreover, a spacious area was provided for subsequently consolidating the orders.

The docks, located on either side, have their own preloading channels on the ground; these allow access to the pallets from both sides, thus optimising truck loading.

The conventional pallet racking has the capacity for 10,386 pallets, and with the Pallet Shuttle system the capacity is 5,544.

Warehouse AMecalux’s proposed solutionAfter analysing all the operations, and Luís Simões’s needs and flows, Mecalux proposed a separate solution for each building, which are interconnected and share the same management and control centre.

Moreover, the new logistics centre has 34 loading and unloading docks, as well as three spacious order consolidation preloading areas.

Warehouse AIn Warehouse A, a semiautomatic compact Pallet Shuttle system combined with conventional racks was installed, giving rise to two distinct storage areas, each serv ed by reach trucks.

73Best Practices


Warehouse B

Warehouse BWarehouse B consists of twenty rows of singledeep conventional pallet racking enabling direct access to the merchandise with maximum flexibility. The rows of rack ing, which are 130 m long, are served via 10 storage aisles along which the reach truck runs.

The height layout can be seven, eight or nine levels, depending on the product to be stored and the unit load measurements, which may be Europallets (800 x 1,200 mm) or US pallets (1,000 x 1,200 mm).

Three transverse aisles cross the racking to facilitate the movement of operators; they can also be used as emergency es cape routes.

Because of their significant length, and in order to travel the shortest possible distance during maintenance tasks, eight loading docks with their own preloading area were set up at both ends of the warehouse.

Warehouse B’s total storage capacity is 19,503 pallets.

The combination of capacity and flexibility enables Luís Simões to offer its customers quality service and short delivery times, strengthening the firm’s position as a top provider of logistics services in the Iberian Peninsula

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Conventional pallet racking

Conventional pallet rackingThis storage system, which was installed in both warehouses, has two major advantages: direct access to any pallet, and the ability to devote the lower level to picking orders.

The machines used are highlift reach trucks that can operate in a 3metre wide aisle.

The last level of storage is 12 m high. To facilitate handling, avoid impacts and properly centre the pallets and/or forks, observation cameras were fitted on the upper part of the forklift.

Moreover, and as a safety precaution, protectors were fitt ed on all the rack uprights facing the aisles.

The WMS (warehouse management system), an essential element in these types of warehouses, enables “chaotic” storage to be used, achieving high occupancy of all locations

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Pallet Shuttle SystemMass market consumer products, which have a greater number of pallets per item, are stored with this highdensity storage system. The movements inside the rack are independent and follow the in structions that the operator transmits using a WiFi tablet; this significantly reduc es the need for loading and unloading goods.

Racking with the Pallet Shuttle system

Pallet ShuttleIn warehouse A, two blocks with six load levels were installed. The channels are 13.2 m deep and have a unit capacity of 15 pallets. The installation has 378 channels that are served by six Pallet Shuttles.

76 Best Practices


Pallet Shuttle Racking

The racks using Pallet Shuttle are operated as follows:

1. Using the forklift, the operator introduces the Pallet Shuttle into the corresponding channel.

2. With the pallet loaded, the Pallet Shuttle moves horizontally until it reaches the first free location, where it leaves the pallet.

3. While the Pallet Shuttle moves and places the pallet into its location, the opera tor places another pallet in the original position in the channel.

Thus, when the shuttle returns to the beginning of the lane it can successively repeat the same movement.

When loading in the channel is completed, the Pallet Shuttle is moved on to the next one. Extraction is done by reversing these steps.

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The program to control the Pallet Shuttle is installed on each tablet. Various functions can be performed, including:

Selecting the Pallet Shuttle to be used. Automated movements. Manual movements for maintenance. Compacting or relocating pallets, bring

ing them closer to the exit point.

Battery charging station

Interface for operating the shuttle

Inventory: counts the number of pallets stored in each channel.

User management: this funcionality manages shuttle user permissions for autho rised personnel.

Battery charge status.

The observation camera facilitates operations conducted at heights.

A batterycharging station was installed that can charge the batteries of six Pallet Shuttle simultaneously. Batteries can also be charged independently of the shuttles, that is, the battery can be removed from the shuttle and replaced with a previously charged one. In this way, all the shuttles will always be operational to fulfil the orders needed.

Observation camera

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Technical data


Pallet capacity 1,000 x 1,000 mm 26,000

Pallet capacity 1,200 x 1,200 mm 1,600

Total storage capacity 27,600 pallets


Maximum height of last level 12.3 m

Type of reach truck retractable

Pallet Racking with Pallet Shuttle

Pallet capacity 800 x 1,000 mm 5,550


Number of channels 378

Channel depth 13.2 m

Channel pallet capacity 15

Maximum height of last level 12.5 m

Number of Pallet Shuttle 6

Type of control wifi

Number of tablets 4

Type of reach truck retractable

Advantages for Luís Simões

- Optimal use of space: the flexibility of conventional pallet racking and the highdensity storage provided by the Pallet Shuttle enables a total capacity of 33,150 pallets.

- Increased productivity: the Pallet Shuttle increases the flow of pallets per hour and allows for greater diversification by enabling items to be grouped by channel.

- Strategic positioning: this new logistics platform has given an important competitive advantage to Luís Simões, positioning the firm as a leading logistics centre on the Atlantic coast and bolstering its drive towards internationalisation.


79Best Practices

Case study: DHL

Mecalux installs a new logistics centre for DHL on the outskirts of Madrid

Location: Spain

The warehouse, with a capacity for more than 90,000 pallets, has two areas allocated for palletised products. Another, formed by a two level high mezzanine floor, is earmarked for hanging garments.

Its strategic location allows DHL to respond quickly to all its main customers’ stores within the Iberian Peninsula (Spain and Portugal).

80 Best Practices

Case Study I DHL

Storage of products on palletsDue to the fact that the majority of orders delivered by DHL to these stores are full boxes and they move very few pallets with a single item type, it was necessary to allo-cate the bottom level of the conventional pallet racks for picking activities. Reserve palletised goods are stored on higher levels.

Handling equipment used to place the pallets on the racks are reach trucks. However, during order preparation, spe-cific machines are used that have the ca pacity to transport up to two pallets at a time.

81Best Practices

Case Study I DHL

Conventional pallet racks are an ideal system

to quickly replenish locations that have been

left without product

Operators maximise streamlining routes inside the logistics centre thanks to the WMS (Warehouse Management Software), which divides the warehouse so that each operator is responsible for a single zone. This means that an order can be prepared by several people at the same time. Once their part of the order is finis-hed, each operator will transfer it to one of the consolidation areas according to the assigned dock.

Full use of the racks was made to install fire protection system pipelines and sprinklers. These coincide with the rack beams or gir-ders to waste the minimum space possible.

82 Best Practices

Case Study I DHL

Assembly by phasesMecalux adapted to the company’s needs, thus they decided to build the warehouse in phases. So, DHL could make a tailored, gradual investment as it ran each project phase.

Aisle length forced them to build inter-mediate passageways wide enough to give two pieces of handling equipment the ability to cross each other at the same point.

Each sector of the warehouse has its own loading docks in order to avoid large dis-placements and significantly reduce ope-rating costs. The warehouse is also com-partmentalised for security reasons.

The breadth of consolidation areas, and the laying of pre-loads on the floor just in front of their assigned dock, allows for speedy loading of transport vehicles.

83Best Practices

Case Study I DHL

The total storage capacity of more than 90,000 pallets and more

than 30,000 metres of profiles used to hang garments on the racks

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Case Study I DHL

The garment hanging areaRacks specifically for hanging garments are on the mezzanine floor and are two, fully interconnected, levels high. On each floor, a space has been left without racks to allow for the circulation and classifica-tion of garments.

Thanks to the mezzanine floor, the produc-tive surface area was multiplied, adding two extra floors that are perfectly suited to the space available.

The connection of the operators with the different warehouse floors is done via a pedestrian access staircase. On the other hand, conveyors have stairs and spaces specifically for automatic access to over-head carriage that transports hanging garments.

The Sigma profiles used for the mezzanine floor construction system join all the uprights in the installation, as well as attach the rails of the overhead conveyor system to the hanging garments

85Best Practices

Case Study I DHL

The tubes used for hanging garments on the racks are located at an optimum height from an ergonomic point of view and, although they have bearings every 2.2 m, the hangers slide and are grouped by items without producing any kind of interference.

Both the fire safety system tubes, sprinklers and the warehouse lighting are attached to the structure. The overhead shuttle trans-portation rails that are situated in the cen-tral area of the aisles hang there upon.

Spaces between pedestrian aisles are protected to avoid garments falling from one floor to another

86 Best Practices

Case Study I DHL

Technical data



Pallet size 800 x 1,200 mm1,000 x 1,200 mm


Handling equipment reach truck

Order picker ground floor with forks for 2 pallets

Hung garment area

Surface area occupied 3,000 m2

Surface area of the 3 floors 9,000 m2

Hanger profiles > 30,000 linear metres

Advantages for DHL

- Streamlining the space: the DHL warehouse is set up to store more than 90,000 pallets and more than 30,000 m of hanger profiles.

- Increased productivity: the compartmentalisation of items, the breadth of consolidation areas and the location of pre-loading zones are some of the factors that help increase the volume and efficiency of the movement of goods.

- Cost savings: each sector has its own loading dock, thus avoiding large displacements and notably reducing operation costs.

- Efficient service: thanks to this new logistics center, DHL has met the high level of service demanded by its customers and is capable of offering fast delivery without errors in the goods sent.

87Best Practices

Case study: PAVI-Groupauto

Conveyor belts as the axis of a picking installation distributed over several floors

Location: France

PAVI-Groupauto, a major supplier of auto spare parts from France, hired Mecalux to install the necessary equipment in its warehouse in Saint-Priest, a town near the city of Lyon.

The supply included two levels of mezza-nines, racking, conveyor belts and auto-matic sorters, as well as the Mecalux Easy WMS warehouse management system.

88 Best Practices

Case Study I PAVI‑Groupauto

Analysing the needsThe needs of PAVI-Groupauto required the construction of a warehouse capa-ble of storing a large number of SKUs of varying dimensions and characteristics, as well as being low consumption.

To do this, a storage system was needed that offered optimal use of the surface area, as well as being highly flexible and allowing direct access to any product.

The main objective of the company was thus met: rapid service for its customers.

Solution adopted: a conveyor circuitThe need to maximise the size of the ware-house and the fact that most of the orders consist of very few units and different SKUs led Mecalux to propose and install the following solution:

- Construction of a structure capable of integrating two raised floors on a 2,000 m2 area, which would allow the floor space to be tripled.

- Installation, on each of the floors, of racking with different sizes and types of distribution in order to suit the different products.

- Implementation of a continuous and automatic transport system connecting all the floors. This means operators can prepare orders by area, and transport them to the specific sorting and consoli-dation area after completion. The circuit is also used to send empty boxes from the lower level to the order preparation stations.

- Replenishment of the goods directly from the receiving container to their lo-cations. On each floor, pallet unloading docks have been installed on the other side of safety swing doors.

89Best Practices


- Swivel modules have also been located at strategic points along the transport circuit for the passage of operators.

- Installation of access stairs between floors, enabling access and rapid eva-cuation during possible emergencies.

All of this is controlled using the Mecalux Easy WMS warehouse management system.

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Ground floorThe ground floor is dedicated to bulkier products with direct picking and does not require the use of conveyors.

Also, the high consumption products are stored here, for which picking stations have been prepared adjacent to the con-veyor belts.

On the ground floor the conveyor belt borders the installation on two sides and is connected to the first floor via a ramp located on the third side

91Best Practices


Second and third floorsThe second and third floors of the PAVI-Groupauto warehouse have a very similar distribution and products of identical size are stored on both of them.

In addition, the conveyor circuit on these two floors runs along the main aisle, with the order picking finishing on the top floor.

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Preparation and consolidation of ordersRoller tables have been set up and attach-ed to both sides of the conveyors on differ-ent parts of each floor in order to collect the boxes containing unfinished orders and serving at the same time as picking stations.

Throughout the three floors, ten picking stations have been set up, each one corres-ponding to a different area or sector in the warehouse.

The boxes, once the part of the order as-signed to a zone has been put together or completed, are placed on the main conve-yor circuit to be transferred to the stations in other areas or to the sorting area.

The circuit descends along conveyor belts from the third floor to the bottom floor, where the classification and consolidation of orders is performed.

In this area, the operators check, pack and draw up the packing list and the shipping labels of the orders.To complete the oper-ation, there are packing boxes of different sizes, prep tables, computers and printers.

Once the orders are completed, they are

sent to the staging areas located opposite the

loading docks to be sorted into dispatch routes

93Best Practices


Easy WMS: Warehouse Management SystemThe Mecalux Easy WMS (Warehouse Management System) is responsible, among other things, for managing all the incoming processes, choosing the location where the goods are received, controlling the stock, designating the picking functions to be performed by each operator, executing the movement of the boxes and sending the orders via computer terminals.

The program for controlling the conveyors is connected to the WMS itself in order to ensure the efficient transport and alloca-tion of boxes, eliminating human error and reducing PAVI-Groupauto’s personnel costs.

The conveyor belts allow height differences to be overcome and movements to be carried out at different levels, while the swing conveyors allow the passage of the operators

94 Best Practices


Technical data

No. of floors 3

Surface area per floor 2,000 m2

Total surface area occupied 6,000 m2

Access stairs 6

Conveyor length 800 m

Picking stations 10

Automatic order sorters 4

Total No. of SKUs stored 50,000

Advantages for PAVI-Groupauto

- Excellent use of space: it was possible to increase storage capacity and triple the floor space through the construction of two raised floors.

- Integrated warehouse: each of the parts that make up the warehouse are integrated with each other.

- Adjustable storage needs: the distribution of the racking can be changed if the turnover rate of a pro-duct varies or if the future needs of PAVI-Groupauto so require.

- Elimination of internal movement: as a result of the installed conveyor circuit and the optimal place-ment of the racking, it has been possible to eliminate part of the internal movement made by the opera-tors. In this way productivity is increased and human errors are minimised.

- Fast order picking: the storage system installed is highly flexible and allows the operator to have direct access to any product.

- Efficient picking: operators can prepare orders by area using the continuous and automatic conveyor belt circuit that connects all the floors.

- Perfect control of the stock: using the Mecalux Easy WMS, PAVI-Groupauto can manage all the flows, processes and operations that take place within its warehouse.

95Best Practices

Case study: Hemosa

Multi-system Mecalux solution: Hemosa’s preparation centre beefs up automation

Location: Spain

Hemosa, a company specialised in the supply of fresh meats and pork-based products, has entrusted Mecalux to fit out its new warehouse with the latest automation technologies and computerisation of its manufacturing processes. For this reason, and with the objective of offering maximum quality products, they have installed various storage systems ranging from an automated warehouse with Pallet Shuttle and stacker cranes to drive-in and live pallet rackings.

96 Best Practices

Case Study I Hemosa

A totally automated version of Pallet Shuttle has been installed which uses a stacker crane as its

transport equipment that lends to great speed and efficient stock control

Automated warehouse with Pallet Shuttle: finished productsThe Pallet Shuttle system is a version of compact solutions that offers maximum storage capacity, with the added advantage of having load channels with variable depths. Pallets are transported internally through the channels using autonomous shuttles, hence the system name.

The version installed in the Hemosa warehouse is totally automatic and uses stacker cranes as its primary transport equipment between warehouse entry/exits and channel locations, lending to great speed and efficient control of both stock and operations done. The total capacity of this warehouse is 1,050 pallets, 1,200 x 1,200 mm in size with a maximum weight of 700 kg.

The Mecalux Easy WMS is a system which manages all operational basis in a warehouse; starting with entry, next placement based on parametrizable criteria and ending with subsequent dispatch.

Stacker crane

Pallet Shuttle

97Best Practices

Case Study I Hemosa

The Pallet Shuttle is housed on the cradle of the stacker crane in a position, slightly inferior to the pallet support level; said level is made up of two motorized chains which pick up and drop off the pallet in the entry/exit positions. When the stacker crane is positioned in front of the assigned location, the shuttle raises with the pallet on it and introduces it into the channel. It is placed on top of the support rail in the available location furthest from the aisle. The profile is also prepared to make movements guided by the Pallet Shuttle. Extractions are done in inverted order.

In the warehouse the following elements have been installed:

Racks

Stacker cranes

Pallet Shuttles

Entry conveyors

Exit conveyors

This image represents a solution similar to the one used in the Hemosa

installation.

The Pallet Shuttle is autonomous and charg es its battery in the cradle of the stacker crane in an automatic and straightforward manner. Each shuttle has eight wheels which provide the correct distribution of the weight upon the profile and which help it move smoothly from the stacker crane into the channels. On each side of the aisle, rails allow centering elements to facilitate the movement of the shuttle.

98 Best Practices

Case Study I Hemosa

Pallet entry and exit Two entry and one exit doors have been enabled. In each of these, a conveyor is entrusted to pick up and drop off pallets in the position which coincides with the aisle where the stacker crane circulates.

Moreover, the doors are protected by rapid action vertical curtains that only open via a signal sent by the Easy WMS when the pallet passes through, avoiding changes in the internal temperature of the coldstorage.

When the stacker crane is positioned in front of the conveyor, it sends a signal both to the corresponding conveyor, as well as to the one it carries in the cradle, in order

to act in unison and move the pallet from one to another. It also emits a signal to the same Pallet Shuttle when it is positioned in front of the channel where it must perform, ordering its displacement and the operation to be done.

The two located profiles on both sides of the channel are shaped to allow for double supporting functions both to the pallets and the guide rail, ensuring that the shut tle moves along safely.

From the moment the operator drops off the pallet in one of the entry points and the system is indicated which reference it contains, Easy WMS takes over control of it and its internal management.

The warehouse is a cold storage unit with temperatures kept slightly above 0 ºC, which conserves

products deposited there in optimal condition

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Case Study I Hemosa

100 Best Practices

Case Study I Hemosa

Live Pallet Racking: semi-prepared fresh productsThis type of racking, as well as the Pallet Shuttle, is incorporated within the compact storage systems and also maximises space. The peculiarity of this warehouse is that it is composed of storage channels with a slight incline. Each channel has rollers on which the pallet, introduced into the more inclined side, moves along via gravity until the first position on the con

Live pallet racking, which is 5.5 m in height, has the capacity to store 188 pallets, 800 x 1,200 mm in size and weighing a maximum of 600 kg

trary side. The velocity of pallet movements of is controlled via roller brakes.

Choosing said storage solution has to do with the type of products stored. Racks used for pallets with semiprepared fresh products that need a perfect product turn over (FIFO). In order to achieve efficient turnover, live pallet racking is ideal be cause the first pallet to enter the channel is the first to leave.

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Case Study I Hemosa

Easy WMSThis is a powerful, tried and true warehouse management system developed by Mecalux. It controls all internal operational basis in any warehouse, from reception to verification and location assigned within the warehouse, picking functions and final dispatch based on rules and parametrizable criteria.

Drive-in system: semi-prepared frozen productsRacks are put together having internal lanes of variable depth, in which forklifts enter with pallets raised to the corresponding height. At each level and on both

sides, profiles are ready to support the pallets.

Moreover, conventional pallet racking has been supplied to store other small volume products for internal consumption.

The system installed in Hemosa is meant to store pallets of semiprepared frozen products and large volume consumables, like packaging

In the case of Hemosa and in regards to the automated warehouse, the execution of movements is ordered via the Galileo control module. This software takes charge of controlling all actions which must be done by each moving device.

The connection with ERP SAP or the general management system of Hemosa is permanent and bidirectional, exchanging information and instructions that permit the total control of all operations done.

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Case Study I Hemosa

Technical data

Automated warehouse



Warehouse height 10 m


Type of stacker crane single mast + Pallet Shuttle

Constructive system Pallet Shuttle – traditional construction

Live pallet racking


Maximum pallet weight 600 kg

Channel depth 6.2 m

Maximum height 5.5 m

Drivein pallet racking


Maximum pallet weight 1,000 kg

Maximum lane depth 5 m

Maximum height 6.8 m

Advantages for Hemosa

- High-density storage: the storage capacity demanded by Hemosa has been achieved thanks to a combination of distinct systems installed.

- A place for each product: a storage solution has been enabled which best adapts to the characteristics and needs of each product that Hemosa works with, attaining perfect turnover and increased productivity.

- Total control of the automated warehouse: Easy WMS from Mecalux controls all processes and operations that take place within a warehouse, from the moment the product leaves the packaging line, up until dispatch.

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Case study: Zbyszko Company

A high profit automated warehouse:

200 pallets/hour and 18,000 pallets stored

Location: Poland

Aiming to keep pace with its growing business, the company Zbyszko wanted to expand the capacity and agility of their warehouse in addition to integrating their production and storage processes. In order to meet this demand, Mecalux built them an automated warehouse connected to the production plant via a 100 m long overpass equipped with conveyors. All this is coordinated and controlled by the warehouse management system Mecalux Easy WMS software.

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Case Study I Zbyszko

Zbyszko Company and their needsZbyszko Company, a company specialised in the production of carbonated drinks, soft drinks and flavoured waters, was creat ed by Zbigniew Bojanowicz in 1993 in the Polish city of Białobrzegi.

In just 10 years, the Zbyszko Company has experienced spectacular growth that has made it one of the most successful Polish manufacturers within the natural beverages market.

The Zbyszko Company hired Mecalux to construct its newest warehouse

located in the Polish city of Radom

In the face of its incessant headway, Zbyszko Company has relied on Mecalux to provide it with a new storage centre to centralise all the company’s logistical activities and which is equipped with the newest, most innovative technologies in order to deal with high production rates and save on logistics costs. Present and future growth demand it.

Speeding up internal transport was also a crucial prerequisite of the project, creating a direct connection between the warehouse and the production area. This was done via maximum automation of the storage processes in order to increase Zbyszko Company’s market competitiveness.

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Connecting the production area and the warehouseMecalux has set up an automated warehouse that connects the production area via a 100 m long overpass through which already palletised goods circulate on a circuit of roller conveyors.

The checkpoint, located at the beginning of the circuit and within the same production area, verifies that the dimensions and the quality of each pallet are appropriate.

The conveyors have two lines – one in each direction – working independently despite being placed in parallel.

Inside the warehouse two levels of conveyors are arranged. The upper level is allocated to the input of goods, while the lower level has been reserved for outputs.

There is also the possibility that outside goods, destined for the warehouse or the production area, can enter at this level. Not to mix operations, they have set up a conveyor just above the docks for inputs into the warehouse, with a lift placed at the end that raises the pallets to the upper level.

On the ground floor, so that throughput is as high as possible, a circuit of electrified

The Zbyszko Company warehouse is connected with the production area via a 100 m long overpass fitted with roller conveyors

monorails capable of transporting SKUs at more than 100 m/min – and which links the warehouse with the preload area – was installed.

This system is ideal for connecting distant points of the installation at a steady pace, eliminating unnecessary movements between rack areas.

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Inside the warehouseThe warehouse occupies a 7,000 m2 surface area and is built in a facility only 11 m high.

The installation of stacker cranes makes it possible to warehouse up to 18,000 pallets despite this limited height.

Having few SKUs, they chose to place doubledepth racks, a very common method in automated logistics centres that require a large storage capacity.

The racks are served by eleven, fully automated stacker cranes, which move quickly along their respective aisles handling pallets weighing up to 1,000 kg each.

Level 5 metres high Overpass

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The seven stacker cranes that are located in the middle zone are 11 m high, while the remaining four left at either end of the warehouse have been retrofitted to the shape of the building, with a height of 9 m

Ground floor

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DispatchesThe stacker cranes are responsible for automatically extracting stored goods from the production area and bringing them to the corresponding output conveyor. Once on the conveyor, the electrified monorails directed each pallet to their assigned preload area.

There are numerous options for creating an electrified monorail circuit. In Zbyszko Company’s case it was decided that a simple loop circuit, operated by 21 individually controlled shuttles, was the most costeffective, seamless solution.

The software that controls the machines is connected with the WMS (Warehouse Management Software) throughout the warehouse, and to the customer’s ERP.

The image on the right is differentiated into the following areas: Warehouse Inputs into the upper level Electrified monorails Preloads area Input conveyors from the docks

The pallets are loaded onto the shuttles on one side of the circuit and are unloaded in the consolidation area located on the opposite side

1

3

Input conveyor on upper floor Shuttle depositing goods in preloads

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Warehouse Management System: Mecalux EASY WMS Zbyszko Company uses the warehouse management system Mecalux Easy WMS to check each and every one of the movements that takes place in the logistics centre, and thus efficiently manage their storage space.

Easy WMS communicates with the customer’s ERP SAP in order to be able to carry out the dispatch, reception, distribution, transfer processes, and other tasks related to the logistics centre.

This powerful system ensures the proper operation of the machines that are used in the automation of the warehouses, which simplifies transportation, eliminates human errors and reduces staffing costs.

2

4

5

Overpass between production and the warehouse

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Technical data

Advantages for Zbyszko Company

- Maximum space utilisation: the warehouse, only 11 m high, has an 18,000 pallet storage capacity in a 7,000 m2 surface area.

- Cost savings: the overpass that connects the warehouse to the production area allows Zbyszko to save in logistical costs.

- Increased productivity: order preparation is fast and efficient thanks to the speed of the stacker cranes, the conveyor circuits and the electrified monorails installed, which can issue up to 200 pallets/hour.




Warehouse surface area 7,000 m2


Fork type double-depth

No. of shuttles on the electrified monorails 21

Length of the overpass 100 m

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Case study: DAFSA

A single warehouse in choice surroundings

Location: Spain

Mecalux builds DAFSA an automated clad-rack warehouse, in the scenic countryside near Valencia, whose outer finish was carefully made

to be environmentally friendly. The new warehouse, with a capacity for more than 23,000 pallets, is integrated with production outputs via a two

level overpass. Mecalux Easy WMS (Warehouse Management System) was supplied, which is responsible for managing all the warehouse processes.

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Case Study I DAFSA

Who is DAFSA?DAFSA, manufacturer of juices, vegetable purees and horchata, was established in 2006 as an exclusive provider to Mercadona, Spain’s top supermarket. Strong growth experienced in recent years has made DAFSA one of the most active companies within its sector. They turn on more than 250 million litres a year.

In 2014, with the startup of the new production plant in Segorbe (Castellón), that has a 66,000 m2 total surface area, it became their sector’s most advanced and sustainable production, processing and packaging factory in Europe. Within the premises, is the most noteworthy automated warehouse built by Mecalux.

The collaboration between the two companies dates back to DAFSA’s beginnings. Since then, Mecalux has built differ ent warehouse solutions adapted to the company’s ever changing needs.

Current warehouse of DAFSA and the area reseved for future expansion.

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Case Study I DAFSA

A clad-rack warehouse: today and beyond The attached picture shows the design of the warehouse installed and the space reserved for future growth, which is intended to multiply storage capacity up to 40,000 pallets if needed.

In a cladrack warehouse like this, the racks are the building’s structure and the wall and roof cladding is placed on them. In addition to the building’s own weight, the racks must bear the pallets stored and the external forces indicated by regulations, including wind.

DAFSA has a reserved space with which they can double current storage capacity

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Case Study I DAFSA

Thanks to the warehouse design, the second phase could be built without interrupting DAFSA’s production or installation operations

The warehouse is 39 m high, 31 m wide and 102 m long and has four storage aisles.

One of these aisles was isolated from the rest in order to store refrigerated products. To achieve this, a specific type of construction was required aimed at integrating the aisle into the same facility, but without having to install components that act as coldbridging.

The equipment supplied by Mecalux and the warehouse management system Easy WMS is responsible for palletised product movement at the end of production lines, achieving total integration between the factory and the warehouse. This minimises the human intervention needed to move the goods between different areas.

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Case Study I DAFSA

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Case Study I DAFSA

Entrance into the warehouse: upper levelThe warehouse, located on one side of the plant, is linked to production output via a two level overpass, leaving the middle area for future growth.

So pallets could enter the warehouse, elevators were enabled at the overpass’ end that raise the load to the top level. Then a circuit of automatic conveyors is responsible for transferring pallets up to the stor age aisle allocated by the Easy WMS (Warehouse Management Software).

Various checkpoints and set ups ensure the size and excellent condition of the pallets coming into the warehouse. Quality control is essential, since 1,200 x 800 mm sized europallets and medium sized 600 x 800 mm pallets are deposited in the same warehouse.

An entry point was provided, which is served by forklifts for products from other plants

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Case Study I DAFSA

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Case Study I DAFSA

Inside the warehouseHigh platforms were installed that coincide with the overpass’ top level, on top of which the aisle input conveyors are placed.

The warehouse is composed of four aisles where stacker cranes circulate. These are responsible for making movements between locations and the conveyors for the input and output of pallets. As mentioned previously, one of the aisles was isolated from the rest in order to store refrigerated products.

Racks, double in depth, were readied on both sides of the aisles, with 16 storage levels adapted to store the two pallet formats which DAFSA uses.

The refrigeration equipment, fire protection systems, the stacker cranes’ upper guides and the rest of internal equipment are supported and attached to the racks themselves forming an integral part thereof.

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Case Study I DAFSA

The stacker cranes are twinmast in nature and incorporate a mounted booth to facilitate maintenance work, as shown in the photo below and to the right.

The installation is distributed in the following areas identified in the layout:

1. Ambient temperature warehouse

2. Cold storage aisle

3. Connection overpass

4. Entries from production

5. Preloads deliveries

6. Future expansion of the warehouse

The warehouse’s capacity is for more than 23,000 pallets,

1,200 x 800 mm in size, 1,700 mm high and

weighing 1,050 kg each. If all the pallets were

600 x 800 mm sized, the storage capacity would

increase to more than 46,000 pallets

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Case Study I DAFSA

Pallet output: lower level Even though the overpass’ top level was intended for inputs only, on the lower level outputs coexist with inputs, allowing for duplicate flow of inputs.

The main circuit, located on the overpass’ lower floor, has dual conveyor strands to perform pallet input and output tasks.

In bottom photo, of the overpass, you can see the access point to an ambient temperature aisle, followed by vertical access doors to the cold storage aisle.

The main circuit of conveyors on the lower floor is connected via three doors with the conveyor circuit in the dispatch area, located in an adjoining building.

Once there, two shuttles are tasked with depositing the pallets in one of the pallet flow channels available on the ground level.

On the overpasses’ lower level is the consolidation area of the warehouse, where outputs and inputs exist side by side

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Case Study I DAFSA

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Case Study I DAFSA

DeliveriesDeliveries are also segmented depending on the product. Thereby, the part reserved for refrigerated products is built in a closed area that has a double preload capacity and vertical rollup doors that automatically open for pallets to be deposited into the live channels.

In all, seven preload groups and a quick exit have been provided. Each group consists

of three live channels with a pallet capacity of 11 each. Between them the three full loads, 33 pallets in all, fill a lorry.

The channels are prepared for the pallets, whose extraction is handled via electric pallet trucks.

Preload outputs coincide with the lorry loading docks, as illustrated by the photographs on this twopage spread.

A shuttle is responsible for

connecting the output stations with different

order consolidation channels

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Case Study I DAFSA

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Case Study I DAFSA

Different pallets, different solutionsThe installation is outfitted to receive 800 x 1,200 mm sized europallets and medium 800 x 600 mm sized pallets.

The use of medium sized pallets is very frequent in the distribution sector, especially for high consumption products, because they go directly from production to linear supermarket shelves, avoiding interim handling.

To store 800 x 1,200 mm sized pallets of indiscriminate depth with the utmost security, crossties were put in the racks, as shown in the picture below on the right.

The conveyors were also adapted for medium sized pallets. In the rollers, the separation between them is less than usual, while in the chain conveyors four strands are available. Furthermore, and in order to avoid confusion, checkpoints help to differ entiate the two pallet types.

The facility was set up to handle and store medium sized pallets since the percentage, compared to europallets, is higher 800 x 600 mm medium pallet

800 x 1,200 mm Euro-pallet

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Case Study I DAFSA

Easy WMSEasy WMS is the nerve centre that governs all operations from production outputs to their dispatch. This powerful warehouse management system developed by Mecalux performs, among others, these roles:

Management of the input of goods from production lines.

Pallet location in the warehouse using previously parameterised rules, according to the following criteria: product type, space optimisation and maximum productivity.

Stock management and the warehouse’s layout (what and where the goods are). Outputs to deliveries by batch and via FIFO criteria.

Preload fulfilment according to the order requested and subsequently loading the trucks.

well as its safety measures, are managed.The communication between Easy WMS (Warehouse Management System) and the customer’s ERP is permanent and bidirectional, transferring the data both systems need to operate and to effectively manage the warehouse.

Query the status of various parts of the warehouse and the machines that operate in them.

Thanks to the Galileo control module, all movements of the different equipment that the installation is comprised of, as

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Case Study I DAFSA




Type of stacker cranes Double-deep, twin-mast


No. of shuttles 2

Preload channels 21

Capacity per channel 11

Construction system Self-supporting

Advantages for DAFSA

- Enhanced storage capacity: the DAFSA warehouse has a capacity of more than 23,000 pallets, 800 x 1200 mm in size. The facility has a space purposed for future expansion, which allows storage capacity to be multiplied up to 40,000 pallets.

- Overall appearance: construction of a modern, high technology logistics centre, but at the same time integrated into the countryside in which it is located.

- Increased logistical efficiency: DAFSA has improved its logistical efficiency thanks to the automation of inhouse movements and the connection with production outputs.

- Complete control: the Mecalux Easy MWS software manages all movements, processes and operations that take place inside the warehouse.

Technical data

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Case study: Havi Logistics

Mobile racks for continued growth at Havi Logistics

Location: Italy

Since its creation in Germany in 1981 as a small family business, Havi Logistics has expanded its market to become one of the leading suppliers of integrated logistics services, with 48 distribution centres in Europe and more than 5,000 employees. Its customers range from restaurant chains like McDonald’s to BP service station kiosks. The company is growing so fast that it has had to expand its facility in Lodi, Italy, and it has entrusted this project to Mecalux.

Minding the essentialsHavi’s logistics centre in Lodi, Italy, was opened in 2009 with a capacity for 4,566 pallets. Given the company’s continuous growth and expanding customer base – and therefore the number of products to be stored and distributed – it quickly out-grew the facility. There was thus a clear need: to multiply the useful storage space by expanding the 4,870 m2 available in the original warehouse.

Furthermore, the characteristics of Havi Logistics’s activity had to be considered. Havi manages the supply chain for perish-able and non-perishable products for a wide range of customers: frozen goods, fruits and vegetables, meat, dairy produce

and cleaning products, amongst others. This made it necessary to conserve stor-age and handling areas with four different temperature ranges, with a particular fo-cus on preserving the cold chain through-out the entire process to ensure optimal safety and conservation of the food that Havi stores and distributes daily.

This project began with a very clear need: to reduce storage costs, especially in order to accommodate new customers. The result has been the combination of conventional pallet racks with mobile rack-ing. By combining these two kinds of racks the size of the building needed to work with a given volume of pallets can be reduced.

Case study I Havi Logistics

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The answerMecalux’s technical team calculated the facility’s expansion and remodelling down to the tiniest detail. Since the customer’s priority was to multiply its storage capa-city the Movirack mobile racks stole the show. These racks boast optimal perfor-mance at all temperatures. The immediate result was to expand from the original sto-rage capacity of 4,566 pallets to the cur-rent capacity of 12,500 pallets, enlarging 4,870 m2 of surface area to 10,000 m2.

As required by the customer, the four dis-tinct zones with different temperatures at the Havi Logistics centre in Lodi were con-served, but the layout of each one was changed by implementing various storage solutions tailored to the specifications of the different products:

- Dry or ambient temperature zone: 370 linear metres of Movirack mobileracks were installed in this zone to a height of 9 metres. This system elimi-nates unnecessary storage aisles, as the operator selects the aisle that he or she needs to use, whether manually or by remote control, and the mobile racks move laterally on rails embedded in the floor. This leaves the space required for loading, unloading or picking access on the selected racks. Push-back racks for accumulative storage and conventional pallet racking were also installed. In this way, high occupancy was achieved and goods handling time was reduced.

- Refrigerated zone: Movirack mobile racks combined with Push-back racks were installed here as well. This system allows four pallets per level to be placed in deep storage and uses the LIFO load management method (the last pallet in is the first out). The combination ofboth systems saves a significant amount of space and achieves high storage den-sity while speeding the picking and re-plenishment of goods, which is essential in fresh food supply.

- Freezing zone: in the cold storage area the Movirack mobile racks make it pos-sible to reduce the volume that must be stored at low temperatures, thereby saving energy. Roller and trolley push-back racks and drive-in pallet racks were installed to round off this area.

- Cool dock zone: this is a lengthwise

loading and unloading zone linking the three storage areas described. Its function is to allow the goods to be han-dled without breaking the cold chain, which is kept at a temperature between

1 and 4 degrees. This mode ensures that all products reach their destination in perfect condition.

- Picking area without capacity loss: in this area there is a mix of convention-al pallet racks, located on the sides, with Moviracks placed inside. The mo-bility and accessibility that the Movirack system offers frees up a wide aisle so that a forklift working with pallets can enter. It also opens all aisles so that operators carry out picking. Thereby, the area is set up to function both with pallets or smal-ler products that require picking.

Mecalux has implemented a made-to-measure project that has allowed the Havi Logistics group to double the useful storage space and reap the benefits of a Movirack system on mobile bases


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Push-back system with shuttles

Push-back system with rollers

Drive-in pallet racksConventional pallet racking Movirack Mobile pallet racking


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Advantages for Havi Logistics

- Increased storage capacity: the Havi Logistics warehouse has almost tripled the storage capa-city, from 4,566 pallets to 12,500 pallets, doubling the surface area from 4,870 m2 to 10,000 m2

- Profitable model: the distribution centre Havi Logistics has in Lodi has become a model of profit-ability and efficiency that will allow the company to manage future growth in a flexible manner.

- Cost savings: with the remodelling and expansion of this installation, logistics costs have been reduced without affecting the service quality of the company and maintaining a high level of productivity.

Technical data



Width of the warehouse 62,5 m


No. of racks 60

No. of aisles 33

No. of load levels 3, 4 and 5

No. of Movirack mobile racks 12 double

No. of push-back racks 9

No. of drive-in racks 3

No. of fixed conventional racks 20

Pallet size 800 x 1,200 x 1,650 / 2,300 mm


The first diagram (A) shows the solution where only one aisle is freed up to operate with a fork-lift. In the second (B), this option displays when two aisles are opened up to do picking.

A

B


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Case study: Hepco Motion

Mecalux installs a special mobile cantilever rack solution for metallic profiles

Location: United Kingdom

Hepco Motion, a world leader in the field of linear motion systems, has expanded its storage facility in Tiverton (Devon), with the aim of expanding their production growth and cutting down order fulfillment and delivery times. To optimize their warehouse capacity they put their trust in Mecalux, who installed cantilever racks on Movirack mobile bases for them.

Case Study I Hepco Motion

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The needs of the customerHepco Motion, a British company that is part of the Hepco business group, has bran-ches and accredited distributors throughout the world and more than 40 years of experience. The company offers a wide range of products that are constantly be-ing updated to meet the demands of their customers within the automation and other industrial sectors, offering all kinds of innovative linear move ment solutions.

Due to their continued growth rate, Hepco has recently launched an expansion of its production and storage facility head-quarters in Tiverton, UK.

Given that the old warehouse was used to expand production area, storage pro-cesses were moved to a new premises ad-jacent to the factory. In other words, the main goal put forward by Hepco Motion has been to optimise this new space, which is 53 m x 13.5 m x 6.5 m in size.

Another project requirement has been the reuse of stationary cantilever racks from the old warehouse, so that they could be integrated into the new facility.

The company entrusted Mecalux with the development and implementation of this storage project, so in addition to sorting out space requirements, it also took in-to consideration the specific nature of the product: profiles of various lengths.

Given product characteristics and the need to maximise storage capacity, the solution proposed by the Mecalux delegation in the UK (located in Birmingham) was to install cantilever racks on Movirack mobile bases


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The solution proposed by MecaluxIn all, nine Moviracks were installed, grouped in 3 blocks of 3 racks each. Each Movirack cantilever is 11 m long, which allows you to make full use of the 13.5 m wide warehouse.

The three blocks of mobile rack were inter-spersed with the stationary cantilever racks for heavy loads that came from the old warehouse: two single, one on each end of the warehouse, and 5 double, with access on both sides.

A cantilever system is the best option for the storage of different length profiles, because the cantilever arms that support load units allow for easy, safe handling. In addition, it is possible to adapt them to the size, stiffness, tolerance, weight, etc. of the goods.

In respect to the Movirack mobile base sys-tem, its main feature is the automatic side-ways movement along rails embedded into the floor. This takes up less space by elimi-nating unnecessary aisles, but without los-

ing direct access to the products stored in the warehouse.

Consequently, each of the 3 blocks of 3 Moviracks installed only needs a single work aisle, instead of the 4 that would be needed in a conventional system.

Taking into account that rack length is 11 m and aisle width is 2.6 m, this amounts to an overall space saving of more than 250 m2, which has resulted in significant cost savings in the construction of the new building.

The dimensions of the warehouse

have been adjusted to the storage system,

lining up the entry doors with the work aisles

of the Movirack units


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Technical data

No. of Movirack racks 9

No. of rack units 3

No. of possible aisles 4 per rack unit

Aisle width 2.6 m

No. of load levels 7

Height of the load levels variable


Width of the warehouse 13.5 m

Height of the warehouse 6.5 m

Rack length 11 m

Rack width 2.4 m for each mobile base

Rack height 5.3 m

Advantages for Hepco Motion

- Higher productivity: the installation of mobile bases allows faster processing of inbound and outbound goods, optimising product placement and workflow.

- Cost savings: the high-density nature of the mobile bases has made it possible to reduce the size of the new industrial building, requiring less surface area to achieve the desired storage capacity. The opportunity of combining mobile and stationary cantilever systems, by reusing old racks, has also resulted in cost savings.

- Optimal warehouse management: the above benefits will improve the management of warehouse processes.

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Case study: Iron Mountain

Earthquake-proof racking: an installation with conventional racking on the Pacific Rim

Location: Chile

The Mecalux racks installed in Warehouse 11 of Iron Mountain, a leading records management and archiving company, were the only ones which were able to withstand the 8.8 magnitude earthquake in 2010 that devastated the Chilean regions of Maule and Bio Bio. After the earthquake, Iron Mountain commissioned Mecalux to rebuild its many damaged buildings and to build two new warehouses with similar characteristics.

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Case Study I Iron Mountain

The collaboration between the two com-panies began five months before the earth-quake, when Iron Mountain hired Mecalux to build Warehouse 11, which holds more than 1.4 million boxes.

As soon as Mecalux took over the project for Warehouse 11, the design went through a structural review that took a variety of consi-derations into account, such as local seismic regulations and fire protection, electrical protection and safety systems. The conven-tional pallet racking is designed with a focus on the seismic resistance of the shelves.

Before starting the installation of the ware-house, the racks also went through a pre-liminary design phase, so they would be capable of absorbing the force generated by any potential earthquakes. The ware-house, divided into four floors in order to allow manual handling of the goods, is made up of tall, high-resistance racks with shelves at different levels on which the boxes containing the files are deposited.

Access to the various floors of the ware-house is performed by means of stairs, lifts and walkways.

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The conventional pallet racks put in place were designed from the inside out – first the shelves and then the building envelope.

Longitudinal rigid frames to reinforce the beams and columns on the four floors of the warehouse were also installed, along with the creation of a 4 m wide central aisle that enables comfortable handling of the load at the different locations. The central frames were fixed on a base plate calculated with sufficient thickness to pro-vide maximum absorption of the shocks, since according to the calculations made, the seismic waves would travel longitudi-nally through the frames.

The land on which Warehouse 11 was built was classified as Type 3, of the lowest pos-sible quality, so extraordinary measures were taken to reinforce the entire building.

The earthquake and the reconstructionOn 27 February 2010, an earthquake mea-suring 8.8 on the Richter scale struck the Chilean regions of Maule and Biobío with devastating consequences. The company lost seven of its facilities, but there was one that was indeed able to pass the test: the warehouse built by Mecalux, which was still only half-finished.

Given this natural disaster, many busines-ses were looking to store their documents and files in more secure facilities such as those Iron Mountain had been proven to have.

Even so, the company needed to relo-cate the many thousands of boxes that were scattered on the floor, so the second

An efficient and safe projectWith this earthquake-resistant project, Mecalux demonstrated its high standards of quality, safety and commitment. The challenge of building a warehouse of this kind in such a powerful earthquake zone was overcome while complying with local seismic regulations and supplying an installation which was fully reinforced and pre-pared to protect the workers and stored goods against earthquake tremors.

Mecalux also pledged to assist in the diffi-cult tasks of reconstruction through the construction of two new warehouses which were equally resistant.

phase of construction was begun quickly with the aim of storing part of those loads. However, Iron Mountain not only needed to rebuild all its facilities, it also had to progress and keep growing. For this reason, the company commissioned Mecalux to build two warehouses similar to Warehouse 11, with a total capacity of more than 3 million boxes.

With so little time to lose, Mecalux made a su-preme effort to meet the deadlines and erect the new facilities at a dizzying speed, so that the company would be able to resume its activities as quickly as possible and relocate its personnel to their regular workstations.

The Iron Mountain warehouse in Chile is located in the Ring of Fire on the Pacific Rim, one of the regions with the most seismic activity in the world. Therefore, Mecalux prioritised the safety of the installation and built a reinforced system that would be capable of withstanding potential earthquakes

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Technical data

Warehouse No. 11 – Iron Mountain

1st stage

Total capacity 720,000 boxes

Number of staircases 4 levels

Frame height 12,600 mm

Central aisles 4 metres

Warehouse No. 12 – Iron Mountain




2nd stage




Central aisles 4 metres

Warehouse No. 77 – SA Storbox




Advantages for Iron Mountain

- Security against earthquakes: installation is reinforced to withstand any seismic movement.

- Higher capacity: the three warehouses built by Mecalux have a total capacity of more than 3 million boxes, which far exceeds the needs of Iron Mountain.

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Case study: Benco Dental

Uprooting Benco Dental: a customized warehouse to speed up picking

Location: USA

The founder Ben Cohen put down roots in Pennsylvania in the 1930s and formally started Benco Dental in a modestly sized Wilkes-Barre Township office. Benco grew the business there for the next 30 years. In Wilkes-Barre, the enterprise was hamper-ed by, among other things, limited and undersized pick locations, pockets of scattered secondary stock, and bins with inefficient replenishment.

“The most bang-for-your-buck happens when companies receive product, stick it in its primary location and pick it,” said a Benco spokesperson. “That’s the philoso-phy we took when we designed the new facility.”

In its latest move, Benco swapped a 6,400 m² installation for over 14,900 m² just 11 km away in Pittston.

In January 2010, dental equipment supplier Benco Dental teamed up with Interlake Mecalux (IKMX) to create the nucleus of its rapidly swelling business: a new home office doubling as a distribution centre and lavish product showroom. After a decade that saw the Pennsylvania company open distribution centres throughout the USA, Benco Dental’s next step was to bring the corporation back home.

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Case Study I Benco Dental

Mecalux steps inBob Novak, Interlake Mecalux’s North East Market Manager, explained, explained that he first got involved with Benco Dental after one of its lift truck distributors came to him for help designing Benco’s pick mo-dule in Fort Wayne.

He noted that after IKMX’s involvement with the Indiana installation, Benco Dental commissioned the well-known Spanish warehouse solutions provider to install racks in its future installations.

As it often does, the evolution of this pro-cess started with Benco Dental’s concep-tual drawings. After the sides volleyed their ideas back and forth, the concept was whittled down to a final design.

“We went in as the experts on pick mo-dules and have worked with Benco ever since,” said Novak. “It worked out pretty well,” top Benco managers replied, re-flecting on both Benco’s reenlistment of Interlake Mecalux and the six-week installation.

The fastest growing private dental distributor in the U.S. implemented a pick module as part of its expansion and legacy

Customized V-shaped shelves above conveyors for quick storage of small items

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Today, more than 400 employees work out of the Pittston facility – not just in the distribution warehouse, but in the offices, classrooms and showrooms built into the structure’s design. “We have the biggest single place in the U.S., where dentists can come see all kinds of working operato-ries,” a spokesperson continued. Twenty-six office sets display the products and tech nologies Benco distributes.

Challenge and successRelocating a company is a tough busi-ness, even if it only means moving 11 km away. The Pittston installation rests in a never-occu pied building within a stor-age park that was adapted by Interlake Mecalux (IKMX) according to Benco’s specifications.

Benco Dental’s team realized how tric-ky the several months preceding the move were going to be. It meant having to manually move 34,000 items one-by-one from old pick slots to new ones. “Maintaining customer satisfaction dur-ing the move was the biggest challenge,” Benco management explained, “We didn’t shut down for one day.”

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Benco Dental reinventedThe design and size of Benco Dental’s in-stallation ensures that it isn’t strained by constant restocking demands. Warehouse dimensions aside, the dental product dis-tributor uses its space wisely by also build-ing up and canvassing each square meter with efficient operations.

Benco’s floor plan certainly fulfils all of its basic requirements, but it is the system’s bells and whistles that add a unique effi-ciency exclusive to that Pittston facility.

In addition to the improvements the racks inherently create on the premises, the ex-pert innovations and specialized flour- ishes of the Pittston location optimize production.

Mobilizing Mecalux’s knowledge into in-novative solutions is what helped solidify

Benco. “I approached Interlake Mecalux with a basic design in mind, they tweaked it, and we both added some great features,” said a key Benco manager.

Here are Pittston’s biggest customisa-tions – and why they are necessary:

Adjustable decks: make it easier for any-one to stock top shelves. The solution was to incline the deck on the higher end of the carton flow module by several inches and install multiple catwalks connecting the two. The end result is a seamlessly equal reach for personnel on both sides.

An overpass: in addition to the cat-walks, Novak and the IKMX design crew were able to create an overpass connect-ing the second floor of the pick modu-le with a structural mezzanine for greater throughput.

Extra shelf picking area: the design al-so called for shelf pick areas allowing for maximised order fulfilment or just-in-ti-me shipping. Shuffling the product out the door or back into the system is easier to do the more shelf picking areas one has.

Once a pallet is unloaded onto the dock, lift trucks transport the pallets to their lo-cations throughout the module.

Steel-encased flow rail: the ground level pallet flow rails were last-minute additions designed to maintain a productive picking speed of oversized products. It keeps pro-duct both stored and out of the way, and protects against possible damage done by lift trucks.

V-shaped shelves: Benco Dental want-ed their smaller, slower-moving products to be accessible to the pick area without going to great lengths to retrieve them – a common wish among facilities with simi-lar products. For this, the group designed V-shaped shelves. The 20-inch deep units hang above the conveyor – accessible, but out of the way.

Bonus storage: adding more storage spa-ce to each level meant that Benco would have extra floor space where pallet stor-age would have been.

The extra floor space can be used by forklifts to unload additional goods faster.

The stocking area rises 10 inches between the picking side and the charge side.

Pallets arrive on the outer decks of the module to be loaded on to the flow rails

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Pick module safetyHow Interlake Mecalux worked with Benco Dental to ensure safety.

1 Safety straps. The operator is hooked into a harness, as well as a safety strap. The strap rides along a trolley line that runs the length of each module level (other than the ground floor).

2 Galvanized safety deck. Once a pallet is fully picked, personnel relocate the pallet. The galvanizing ensures an easy, undamaged course of the pallet to a re-turn lane, and the safety of personnel below from wood shards.

3 Safety netting. The netting extends past the safety deck in order to deter personnel from approaching the edge of the pick module, and to protect them if they do.

The extra shelf picking areas ensure constant quick turnaround.

Added height for pallets and steel-encased flow rail keep product safely housed.

The safety of the picking installation was fundamental throughout the design process

1

2

3

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1. Product is received within 24 hoursReduce store inventory by optimizing the time it sits in the factory, eliminating “change overtime” that would normally cause delays at the beginning of the process.

2. Expedited product is sent straight to order fulfillmentSchedules are synchronized with demand. If there is not product demand, personnel is placed else where, making multi-skilled employees more useful.

3. Remaining stock is storedWith less inventory, there is decreased risk of product damage or expiration.

6. Product is unloaded to dockFewer pieces mean fewer delays.

4. Fulfilled orders loaded and shippedWhen production demand and supply is synchronized and goods move directly from receiving to order fulfillment, less space is necessary for storage.

5. Employee effort, emphasis is spent elsewhereSupplier relationships are enhanced as a company with limited inventory will do whatever it takes to avoid part shortages.

CYCLING THROUGH A RESPONSIVE REPLENISHMENT METHODBenco Dental has made it a company practice to saturate its distribution centers with efficient production strategies including its just-in-time replenishment method. JIT is a means to reduce stored inventory by optimizing system performance. Here is how Interlake Mecalux helped ensure Benco Dental’s efficiency:

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Advantages for Benco Dental

- Design and dimensions: special design features and the large-scale installation ensure that they are able to supply the continuous demands of restocking products.

- Space optimization: Dental Benco uses the available space intelligently, taking advantage of every square meter for efficient operations that contribute to the strong performance of the installation.

- Development of made-to-measure products: the customization of the system, in accordance with the needs and requirements of the client, gives the installation unique efficiency. The appli-cation of Mecalux’s technical knowledge, in regards to innovative solutions, has helped Benco to stand out among their competitors.

- Enhanced productivity: as a result of the incorporation of massive picking modules from Interlake Mecalux and other systems in the Pittston installation, Benco estimates that has increa-sed its productivity by 12% in comparison to what it earned in its previous facilities.

Our experts I Software

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This paradigm shift has been led principa-lly by the needs of the clients themselves, who in light of periods of crisis have opted for the type of solutions that only the cloud can offer: controlled expenditure, versatility and portability.

However, it is also important to take into account the fundamental influence that the evolution of technology has brought upon us, which has made it possible to increase the connection capacity both within loca-lly or mobile based communications. The social changes caused by globalisation, the sharing of information and the need for

continuous access to information can also not be ignored.

What do we mean when we talk about “the cloud”? There are many definitions for such a broad term and that, in the here and now, is part of almost any solution. Perhaps the one that co-mes closest says that it is a “consumer technology model” (applications, computing and storage) as a service through a network (usually the Internet), without the need for investments, securely and accessible from anywhere. This virtual set up makes data control and management more obtainable.

Key advantagesThe main features that have led to this growth in cloud based solutions are:

• Savings in the initial investment of any project of software deployment. The hardware infrastructure to house the solution is eliminated, and only the equip-ment in use is required. Nor is the initial cost of licensing necessary, since a payment by use and monthly service (SaaS) is applied.

• Automatic and secure application updates. There is no need to spend several weeks to update a company’s applications, with problems that can result in loss of da-ta, downtimes, etc. Updates are comple-tely transparent and without any form of intervention.

• Savings in maintenance costs. By adopting a SaaS model, the maintenance of the application and the housing of the so-lution lies with the provider. Who is the one responsible for hardware upkeep.

Logistics software: the cloud is the future Due to the continuous evolution of technology, our business landscape is changing at a high speed. One of the most important paradigm changes that has taken place in recent years has been caused by the software industry, with the creation of cloud-based applications. The logistics operations of companies have quickly adapted to this change, demanding that software applications be implemented which are increasingly compatible with the cloud.

Our experts I Software

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• Flexibility. This model is ideal for busi-nesses with fluctuating growth over time, so that it is always possible to increase or decrease the service you are receiving.

• Access to information from any loca-tion. Only an Internet connection is requi-red to be able to work remotely.

• Reduction of the implementation times when performing a solution rollout because it is unnecessary for clients to install software to access the computer program from an Internet browser.

• Security. The cloud does not depend on computer equipment, so that data is not lost in the event of portable devices being

misplaced, or because of any type of break-down in a client’s computer. That is to say, because the data is stored in the cloud, you can access the information in the company, regardless of anything that happens to your computer.

Some “cons”All these features are advantages that cu-rrently lead more than 60% of medium-si-zed companies to use cloud-based services. But there are also drawbacks to working in the cloud:

• Dependence of network connections. For this reason, before deciding to step into the cloud, you should verify that your net-work infrastructure, that will support these services, is adequate enough and even be sure to have a contingency plan for network breakdowns. This way, you will get a solid system.

• Loss of data control. This is the biggest drawback that many companies face when making the leap into the cloud. To upload information into a server hosted in the clo-ud that can be replicated in any other secu-re backup in the recovery of a system, relo-cation of the information is clear and this makes many businesses fearful. This distrust is based, in part, on the perception that data is more secure in their own facility, when the truth is that it is easier for data leaks to occur

WANLAN

HOST

LAN

CLOUD

ON-PREMISE

at a domestic level. The possibility of an inci-dent within their own systems is much more likely than with any cloud hosted service.

An example of evolution: Easy WMSFundamentally, when analysing the pros and cons of using the cloud, it is obvious that the future of software and services lies within this new platform. In the coming years, companies will increasingly rely on adopting this technology.

Responding to the changing needs of its customers and to this new paradigm, Me-calux Software Solutions – Mecalux’s soft-ware development division – has created a new version of its Easy WMS Warehouse Management Software, so that clients can operate as per the architecture that they desire to use:

• Either in the cloud, offering a cloud ser-vice model, namely SaaS (Software as a Service).

• Or the traditional client/server “on-pre-mise” model, hosted in their facilities.

This way it is the client who decides which option they feel more comfortable working with. And even if you prefer to start with the traditional model, you can then jump into the cloud or vice versa. Flexibility, is first and foremost. u

Our experts I Clack-racks

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Clad-rack warehouses When racks also support the buildingThis type of constructions are integrated buildings formed by the racks themselves, whose structure is coupled to both the roof and wall cladding. Clad-rack warehouses have achieved great importance in the last 30 years, mainly because of the need for space optimisation, and resulting in the construction of buildings that are taller than 45 m.

• The warehouse, or one of its parts, is composed of racks that occupy the total height of the building’s interior.

• There are usually heavy pallets stored on the racks, so calculations must be done to withstand all the stored goods.

• The racks are metal structures that have a large number of pillars (frames/uprights) that distribute the weight evenly on the floor of the warehouse.

• The forces that the racking units trans-mit to the ground are much higher than those that the pillars of the building trans-mit, although individually. Each upright transmits a much lighter load and which, above all, is distributed.

• If the external forces that support the building were transmitted to the ground via the racks, it would add a relatively small

In order to better understand the ad-vantages offered by building a clad-rack warehouse, we should first consider some features of the traditionally built ware-houses:

• The building of a traditional warehouse is formed by a supporting structure, with its pillars, trusses, roof girders, side walls and roofing, on which external forces such as the wind, snow or earthquakes act against, depending on its geographic location.

All the forces are transmitted to the ground through the pillars, which requi-re the construction of load-redistribution footings.

It is also essential to build a slab or floor with sufficient load capacity to be able to support the weight of the goods and han-dling equipment.

percentage to each upright in comparison with the loads derived from the goods.

Advantages of a clad-rack warehouse• Full use of the surface area: the ware-house is designed at the same time as the racks and only occupies the space required, without intermediate pillars that influence their distribution.

• Optimisationofheight: as with the surface area, the height will be only that which is required. At the same time, the upper trusses or girders require less height and incline being directly supported on the racking.

• Maximum height of the construc-tion: you can build to any height, it only depends on local regulations or the scope of the handling means which are used, be-ing able to exceed 45 m high (which would


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be complex and expensive in traditional construction).

• Simplerconstruction: the entire struc-ture is assembled on a concrete slab of suita-ble thickness to achieve uniform distribution of the forces on the foundation; there isn’t a high concentration of loads

• Lesstimeforcompletion: once the slab is built, the entire structure and clad-ding are progressively and concurrently installed.

• Cost savings: As a general rule, the cost of a clad-rack warehouse is less than the more traditional racks. The greater the construction height, the more profitable the clad-rack system.

• Minimalcivilworks: it only requires the construction of the slab on the ground and, in some cases, a waterproof wall bet-ween one and two metres high. In which case the operations area needs to be ex-panded for receipt and dispatch, a traditio-nal building can be built, but of sufficient height without reaching the total height of the warehouse.

• Easily removable: being a structure formed by standard rack elements that co-

me pre-assembled or bolted, they can be dismounted with ease and a high percen-tage of components recovered.

Wheninstallingaclad-rackwarehouseThe variety of applications of this type of warehouses are very broad, although it is particularly suitable solution in the fo-llowing cases:

•When the warehouse exceeds 12 m high. •Whentheconstructionisofalower,but

its use is temporary or pro-visional.•When the maximum optimisation of spa-

ce and volume is required, regardless of the height of construction that is built.

In the case of clad-rack warehouses which are less than 12 m high, the storage sys-tem which is often used is non-automated


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9 8

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compact (drive-in palletising, push-back, Pallet Shuttle and live by gravity).

The use of conventional pallet racking, ei-ther single or double-depth, is more com-mon starting at this height. On the other hand, when above 15 m high handling machines should be automatic.

As a general rule, in the case of automated warehouses, the best practice is to take ad-vantage of the maximum height allowed by local regulations. This is provided that the amount of machines designed for the installation makes it possible to achieve the desired number of movements. To get same storage capacity, you can opt for a reduced height installation, but with more work aisles –which involves installing mo-re machines–or opt for a warehouse with more height and less aisles, and therefore less machines.

Basiccomponents of a clad-rack warehouseThe constructive system is very simple: the structure is composed by the racks them-selves on which the upper trusses, roof girders and the side profiles are placed, which are used for attaching the panels that make up the walls and roofing.

When the handling equipment are au-tomatic stacker cranes, the upper guides are attached to the trusses, so that the

At the height of 12 m the inflection point between the costs of constructing a traditional warehouse and a clad-rack warehouse is usually found

1.Frame2.Beam3. Footplates and anchorbolts4. Roof trusses5.Guiderails6.Roofjoist7.Walljoist8. Roof9.Claddedwalls

the structure be respected (wind actions, roof overloads, seismic action, etc.), but also the specific regulations for the metal racking.

On a European level, the following regula-tions are in force for all metal structures:

• EN1990 / Basis of structural design.

• EN 1991 / Eurocode 1: Actions on structures.

• EN1993/Eurocode3: Design of steel structures

• EN1998/Eurocode8: Design of struc-tures for earthquake resistance.

Logically, in each territory there are different climatic actions that involve deviations from the general rule. Moreover, certain coun-tries require different calculation conditions (for example: more stringent security co-efficients than those specified in European regulations).

In regard to the European regulations spe-cific to metal racking, the following are underscored:

• EN15512 / Steel static storage systems. Adjustable pallet racking systems. Principles for structural design.

racks must also bear the forces that they transmit.

How a warehouse clad-rack iscalculatedApart from having to bear loads generated by the goods stored and the forces from the handling machines, clad-rack warehouses must also be designed to withstand the ac-tions of a building, for example, the action of the wind, overburdened roofing (main-tenance, snow, etc.), the weight itself and of the wall cladding – both covering and the facades – besides considering the seismic coefficient that corresponds to the zone where it is installed.

As with any civil engineering structure, the clad-rack warehouse forms part of the building structure. However, this involves very specific constructions, because in addition to the peculiarities of a building used, the specifications of the racks must be taken into account.

Thus, when calculating and designing the structure of a clad-rack warehouse, not only must each country’s rules of cons-truction and the actions that can affect


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• EN15620 / Steel static storage systems. Adjustable pallet racking. Tolerances, de-formations and clearances.

• EN15635 / Steel static storage systems. Application and maintenance of storage equipment.

The structure of a clad-rack warehouse is composed of thousands of junctions and rods, so you need powerful calculation programs to model and calculate this type of installation in three dimensions. 3D mo-delling is indispensable if we want to pre-dict the torsional effects that a simplified analysis in two dimensions cannot reveal.

Calculation programs allow.

• Toconsidertheactionsonthestructure.For example, the stored load is modelled as a load evenly distributed on the beams. It also takes into account the action of the wind, roof overloads...

• Toobtaintheforcesthattheracksbear:bending, shearing and axil moments on each rod and each junction.

• Toobtainthedeformationsanddisplace-ments of all the structure’s components.

• Checkthesuitabilityofthesectionsorprofiles hypothesised in the calculation, applying the verification formulas outlined in the EN 1993 and 15512 regulations.

EIn very tall facilities (25 m and upwards), it is not enough to ensure that the profi-les are sufficiently resistant to the forces which they must absorb, but warehouse displacement within the range specified

by regulation EN 15620 must also be subs-tantiated in two dimensions.

It is important to point out that the cal-culation of a clad-rack warehouse is an iterative process. Which means that the person calculating uses some profiles and, subsequently, checks and verifies their appropriateness. This process is repeated until getting the most finely-honed solu-tion possible, that meets all safety requi-

rements and that delivers maximum profi-tability. The iterative process will be longer or shorter depending on the experience of the person calculating.

CivilworksandassemblyThebasiccivilworkisminimal: only the slab on which the structure sits and the pi-pes for the drains are required. Likewise, depending on its use, a water-proof pe-rimeter wall and an additional operations

Modellingforthecalculationofacrosssectionofthestructurein2D

Modellingforthecalculationofthestructurein3D


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The slab must have suitable strength and thickness for bearing the weight of the structure plus the goods stored, as well as to withstand the forces produced by external factors

slabs are built – one on top of the other – and you install insulation between them. At the same time, the bottom slab incor-porates a ventilation system, or a circuit of pipes, to prevent the foundation from freezing.

Another determining factor is height. When more height is required than is allowed by applicable regulations, there is the possibility of building part of the warehouse in a trench. In these cases, provisions for a hatch or door must be made for maintenance workers and the installation of access ladders, drains and over-flow water pumps.

On other occasions, height will be de-termined by factors such as the wind or the seismicity that affects the zone. The repercussions of this factor will be grea-ter the higher the warehouse, the vertical bracing has to transmit forces produced in the structure along to the concrete slab that makes up the floor.

area of appropriate height can be erected, as has already been mentioned.

In the process of the structure’s assembly, the first job that is performed on site is the verification of the correct levelling of the slab, after which part of the anchor plates are placed in their final position (before putting up the structure). Once you have verified the correct levelling of the racks, you can fill the space between the plate and the ground with a non-shrink concrete.

The next step is to assemble the structure. You can install any type of pallet storage system, both single and double-depth, with live racks, with or without Pallet Shuttle and

in combination with stacker cranes or trans-fer cars. It is also possible to install clad-rack warehouses for boxes, particularly suited in combination with the miniload automated system (stacker cranes for boxes).

The assembly usually starts at the head of the warehouse and, after putting up the first racks and part of the cladding (the coverings and facades), the handling ma-chines are introduced. Then, the structure is finished being assembled and the rest of the cladding is placed. The requirements of clad-rack warehouse can vary depending on several factors. For example, when used as cold storage, two


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Integration of the warehouseIn general, warehouses are built next to other production processes. When the constructive system is self-supporting, even more so if the handling machines are automatic, the height is usually much higher than the rest of the buildings and the site it is located at has been well analysed. It is essential to install the warehouse in a strategic zone, to simplify the flows bet-ween the different areas that have been connected as much as is possible. This will be easier when it is a part of a totally new plant, and according to the experience and know-how of the designer.

Although the majority of the warehouses are joined to the production buildings, the-re are situations in which the warehouse will be more distant: for logistical needs, or future expansion, or to not eliminate in-ner lanes. To connect the warehouse with

other buildings, you may resort to any of these options:

1. Have shuttle trucks that connect the pro-duction centres with the warehouse. The logical thing to do in this case is that the vehicles and the warehouse are ready to perform unloading automatically.

2. Build an underground tunnel to connect the two areas via conveyors.

3. Build an overpass on a raised structure.

ConclusionThe possibility of configuring the ware-house with different types of storage sys-tems for pallets and for boxes, both ma-nual and automatic, allows you to respond to all types of loading units, operations and necessities.

In any case, only companies Mecalux’s experience and service quality can under-take this type of construction and offer

the best solution based on the demands, the intended utility, the location and the height of the construction while acting as the sole interlocutor throughout the pro-cess. Furthermore, Mecalux is committed to the development of the engineering of projects with its own team of technicians, whether it be in the mechanical, electri-cal, electronics or software specialist. This helps to ensure the fulfilment of all the technical and legal rules applicable to the installations.

Clad-rack warehouses implemented by Mecalux have demonstrated their effec-tiveness in diverse sectors such as food, automotive, pharmaceutical, spare parts, petroleum, ceramics, metallurgy, chemical and cosmetics products, plastic products, logistics operators, etc. This solution is also recommended for cold or frozen storage, in particular when combined with automa-ted handling systems. Thus, transforming know-how and cold-storage into profita-bility u

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Our experts I Structural Calculation

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The European EN 15512 norm, according to its definition, specifies the requirements for structural design applicable to con-ventional pallet racking (selective racks) manufactured from steel components, designed to store palletised unit loads and subject to essentially stationary loads. It has become the main benchmark on this matter, and provides additional technical information required for the implementa-tion of the Eurocodes.

In addition, designers must also provide for the EN 15620, EN 15629 and EN 15635 standards as guides for the specifications of the storage system, the required tole-rances during assembly and the safe ope-ration of the installation.

Likewise, conventional racks for palleti-sed loads are metal structures, generally formed by components made out of thin, cold-formed, steel sheet metal. They are able to withstand heavy loads, while the

installation is designed to be as lightweight as possible; consequently the rack’s own weight rarely exceeds 5% of the load sto-red in the facility’s interior.

On the other hand, it is imperative that this type of installations for palletised loads be versatile, to be able to adapt to different load types. For this reason, the connec-tions between the main parts of the struc-ture must be adjustable, and quick and easy to assemble.

The uprights of these structures usually have perforations along the entire profile, while the beams include connectors pro-vided with hooks that fit into the perfora-tions of these uprights.

Basic structural components • Frames: are vertical pieces composed of two uprights joined together by beams and cross-ties forming a lattice.

• Uprights: these tend to be cold-profi-led components of thin sheet metal, with open sections and are always perforated, which makes them prone to distortion and torsional type sagging.

• Beams: are horizontal pieces that bear the burden of the pallets. These tend to be cold-profiled and have connectors on their ends for attaching them to frame uprights.

• Connectors: are parts welded onto the ends of beams to attach them to the uprights. They are equipped with ho-oks that fit into the perforations of the uprights.

How to calculate the structure of a conventional pallet rack What forces must be pondered when designing metal pallet racks? How do we verify that the structure will be suitable to withstand all loads? These and other issues are those which should be taken into account in the design of this type of rack, with the goal of ensuring its stability and resistance, and therefore the overall security of the installations.

Close up of the joining of an upright

and a beam

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It includes two types of analysis: - Down-aisle analysis: analysis in 2D on a

vertical layout parallel to the load aisles. This analysis also includes the semi-rigid connections of the upright-beam and upright-floor, obtained by testing.

- Cross-aisle analysis: analysis in 2D on a vertical layout perpendicular to the load aisles. Usually involves the articulated upright-floor joint.

In both cases, the global imperfection can be modelled as:- The tilt of the agreed uprights to the

imperfection.- Horizontal forces at the height of

the load levels corresponding to the imperfection.

Type of analysis according to the classification of the structureThis classification is based on the relations-hip of the expected load design in regards to the critical load of the structure. Accor-ding to the coefficient obtained by this re-

Calculation types: general and individualThe calculation is carried out in two stages:

1. General analysis of the structureNormally filiform, two-dimensional (2D) models with second order calculations applying the finite element method are used. In some types of installations, calcu-lations are also frequently done via 3D mo-dels in accordance with the EN 1993-1-1.

This analysis must incorporate the mode-lling of the actual behaviour of the con-nection between the upright-beams and the frame-ground.

2. Individual verification of pieces Once the overall analysis is performed, it is vital to check the correctness of the design by verifying the buckling and the tensions of the pieces that make up the racking.

Basically, the following items are verified:- General stability of the installation. - Stress state of frames: uprights and

diagonals.- Base plates: pressure on the slab and

anchorage.- Beams: buckling and stress state.- Connectors.

General analysis: structural model For general analysis, it is usual to consider two, two-dimensional (2D) structures in concurrent vertical and perpendicular la-youts with respect to the storage aisles.

In the model calculation, the following re-quirements are observed:

General analysis• Filiformmodel.• SystemlinesthroughtheCG(centreofgravity) of the gross section, or also through the CG of the actual cross section.

• Termsofsectioncorrespondingtothegross section of the pieces (or also of the actual cross section).

In this analysis the aim is to obtain:- The internal forces on the different pie-

ces for their subsequent verification, combining the down-aisle and cross-aisle calculations.

- Checking the overall stability of the installation.

Example of down‐aisle analysis

Example of cross‐aisle analysis

Overall analysis of a 2D structure

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lationship, the need to perform a second order calculation will be determined.

Individual analysis: verifying elementsIn the verification of the different elements that make up the structure the following concepts, among others, must be taken into account:

Uprights - Frames - Anchorage plates- Upright mainly function by compression

and flexion.- The use of the reduction factor for buc-

kling, obtained by laboratory testing or by using theoretical formulas.

- The internal forces obtained from the down-aisle and cross-aisle calculations will be jointly perpended.

- Axil force on the diagonals of the frame.

- Axil force and momentum on uprights’ footplates.

- Axil and shear force on fastening ancho-rage to the slab.

Beams - Connectors- Working primarily with bending and

shearing forces. - Buckling (deflection) is limited to a maxi-

mum of L/200. Occasionally, for certain installations smaller value deflections are required.

- Consideration of the cross-aisle forces of location.

- Verifying the shear force and deflection in the endplate.

Blocks of bracing - Vertical and hori-zontal bracing - Spacers- The brace diagonals work exclusively on

axil force. - Verification of the deflection and shear

forces on the elements that connect the diagonals of the vertical bracing to the frames (bracing spacers).

- The actions of the bracing increases the forces on the uprights and beams that form part of the block of bracing or that are adjacent to it.

- The eccentricity of the actions of the vertical bracing in respect to the racks

So that the conventional pallet racking function safely, it is fundamental to know the structure you are working with, the preventive actions that exist and the safety measures to keep in mind.

requires a study of the torsion beha-viour of the elements that form part of the block of bracing, as well as the racks.

Actions There are different types of actions that may affect the strength and stability of the racks, so that it is also imperative to contemplate them when setting up an installation of this kind. The actions on the racking are classified into several groups:

Permanent actions- Weight of the racks.- Permanent loads and various equip-

ment supported by the racking.

Variables actions- Weight of the pallets.- Weight and actions due to mobile loads

on platforms and walkways.- Actions due to the location of the pa-

llets (vertical + horizontal).- Actions on the positioning profiles.- Actions due to storage equipment

guides.- Actions due to the imperfection in the

elements and assembly.- Other actions arising from national re-

gulations (wind, snow, etc.).- The weight of the pallets together with

the general imperfection deemed as a

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structure’s parts subject to the correspon-ding unweighted actions (nominal loads) is studied:

• Verifying the overall stability of the struc-ture.• Verifying beam deflection

Ultimate Limit State (ULS)In each of the load cases the tensional state of components subjected to the co-rresponding weighted actions (affected by factors of security) is studied. In the verification formulas of the elements the combination of forces (down-aisle + cross-aisle) must be considered.

It is also necessary to ponder the uncer-tainty as to the different actions that can affect the racking (described previously). To do this, there are established security coefficients considered, for both the load coefficient and the material, and which can range between 1.0 and 1.5.

Some countries have specific national le-gislation which obliges you to use greater weighting coefficients in the facilities that are built on its territory (A deviations). EccentricitiesWhen the design and/or handling of the storage system allows the pallets to syste-

Variable actions like weight and actions due to moving loads on platforms and walkways.

Vertical and horizontal actions due to the placement of pallets.

considering the following actions or load cases:

• Permanent actions + the most unfavour-able variable action.• Permanent actions + 0.9 x (the totality of variable actions).• Permanent actions + variables + inciden-tals.

State Service Limit (SSL)In each of the load cases the buckling of the

single action, which in turn is the most relevant (unfavourable).

Accidental actions- Forklift blows.- Actions on security profiles.- Seismic actions.

Load states and the combination of actionsIt is viewed as appropriate and sufficient to study the two load states listed below,

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matically become off-centred, the increa-sed load that causes this off-centring on beams and braces must also be taken into account in the design of the structure.

Likewise, the eccentricities of the lines of the structural system must be observed, in the event that they are deemed excessive.

Eccentricities in the positioning of the pallets- Asymmetric position of the pallets in re-

gard to the beams.- Load is not evenly distributed on the

pallet.- Load overflow in regards to the pallet.

Eccentricities of the diagonals of the vertical bracing Although the diagonals of the vertical bra-cing are not physically connected to the racks on the junctions that form the neu-tral lines of the uprights and the beams, in the 2D calculations the diagonals can be viewed as attached to these junctions, provided that the eccentricities of the same are kept below certain values depending on the width of the brace and the edge of the beams. The same happens with the diago-nals of the frames.

Conclusion: the safety of the installation and responsibilitiesLastly, we want to point out that in a large part of the incidents that occur in palle-tised installations, human error interferes and are primarily caused by scraping or impacts of forklifts against the racking. On the other hand, these impacts may represent higher than normal actions on the racks, than those established in the EN 15512 norm.

Thus, not only is it imperative for the ma-nufacturer to carry out a good structural analysis and design of the installation, but it is also makes good use of the sa-me, so that actions against the racking does not exceed those considered in the installation’s structural calculation. This is all the fruit of many years of experience, and studies and trials by FEM (Federation of European Maintenance) and other agencies.

It is essential to keep in mind:

En 15620. - Steel static storage systems. Tolerances, deformations and clearances.

- Flatness of the slab and its buckling un-der load.

- Clearance between pallets, and between the pallet and racks.

- Clearance between racks and civil works.

- Aisle width according to the load unit, the forklift type and the number of pallet locations per hour.

En 15629. - Steel static storage systems. Specification of storage equipment.Individual responsibilities of the different system suppliers that make up the storage equipment.

En 15635. - Steel static storage systems. Application and maintenance of storage equipment.- Designation of a person responsible for

the security of the storage equipment.- Safe load sign. - Education and training of the warehouse

staff.- Damage to the racks and assessment of

the level of damage.- Regular inspections. u

Currently, all the mentioned analysis throughout this article are done via computerised calculation programmes. Mecalux has applied their extensive experience in design, manufacture and installation of warehouse systems to the development of a powerful design software, capable of finding the best option for each warehouse layout, the dimensions of the storage structures and the most ideal profiles. In this way, optimization of capacity and cost of the warehouse is procured, with the utmost safety.

The asymmetrical position of the pallets in respect to the beams.

Software for the structural calculation of racks

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