08.03.2016 Views

Best Practices Magazine - issue nº1 - English

You also want an ePaper? Increase the reach of your titles

YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.

1r Quarter - Year 2016 - No. 1<br />

Cases Studies<br />

Benco Dental / DAFSA / DHL / Gioseppo / Havi Logistics<br />

Hayat Kimya / Hemosa / Hepco Motion / Iron Mountain / Luis Simões<br />

MGA / Nufri / PAVI-Groupauto / Takeda / Ypê / Zbyszko


95<br />

111<br />

79<br />

135<br />

Index<br />

13 HAYAT KIMYA<br />

One of the tallest warehouses in Europe<br />

in an earthquake prone zone in Turkey.<br />

29 GIOSEPPO<br />

Automated clad‐rack warehouse with a<br />

capacity of two million pairs of shoes.<br />

41 YPÊ<br />

High‐rise warehouse with massive<br />

picking area for the Brazilian company<br />

Ypê.<br />

49 TAKEDA<br />

Almacén automático llave en mano<br />

para el gigante farmacéutico japonés<br />

Takeda.<br />

59 NUFRI<br />

Racks on Movirack mobile bases for<br />

their headquarters in Catalonia.<br />

63 MGA<br />

Efficient automated miniload<br />

warehouse with conventional racks.<br />

71 LUIS SIMÕES<br />

The operator equips their installations<br />

with a Pallet Shuttle system combined<br />

with conventional racks.<br />

79 DHL<br />

New logistics centre for DHL on the<br />

outskirts of Madrid.<br />

87 PAVI-GROUPAUTO<br />

Conveyors on several floors the axis of a<br />

picking installation.<br />

95 HEMOSA<br />

Mecalux equips the processing plant for<br />

Hemosa located in Madrid.<br />

103 ZbYSZKO<br />

The Polish manufacturer Zbyszko<br />

Company entrusts Mecalux with the<br />

connection of theproduction area with<br />

a new automated warehouse.<br />

111 DAFSA<br />

A singular warehouse in choice<br />

surroundings.<br />

127 HAVI LOGISTICS<br />

The logistics services business relies on<br />

mobile bases to keep growing.<br />

131 HEPCO MOTION<br />

A special mobile racks with cantilevers<br />

solution installed in the United<br />

Kingdom.<br />

135 IRON MONTAIN<br />

Earthquake‐proof racks in the Belt of<br />

Fire in the Pacific.<br />

139 bENCO DENTAL<br />

Interlake Mecalux speeds up the picking<br />

at Benco Dental.<br />

146 OUR ExPERTS<br />

- Logistics software, the cloud is the<br />

future.<br />

- Clad‐rack warehouses: when the racks<br />

also support the building.<br />

- How to calculate the structure of<br />

conventional pallet racking.<br />

<strong>Best</strong> <strong>Practices</strong><br />

3


News I Mecalux<br />

Mecalux Shop:<br />

a new look, new<br />

clickable content<br />

Keeping with its commitment to innovation<br />

and new technologies, Mecalux has completely<br />

updated its e-commerce portal for<br />

Spain, offering a new design, new content<br />

and a better user experience.<br />

The new Mecalux Shop specialises in the direct<br />

sale of metal shelving and related products<br />

to warehouses, workshops, offices,<br />

archives, change rooms, etc., building on<br />

the extensive knowledge and experience of<br />

Mecalux within the sector.<br />

Among the newly integrated<br />

enhancements<br />

are the following:<br />

• New categories and<br />

advanced search filters which allow<br />

you to easily find any product.<br />

• More information on each product:<br />

description of main product features,<br />

with more detailed technical information<br />

and more pictures.<br />

• Making a purchase is streamlined and<br />

speedy with a user friendly design.<br />

• Optimised design for smartphones and<br />

tablets.<br />

• More advantages for registered users:<br />

custom offers, easy personal data admin,<br />

order tracking, purchase history access,<br />

etc.<br />

Another of the key points of Mecalux Shop<br />

is its Customer Service, with professionals<br />

who know the product and its applica-<br />

tions and that, if necessary, can help the<br />

user to choose between different storage<br />

solutions.<br />

With this rejuvenation and the inclusion of<br />

better features and navigability, Mecalux<br />

has updated its online sales gateway<br />

witn the steady flow of technological<br />

breakthroughs in the field of e-commerce<br />

and in the shifts in user enthusiasm. The<br />

end user will benefit from the esase of use.<br />

Safe and sound: Mecalux introduces<br />

an innovative safety locking mechanism<br />

Safety in the warehouse is the foundation<br />

on which to develop an installation’s day-today<br />

work operations in an efficient and riskfree<br />

way. Therefore, Mecalux invests a significant<br />

part of its R&D resources to improve<br />

the security devices of all its products.<br />

The latest innovation in this respect is the<br />

incorporation of a new junction system<br />

between uprights and beams in Mecalux<br />

pallet racks. This involves a connector with<br />

a locking system, developed to provide<br />

greater safety on the whole.<br />

Its most outstanding contribution is the integration<br />

of a safety locking mechanism in<br />

the actual connector, which results in two<br />

key advantages: on the one hand, it is impossible<br />

for the safety device not to work<br />

or to lose it accidentally; while on the other<br />

hand, once it is assembled it is not possible<br />

to remove it without the disassembly of the<br />

entire beam. This prevents accidental or<br />

deliberate manipulation of the connector –<br />

with a blow by a forklift, for example – thus<br />

avoiding the beam displacement and its<br />

possible consequences, such as the collapse<br />

of the load.<br />

After successfully introducing this new<br />

locking system into installations set up in<br />

the United States, where Mecalux is a leader<br />

in the pallet racking market, it is now<br />

integrating it into all their projects within<br />

Europe.<br />

They are the only manufacturer on the<br />

European continent to develop and incorporate<br />

this breakthrough device into their<br />

storage solutions.<br />

4 <strong>Best</strong> <strong>Practices</strong>


News I Mecalux<br />

Maxi-innovation for Mecalux’s<br />

semi-automated compact storage<br />

As one of the leading companies in storage<br />

solutions for more than 50 years, Mecalux<br />

invests significant resources in the development<br />

of new products and the continuous<br />

improvement of those which are already<br />

part of their catalogue. It always aims to incorporate<br />

the latest in technological innovations<br />

to deliver better profitability.<br />

So, one of the solutions that has experienced<br />

the greatest amount of development<br />

is the semi-automated Pallet Shuttle. This<br />

compact system uses an electric shuttle<br />

instead of forklifts to handle pallets inside<br />

the storage channels (that can reach 40 m<br />

in depth), considerably reducing manoeuvring<br />

times and helping to streamline storage<br />

processes for all kinds of companies.<br />

Among the new add-on innovations what<br />

stands out is the adoption of Wi-Fi techno-<br />

logy, which multiplies<br />

the system<br />

benefits: the forklift<br />

operator communicates<br />

the storage and<br />

removal orders to the shuttle<br />

using a control tablet with Wi-Fi<br />

connection, with an intuitive, user<br />

friendly interface.<br />

Different key features:<br />

• Input and removal of pallets: continuous<br />

or partial.<br />

• Inventory functionality.<br />

• High speed: 90 m/min without load and<br />

lifting time of 2 s.<br />

• Lithium batteries that provide up to<br />

10 h of autonomous use, with a quick<br />

connect battery compartment that eliminates<br />

the need for cables.<br />

• Pallet type selector (the shuttle supports<br />

various sizes).<br />

• LIFO/FIFO setup to select the load management<br />

strategy.<br />

• Position camera that facilitates the operator<br />

in centralising the pallet on the rails<br />

(optional).<br />

• Security scanner: controls access to<br />

the rails while the shuttle is operating<br />

(optional).<br />

• Additional lock system that increases<br />

the clamping of the electric shuttle to the<br />

forklift blades.<br />

• Compatibility with Mecalux Easy WMS<br />

software, or other generic WMS used by<br />

the customer.<br />

• The lifting platform can receive pallets<br />

with buckling of up to 25 mm.<br />

• Tiltmeter: detects the incorrect position<br />

of the shuttle within the channel<br />

• Rescue: recovers the damaged shuttle<br />

from within the channel<br />

The result is a new generation of Pallet<br />

Shuttle, which capitalises new technologies<br />

to enhance the warehouse performance<br />

and its profitability. It is an ideal solution<br />

for companies with a large volume of pallets<br />

per SKU and high loading and unloading<br />

activity.<br />

<strong>Best</strong> <strong>Practices</strong><br />

5


News I Mecalux<br />

Success, innovation & automation: the Mecalux UPC classroom<br />

offers new courses in breakthrough logistics systems in 2016<br />

The three university courses delivered in<br />

2015, within the framework of the Mecalux<br />

UPC classroom, were created through<br />

the collaborative agreement between the<br />

UPC (Universitat Politècnica de Catalunya),<br />

the ETSEIB (Escola Tècnica Superior<br />

d’Enginyeria Industrial) of Barcelona and<br />

Mecalux, all being extremely reputable<br />

parties.<br />

Due to success, this new training modules<br />

will be taught throughout 2016, which will<br />

give new students the opportunity to deepen<br />

their understanding of subjects such<br />

as the development of structures, robotics<br />

and the automation of storage facilities.<br />

The objective of the UPC Mecalux Aula is<br />

to train up tomorrow’s professionals and<br />

provide them with the tools necessary to<br />

make advances in R&D&I within the logistics<br />

industry. To this end, Mecalux offers<br />

scholarships covering course fees for UPC<br />

master’s students, which fulfil the entry<br />

requirements, in addition to putting the<br />

Mecalux technological centres at their disposal<br />

and offering them the possibility of<br />

starting their career in the company.<br />

New courses are scheduled to start in<br />

March of 2016, with 30 lecture hours, at the<br />

Mecalux UPC classroom premises.<br />

Mecalux and the UPC<br />

As a company that bases its leadership on<br />

technological innovation, Mecalux has<br />

for years been committed to fostering this<br />

company-University relationship, collaborating<br />

with the UPC and in particular<br />

with the ETSEIB, since 1979. All this through<br />

the Department of Material Resistance<br />

(LERMA), with which it has developed an<br />

Experimental Analysis of Characterisations<br />

program and another of Research and<br />

Development.<br />

Along these lines, the two entities have<br />

promoted the creation the Mecalux UPC<br />

Aula, as a means of consolidating longterm<br />

collaboration in R&D&I activities and<br />

the transfer of research results and scientific<br />

dissemination within integral logistics<br />

related topics.<br />

For more information and to register<br />

contact:<br />

http://aulamecalux.upc.edu/<br />

E-mail: aula.mecalux@upc.edu<br />

Mecalux Easy Warehouse Management Software: a blockbuster in Mexico<br />

Mecalux has had a significant presence in<br />

Mexico for many years, with 8 sales offices.<br />

Being local, together with the experience<br />

of its team of professionals, has led numerous<br />

Mexican companies to rely on the Easy<br />

WMS Mecalux software, as a means to manage<br />

and capitalise their storage processes.<br />

Among the rollout Easy WMS projects signed<br />

in Mexico in the past few months, the<br />

following stand out:<br />

• Grupo Acuícola Mexicano (GB-<br />

PO). With Easy WMS they can automate<br />

the management of one of<br />

its freezing chambers, controlling<br />

the entries from the production line,<br />

and correct load management<br />

using FIFO and expeditions.<br />

• Distribución Hugo’ss. Within<br />

its improved processes, they have<br />

chosen the Easy WMS, which<br />

communicates with their SAP<br />

ERP, to speed up and streamline<br />

their picking processes, eliminating<br />

customer service errors.<br />

• Polioles. ELeader in the petrochemical<br />

industry. Its main objectives are the reduction<br />

of costs and storage errors, to control<br />

warehouse operations, product traceability<br />

and cross-docking management.<br />

• Diseños Labor. With Easy WMS they<br />

can reconfigure their warehouse layout,<br />

the improved inventory visibility, handles<br />

information real time via bar codes and<br />

radio frequency controls and, in general,<br />

automate warehouse processes.<br />

• Grupo Comrap. They use Easy WMS in<br />

two warehouses, designed and built by<br />

Mecalux, in Mexico DF to manage large<br />

scale picking and fulfil their commitment to<br />

offer excellent service to their customers.<br />

Furthermore, two prestigious universities,<br />

the Autonomous University of<br />

Queretaro (UTEQ) and the Autonomous<br />

University of the State of<br />

Mexico (UAEM) have acquired the<br />

field license for Easy WMS Basic for<br />

academic use in the Logistics degree<br />

professorship.<br />

Visit the Mecalux Mexico<br />

stand in the upcoming industry<br />

fairs at:<br />

Logistic Summit & Expo, México DF,<br />

on April 6 th and 7 th , 2016.<br />

Expopack, México DF, from May<br />

17 th to 20 th , 2016.<br />

6 <strong>Best</strong> <strong>Practices</strong>


News I Our customers<br />

Logistics chain<br />

innovation in Argentina<br />

and Peru: clad-rack<br />

warehouses with Pallet<br />

Shuttle to be built<br />

In recent months, the markets of Argentina<br />

and Peru have opted for the compact<br />

storage system Pallet Shuttle by Mecalux.<br />

This solution incorporates numerous innovations<br />

to streamline the processes of the<br />

entry and exit of goods in the warehouse. It<br />

also provides great storage capacity, thanks<br />

to an electric shuttle that loads and unloads<br />

pallets in the interior of the racks, moving<br />

autonomously along rails.<br />

Among the projects recently carried out in<br />

these countries, two constructions, in particular,<br />

stand out that have combined the benefits<br />

of clad-rack warehouses with those<br />

containing Pallet Shuttle racks.<br />

In Argentina, Granja Tres Arroyos, one of<br />

the major producers and exporters of frozen<br />

chicken, has chosen this solution when<br />

building their new frozen cold-storage. The<br />

combination of a clad-rack warehouse with<br />

the Pallet Shuttle system is particularly recommended<br />

in cold-storage, although, the<br />

building is not of great height. In addition<br />

to lowering manoeuvring times, it offers a<br />

high storage capacity that reduces the volumetric<br />

area to be kept cool, resulting in<br />

energy cost savings.<br />

On the other hand, the Mecalux Peru team<br />

has completed the construction of another<br />

clad-rack warehouse with Pallet Shuttle for<br />

Medifarma, one of the top 5 pharmaceutical<br />

laboratories in Peru. In this project, given<br />

the diversity of the products marketed,<br />

the versatility of the system proved essential,<br />

while also increasing the number of cycles<br />

per hour compared to a conventional<br />

system.<br />

In both cases, it is worth noting that<br />

although these clad-rack warehouses are<br />

not very tall, they have also been the most<br />

profitable option for both companies. This<br />

is because the storage channels were constructed<br />

to the depth which was strictly ne-<br />

Close up of the Granja Tres Arroyos warehouse in Argentina<br />

cessary, calculated according to their required<br />

functionality.<br />

The goal is to put new technologies and<br />

approaches within reach all kinds of companies,<br />

to multiply the productivity and profitability<br />

of storage installations, achieving<br />

maximum performance within the logistics<br />

chain.<br />

Mecalux, in their effort to provide up close<br />

and personal service to its customers, are<br />

present in Argentina with two sales offices<br />

in Buenos Aires and a 21,000 m 2 production<br />

centre, while there is also a delegation in<br />

Lima, Peru. Overall, the strength of the customer<br />

support is second to none.<br />

Close up of the Mediafarma warehouse<br />

<strong>Best</strong> <strong>Practices</strong><br />

7


News I Our customers<br />

Mecalux will build<br />

Çaykur a clad-rack<br />

warehouse with<br />

a capacity for more<br />

than 29,000 pallets<br />

Çaykur’s, the biggest producer of<br />

Turkish tea, new clad-rack warehouse<br />

in Iyidere (Turkey) will be more than<br />

40 m high and almost 160 m long.<br />

Mecalux will provide a large, single aisle,<br />

automated warehouse served by three<br />

single-column stacker cranes and aided<br />

by Pallet Shuttle that are responsible for<br />

transporting 800 x 1200 x 2600 mm sized<br />

pallets with a maximum weight of 600 kg<br />

each.<br />

In order to optimize accessibility to locations,<br />

Mecalux has developed a control<br />

system and safe passageways that allow<br />

the stacker cranes to enter the annex<br />

zones. This is all controlled by the warehouse<br />

management system Easy WMS and<br />

the Galileo control software.<br />

In addition, input of goods will be done<br />

at the side the warehouse via three raised<br />

overpasses that connect the warehouse<br />

with the docking area. The elevated overpasses<br />

allow for workspace savings so<br />

that the ground floor remains completely<br />

available.<br />

Çaykur, which opened its first tea factory<br />

in 1947, produces 133,000 tons of tea annually<br />

in 46 different factories, making it<br />

the largest tea producer in Turkey and one<br />

of the most important worldwide. This<br />

massive solution could only be properly set<br />

up using Mecalux’s extensive know-how.<br />

All in the family: Mecalux expands<br />

the Familia Group warehouse in Colombia<br />

Familia Group, a company specialising in<br />

personal care and hygiene products, will<br />

expand its current clad-rack warehouse<br />

to reach a capacity of more than 16,000<br />

pallets.<br />

In 2011, Mecalux erected Family Group one<br />

of the first automated warehouses within Colombia.<br />

The installation, with a capacity for<br />

7,416 pallets and 31.2 m high, is managed by<br />

three stacker cranes.<br />

A few years later, the company has again chosen<br />

Mecalux to execute the Cájica warehouse<br />

expansion. The objective: to reach 34.4 m in<br />

height, increase capacity to include another<br />

9,480 pallets, and install an additional three<br />

stacker cranes. Moreover, recirculation is set<br />

up that allows both the management of inputs<br />

from outside sources and internal production,<br />

and also direct dispatch from the warehouse.<br />

The warehouse management system, Easy<br />

WMS software, implemented by Mecalux will<br />

also be supplied.<br />

With this expansion, the Family Group warehouse<br />

will achieve greater inputs and outputs,<br />

bringing it to the forefront of logistics within<br />

the t<strong>issue</strong> and the personal hygiene sector.<br />

8<br />

<strong>Best</strong> <strong>Practices</strong>


News I Our customers<br />

Bem Brasil is keeping cool with clad-rack:<br />

Mecalux sets up automated storage in Brazil<br />

United Caps seals<br />

the deal: Mecalux<br />

to automate new<br />

warehouse<br />

This company, specialised in the manufacture<br />

and marketing of caps and closures,<br />

will incorporate an automated<br />

and asymmetrical, four tiered warehouse<br />

into its Wiltz (Luxembourg)<br />

plant.<br />

The warehouse, with a capacity for more<br />

than 5,000 pallets, will be managed by two<br />

stacker cranes and a Pallet Shuttle that will<br />

work with two types of pallets: 800 x 1,200<br />

x 2,200 mm and 800 x 1,200 x 2,700 mm.<br />

The warehouse management system,<br />

Easy WMS, will also be supplied, tasked<br />

with managing all the centre’s own operations.<br />

For the first time in its history,<br />

Easy WMS will be permanently connected<br />

to Axapta (Microsoft Dynamics AX), the<br />

ERP system that the client uses.<br />

United Caps is a leader in the design and production<br />

of plastic caps and closures. With<br />

their headquarters in Luxembourg, this<br />

family business offers its innovative solutions<br />

throughout the world and has its<br />

own production plants in France, Belgium,<br />

Germany, Hungary, Ireland, Luxembourg<br />

and Spain. The company, which had an annual<br />

turnover of 122.000.000 € in 2015,<br />

employs more than 530 workers.<br />

The very popular Brazilian company,<br />

specialised in the production of precooked,<br />

frozen potato products, has<br />

entrusted Mecalux to design, install<br />

and launch a clad-rack automated<br />

warehouse. This warehouse has<br />

the capacity of storing more than<br />

33,000 pallets, 1,000 x 1,200 mm in<br />

size and each with a maximum weight<br />

of 1,120 kg.<br />

The warehouse, which is more than<br />

25 m high, has three twin-mast stacker<br />

cranes with Pallet Shuttle that allow for an<br />

input or output of 105 pallets/hour. Thus,<br />

the company’s required throughputs are<br />

attained. The stacker cranes, when working<br />

in deep lanes, are supported by a<br />

Pallet Shuttle that is responsible for moving<br />

the pallet up to the location designated<br />

by the Mecalux Easy WMS software.<br />

Additionally, in order to ensure the perfect<br />

condition of the goods, Bem Brasil’s<br />

clad-rack frozen storage is expected to<br />

work at a temperature of -30 ºC.<br />

Founded in 2006, Bem Brasil produces<br />

more than 100,000 tons of pre-cooked<br />

frozen fries a year. It has become the national<br />

leader within the sector, and one of<br />

the most consumed brands within Brazil.<br />

<strong>Best</strong> <strong>Practices</strong><br />

9


News I Our customers<br />

Agrarian giant Gregoire Besson announces new automated<br />

miniload warehouse in France by Mecalux<br />

The French company, dedicated to the<br />

technological agribusiness sector, will<br />

have an automated mainland warehouse<br />

for boxes – with a capacity of<br />

more than 10,000 boxes – built.<br />

The miniload warehouse is comprised of two<br />

double depth aisles where a stacker crane will<br />

circulate and be tasked with executing the input<br />

and output of 400 x 600 mm sized boxes,<br />

each weighing a maximum of 50 kg. In the<br />

header of the automated warehouse, three<br />

P&D stations are set up to prepare orders of<br />

smaller products. In addition, the installation<br />

will be equipped with six conventional pallet<br />

rack aisles with a capacity for 4,440 pallets<br />

and a cantilever rack for over-sized products.<br />

Thanks to the different storage solutions<br />

provided by Mecalux, Gregoire Besson<br />

will optimise space and, at the same time,<br />

streamline order preparation.<br />

Gregoire Besson, with almost 200 years’ experience,<br />

is a leading French company in the<br />

manufacture of agricultural machines and<br />

in the implementation of technological solutions<br />

designed to optimise land produced<br />

resources.<br />

With a large representation worldwide, their<br />

ploughing machines are innovative, efficient,<br />

robust and adaptable to the characteristics<br />

of any type of arable land.<br />

Home decor’s largest<br />

warehouse: Mecalux<br />

will equip Maisons<br />

du Monde with new<br />

installation<br />

The new conventional pallet rack warehouse,<br />

of the French company specialised<br />

in home decor, will be built within<br />

a 96,000 m² logistical centre located in<br />

Saint-Martin-de-Crau, a town in the<br />

south of France.<br />

Distrimag, the company responsible for distributing<br />

products to customers of Maisons<br />

du Monde, has once again commissioned<br />

Mecalux with supplying a warehouse for<br />

pallets. Since 2007, Mecalux has built them<br />

10 warehouses that are divided into 4 logistics<br />

centres (Saint Martin, Fos Distriport,<br />

Feuillanne and Boussard) and that allow<br />

the storage of a total of 304,000 pallets. In<br />

this way, Distrimag commands 477,600 m 2<br />

of storage in strategic locations in the south<br />

of France, extending its firm grip on the decoration<br />

market.<br />

Founded in 1990 by Xavier Marie, Maisons<br />

du Monde has 260 shops spread throughout<br />

France, Italy, Spain, Luxembourg, Switzerland,<br />

Germany and Belgium, and which employ<br />

more than 4,500 workers. The Group<br />

has more than 40,000 high-quality products,<br />

making it one of the leading companies<br />

in home decor in France.<br />

10<br />

<strong>Best</strong> <strong>Practices</strong>


News I Our customers<br />

Throughput conveyed and supersized: Quality Pascual and<br />

Mecalux collaborate on new conveyor system in Barcelona<br />

This renowned Spanish food and beverage<br />

company has entrusted Mecalux<br />

in the semi-automation of transport<br />

and delivery processes of Leche<br />

Pascual, one of its leading brands, in<br />

its packaging centre located in Gurb<br />

(Barcelona).<br />

After a thorough study, the technical team<br />

at Mecalux opted for the installation of two<br />

automatic conveyor circuits, one on each<br />

floor of the facility, and a lift which connects<br />

the two levels. Therefore, they get the streamlining<br />

of product throughput and the best<br />

use of available space on the warehouse’s<br />

first floor.<br />

The ground floor conveyor circuits will move<br />

pallets from the end of the production area<br />

to three possible destinations: the drive-in<br />

racks situated on the same floor, the dispatch<br />

area, or the storage-ready area on the<br />

first floor.<br />

On the other hand, the conveyor circuit designed<br />

for this upper floor will be reversible,<br />

so that it can be used for both inputs and<br />

outputs of pallets. The maximisation of this<br />

space will make it possible for the Catalan<br />

Pascual plant to dispense with external warehouses,<br />

with subsequent cost and time savings<br />

in the transport of goods between distant<br />

warehouses.<br />

In addition to the lift which connects the two<br />

levels of the warehouse, they complement<br />

the equipment with a pallet stacker and a pallet<br />

unstacker.<br />

All movements of the equipment will be<br />

monitored by the Mecalux Galileo control<br />

software, which is in communication<br />

with the warehouse management software<br />

currently used by the company in this<br />

installation.<br />

To sum up, the project that Mecalux will<br />

set up in the upcoming months in the Gurb<br />

packaging centre will provide Qualidad<br />

Pascual with greater agility and accuracy in<br />

product throughput and dispatches. This is<br />

all part of the group’s commitment to offering<br />

excellent quality service, and the continuous<br />

improvement of both its products<br />

and processes.<br />

Kronopol goes automated: Mecalux constructs custom<br />

warehouse for timber products<br />

The new automated warehouse, to be<br />

built in the Polish town of Zary can store<br />

more than 20,000 pallets, or 2.9 million<br />

square meters of finished product.<br />

Kronopol, one of the world’s leading producers<br />

in wooden material manufacturing,<br />

has commissioned Mecalux to construct<br />

its new automated warehouse for pallets,<br />

where the floor panels fabricated by the<br />

company will be deposited.<br />

The warehouse,<br />

composed of four aisles<br />

with double depth racks,<br />

measures 30.3 m high,<br />

32.9 m wide and 89.3 m<br />

long. In each aisle a stacker<br />

crane will circulate<br />

that is able to move 840 x<br />

1,410 x 1,200 mm pallets,<br />

with a maximum weight<br />

of 1,075 kg each.<br />

This installation, which<br />

is scheduled for completion<br />

in the third quarter<br />

of 2016, was the Kronopol organisation’s<br />

most substantial investment in 2015. Its<br />

construction, apart from increasing storage<br />

capacity by maximising available space, will<br />

give the company a series of advantages.<br />

Among these are complete automation,<br />

an increase in the loading and unloading<br />

speeds of vehicles, and the preclusion of<br />

damaged goods caused by forklift usage. In<br />

addition, the warehouse is also distinguished<br />

by being environmentally friendly because<br />

the solutions used will work via electricity,<br />

which will eliminate the emission of<br />

gases.<br />

The Polish company Kronopol, present in<br />

more than 50 countries, has been part of<br />

the Swiss Krono Group holding company<br />

since 1994. Throughout this process, the<br />

firm has become a worldwide leader in<br />

their sector, thanks to the quality and variety<br />

of their timber products earmarked for<br />

the manufacture of interior finishings and<br />

furniture.<br />

<strong>Best</strong> <strong>Practices</strong><br />

11


News I Our customers<br />

Design and efficiency go<br />

hand in hand: a new automated<br />

clad-rack warehouse designed<br />

by Mecalux for STUA<br />

Founded in 1983 by Jesus Gasca, STUA<br />

in one of the most internationally recognized<br />

Spanish contemporary furniture<br />

design companies. Recently, its operations<br />

moved to a new facility in Astigarraga<br />

(Guipúzcoa) in order to boost continuous<br />

growth.<br />

After assessing various options for the implementation<br />

of a storage system that best resolved<br />

their needs, STUA finally chose the<br />

project submitted by Mecalux, due to the<br />

confidence that being made in Spain and<br />

their extensive experience conveys.<br />

STUA’s objectives are to gain perfect control<br />

of both their products and deliveries to<br />

any part of the world, in addition to maximise<br />

storage capacity. To fulfil these requirements,<br />

Mecalux has planned out a solution<br />

consisting of an automated clad-rack warehouse<br />

annex to the production building that<br />

stands out for its slenderness, since it has had<br />

to adapt to some unusual measurements:<br />

80 m long, 25 m high and only 9 m wide.<br />

The automatic warehouse is made up of<br />

an aisle where a single-mast stacker crane<br />

circulates, which serves the double depth<br />

racks located on both sides. The racking has<br />

10 levels of different heights in order to locate<br />

various sized load units – some larger<br />

than usual – given the characteristics of the<br />

product. The inputs and outputs of the automated<br />

warehouse have been dealt with a<br />

circuit of conveyors.<br />

Last but not least, to manage all warehouse<br />

processes, Mecalux will implement its Easy<br />

WMS warehouse management software,<br />

which will allow the full control STUA stock<br />

and real-time inventory, while also optimising<br />

and coordinating product throughput,<br />

from its entry into the warehouse to its dispatch<br />

to the end customer.<br />

The new automated clad-rack warehouse will<br />

provide STUA with better efficiency and profitability<br />

in their logistics operations. This will,<br />

in turn, give them a competitive advantage in<br />

their job of innovating and promoting Spanish<br />

design, which was recognized in 2008 with<br />

the National Prize for Innovation and Design.<br />

12<br />

<strong>Best</strong> <strong>Practices</strong>


Case study: Hayat Kimya<br />

Tallest warehouse in Europe constructed:<br />

earthquake prone area in Turkey not an <strong>issue</strong><br />

for Mecalux and its partner Hayat Kimya<br />

Location: Turkey<br />

Hayat Kimya is the leading chemical company in the Turkish and Eurasian<br />

market in the manufacture of cleaning and hygiene products. They entrusted<br />

Mecalux in the construction of a spectacular 12,500 m 2 , 46 m tall automated<br />

logistics centre in the city of Izmit (Turkey).<br />

They were supplied with a plan that included<br />

the warehouse management system<br />

Mecalux Easy WMS, responsible for managing<br />

all the centre’s activities.<br />

The solution implemented for Hayat Kimya<br />

has become a global benchmark for automated<br />

clad-rack warehouses, showcasing<br />

Mecalux’s professional fortitude and skill.<br />

<strong>Best</strong> <strong>Practices</strong><br />

13


Case Study I Hayat Kimya<br />

Who is Hayat Kimya?<br />

Founded in 1937, Hayat Kimya is the leading<br />

chemical company in the Turkish, Asian<br />

and Middle Eastern market for cleaning<br />

and hygiene products.<br />

The company has twelve<br />

brands distributed<br />

in three sectors:<br />

household care, hygiene<br />

products and t<strong>issue</strong>s<br />

At present, Hayat Kimya is the seventh largest<br />

manufacturer in Europe in its sector,<br />

having more than 5,200 employees and<br />

reaching all its consumers through an<br />

export network which covers 101 countries.<br />

The needs of Hayat Kimya<br />

The huge growth experienced by Hayat<br />

had obliged them to distribute goods between<br />

several warehouses located near different<br />

production centres, which involved<br />

high logistical costs that could increase<br />

over the years.<br />

Faced with this situation and seeking to reduce<br />

production costs, Hayat Kimya decided<br />

to build a single warehouse with a<br />

minimum storage capacity of 150,000 pallets<br />

and in which to undertake picking<br />

functions.<br />

In addition, and in order to save on transport<br />

costs, they thought of putting it in<br />

a space available in their largest facility,<br />

equal distance from three of their most important<br />

plants and near a fourth high production<br />

site.<br />

In the two images on this page the warehouse’s<br />

location in relation to the factories<br />

and to the connecting overpasses can be<br />

seen:<br />

1. Logistics centre<br />

2. T<strong>issue</strong> factory 1<br />

3. T<strong>issue</strong> factory 2<br />

4. Hygiene factory 1<br />

5. Hygiene factory<br />

6. Detergent factory<br />

7. T<strong>issue</strong> input overpass 2<br />

8. T<strong>issue</strong> input overpass 1<br />

9. Hygiene input overpass<br />

14 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

The solution<br />

Taking into account the above premises<br />

and the data provided by Hayat Kimya,<br />

Mecalux worked from the outset in the design<br />

and construction of a warehouse with<br />

the following features:<br />

- Automated clad-rack warehouse<br />

with a capacity for 161,000 pallets.<br />

- Four raised overpasses above the lanes<br />

inside the installation that connect<br />

the factories and the main conveyor circuit.<br />

- A ground floor dedicated almost exclusively<br />

to dispatches, with the exception<br />

of two multipurpose docks and a dock<br />

fitted with an automated unloading system<br />

intended for the receipt of merchandise<br />

from other factories.<br />

- First floor used exclusively for offices<br />

and other services.<br />

- Second floor reserved entirely for picking.<br />

- On the third floor is where all inputs<br />

take place in the warehouse from the<br />

factories that are located in the complex,<br />

as well as the outputs intended for picking<br />

areas.<br />

- Wide manoeuvring area and loading/<br />

unloading of trucks, with 21 docks.<br />

3<br />

Map data ©2015 Google<br />

1<br />

5<br />

2<br />

4<br />

For the design of the whole package that makes up<br />

the logistics centre, operative details were meticulously<br />

taken care of, trying to achieve not only the goals<br />

in the initial specifications of required flows,<br />

but that were also the best<br />

6<br />

7<br />

9<br />

8<br />

<strong>Best</strong> <strong>Practices</strong><br />

15


Case Study I Hayat Kimya<br />

The warehouse<br />

The size of the warehouse is 120 m long x<br />

105 m wide and 46 m tall, with a total capacity<br />

that exceeds 161,000 pallets that<br />

are 800 x 1200 mm in size and weigh a<br />

maximum 700 kg each.<br />

The construction system is self-supporting,<br />

that is to say the racks, in addition<br />

to storing goods, have additional structures<br />

on which sheet clad panels are<br />

attached to that make up the building.<br />

This forms a complete unit that is the<br />

warehouse.<br />

The racks must support their own weight,<br />

the pallets stored, the wind pressure, handling<br />

equipment, the seismic activity on<br />

the basis of the coefficient indicated at the<br />

construction site and the weight of snow<br />

that conforms to the regulations.<br />

The Hayat Kimya warehouse consists of<br />

15 aisles with double-depth racks placed<br />

on both sides and is 24 load levels high. In<br />

each aisle a 45 m high stacker crane was<br />

set up that is responsible for the movements<br />

within the warehouse, from the reception<br />

area to product locations.<br />

Each stacker crane is equipped with a<br />

double cradle that allows two pallets<br />

to be moved at a time and with singlemast<br />

construction, something unusual<br />

for a warehouse of this height. The maintenance<br />

of the stacker cranes is carried out<br />

on the side that coincides with the conveyor<br />

circuit.<br />

It is interesting to point out that in each<br />

of the 24 load levels that integrate rack<br />

bays, three pallets in the first position and<br />

three other pallets in the second are stored.<br />

This is very difficult to achieve in a tall<br />

warehouse which is located, as explained<br />

below, in an area with such a high rate of<br />

seismic activity.<br />

In this image the loading<br />

docks and the offices<br />

located on the bottom<br />

floor of the warehouse<br />

can be seen.<br />

16 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

The warehouse itself is an enclosed box<br />

in which all passages between the inside<br />

and the outside connection floor are done<br />

through airlocks that help maintain the<br />

atmosphere required by the fire protection<br />

system.<br />

This system (inerting) works by reducing<br />

the oxygen in the interior’s air, to an<br />

atmospheric level of 14%, at which point<br />

combustion is no longer possible. A piece<br />

of equipment controls the oxygen levels<br />

in the air and adds nitrogen until reaching<br />

the percentage that has been previously<br />

programmed.<br />

The final solution<br />

was the construction<br />

of a huge 12.500 m 2<br />

logistics centre, with<br />

a 46 m tall, clad-rack<br />

warehouse, readied<br />

to house up to<br />

161,000 pallets<br />

<strong>Best</strong> <strong>Practices</strong><br />

17


Case Study I Hayat Kimya<br />

Eurasian Plate<br />

Izmit<br />

Anatolia<br />

Major construction challenge:<br />

its location<br />

The city of Izmit is located at the beginning<br />

of the Northern Anatolian fault line, which<br />

runs along the upper zone of the peninsula<br />

and which makes up the greater part of<br />

Turkey’s territory. This stretch, parallel to<br />

the Black Sea, also coincides with the fault<br />

line that crosses the Sea of Marmara and<br />

the Bosphorus Strait.<br />

African Plate<br />

Arabian Plate<br />

To build a warehouse of these dimensions<br />

in a place with such a high rate of earthquakes,<br />

with a height of more than 45 m<br />

and with stacker cranes prepared to move<br />

two pallets at a time and operate in doubledepth<br />

racks, was a challenge never before<br />

surpassed by Mecalux. Furthermore, the<br />

warehouse was built in an area exposed<br />

18 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

to the wind and where snowfall, although<br />

not frequent, can be abundant when it<br />

does occur.<br />

With all these constraints, only one company<br />

with the experience and quality of<br />

Mecalux was able to build a warehouse on<br />

this scale.<br />

The main difficulty Mecalux faced was<br />

the existence of a major earthquake zone right<br />

where Hayat Kimya wanted to build its<br />

upcoming central warehouse<br />

By its particularities, this logistics centre<br />

could not be built with the traditional<br />

cold-formed profiles. Nor was it possible<br />

to do so with a structure of standard hot<br />

rolled profiles, due to the accuracy of assembly<br />

that this installation required was<br />

extremely high.<br />

The solution provided by Mecalux’s technical<br />

team was to combine the two con-<br />

structive options. The first to conform all<br />

racks, and the second to complete the<br />

construction of a vertical reticulate structure<br />

coupled to the racks.<br />

The objective was to absorb all the horizontal<br />

dynamic forces, mainly those of a<br />

longitudinal direction, which is the least<br />

rigid part of the racks.<br />

The weight of this additional structure was<br />

more than 1,900 t (for the whole structure<br />

10,000 t was used).<br />

Both the dimensions and mode of operation,<br />

as the building’s location, represented<br />

a challenge for the Mecalux’s Structural<br />

Engineering department that had to deal<br />

with some extreme determinants.<br />

<strong>Best</strong> <strong>Practices</strong><br />

19


Case Study I Hayat Kimya<br />

Upper floor: inputs<br />

All warehouse inputs from the factories<br />

that are located on-premises take place<br />

on the third floor of Hayat Kimya’s logistics<br />

centre. The accumulative automatic roller<br />

conveyors have been set up in the four<br />

overpasses connecting the warehouse to<br />

the factories.<br />

All the factories have a conveyor circuit<br />

that is tasked with the input of the pallets<br />

into the system after checking both<br />

its size and its weight. Only then will they<br />

ensure that the pallets that arrive to the<br />

warehouse do so in good condition.<br />

In each overpass two lifts were placed, one<br />

in each factory’s entry points and an other<br />

at the end of each overpass, allowing<br />

goods to be lifted to transport height and<br />

subsequently to the third floor. At the same<br />

time, this floor has a triple electrified monorail<br />

circuit running both the external and<br />

internal movements of the warehouse.<br />

On the third floor, alongside inputs, outputs<br />

of goods that are lowered to the designated<br />

picking floor are also done via the<br />

elevators.<br />

Every day an average<br />

of 6,500 pallets come<br />

into the warehouse,<br />

peaking at 400 pallets<br />

per hour<br />

This image shows the<br />

upper floor where inputs<br />

into the warehouse are<br />

performed.<br />

20 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

<strong>Best</strong> <strong>Practices</strong><br />

21


Case Study I Hayat Kimya<br />

Plant intended for<br />

the picking operations<br />

The second floor of Hayat Kimya’s warehouse<br />

has been reserved for picking functions,<br />

dividing it into two areas:<br />

Zone A: 118 live channels, each three pallets<br />

deep, are grouped into four blocks.<br />

Each block is serviced by a shuttle that<br />

automatically feeds the channels with the<br />

goods from the lifts.<br />

This area is intended for A type products<br />

(high demand).<br />

This image displays the floor<br />

set up for picking.<br />

22 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

Zone B: 174 pallet racking bays with 2 or<br />

4 levels for pallets, including the ground<br />

floor, grouped into four double and two<br />

single rack alignments.<br />

It has a total capacity of 500 pallets for<br />

picking placed directly on the floor and<br />

1,050 reserve pallets on upper levels. This<br />

second area is allocated for the picking of<br />

B type products (medium demand).<br />

In addition, the same racks were set up for<br />

levels of live box picking to give access to<br />

C type products (low demand).<br />

The feeding of the pallet racks is performed<br />

using front loading reach trucks that<br />

take the pallets from the warehouse in a<br />

specific exit, where one of the lifts has previously<br />

deposited the pallets destined for<br />

this zone.<br />

Picking is done manually by the operators,<br />

aided by order fulfilment machines<br />

and a computer terminal that works via<br />

radio frequency.<br />

When the orders are<br />

completed, they are taken<br />

to the baling area and,<br />

via two lifts, are sent to<br />

the ground floor to be<br />

dispatched<br />

<strong>Best</strong> <strong>Practices</strong><br />

23


Case Study I Hayat Kimya<br />

Lower floor: dispatches<br />

All outputs designated for the dispatch<br />

area are carried out on the ground floor<br />

by electrified monorails. These automated<br />

transport units take the pallets from the<br />

conveyor output inside the warehouse,<br />

and the lifts that descend from the picking<br />

floor, and classify them into preloads.<br />

The preloads are composed of 17 triplechannel<br />

groupings, which have a capacity<br />

to deep-store 11 pallets.<br />

Each triple-channel group has a total capacity<br />

of 33 pallets each that correspond to<br />

an order, route or an out-sourced means of<br />

transport (truck or sea container). This request<br />

is prepared before loading the truck<br />

to avoid waiting time in goods being dispatched<br />

from the warehouse.<br />

24 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

Every day an average<br />

of 7,000 pallets<br />

leave the warehouse,<br />

in other words,<br />

more than<br />

200 truckloads<br />

Depending on the means of transport<br />

used, and the agreements with company’s<br />

individual customers, the merchandise<br />

is shipped on pallets (usually by truck) or<br />

in single, stacked boxes (sea container).<br />

For loading trucks generally light, front<br />

loading forklifts are used, since they are<br />

very agile and thus the most suitable.<br />

The dispatch area has 17 docks only for<br />

loading, allowing the preparation of<br />

17 transport vehicles at a time.<br />

<strong>Best</strong> <strong>Practices</strong><br />

25


Case Study I Hayat Kimya<br />

Automatic unloading<br />

In addition, on the lower floor merchandise<br />

inputs from the detergent factory (located<br />

2 km away) is also done.<br />

The inputs take place on the ground floor<br />

via three reception docks, one of which is<br />

readied to automatically run unloading.<br />

The automatic<br />

unloads accumulation<br />

device can receive<br />

all the pallets of a full<br />

truckload (trucks are<br />

set up with similar<br />

equipment)<br />

From here, the pallets pass, one by one,<br />

through the checkpoint and continue via<br />

the electrified monorails to the input<br />

stations located inside the warehouse that<br />

is found on this floor.<br />

26 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hayat Kimya<br />

Electrified monorails and airlocks<br />

All movements from the stations to the<br />

inside of the warehouse, both on the third<br />

floor and on the ground floor, are carried<br />

out by autonomous shuttles hung from<br />

electrified monorail that works at a speed<br />

of 100 meters per minute.<br />

There are more than 900 meters of electrified<br />

monorail and 55 autonomous shuttles<br />

in the entire installation that are able to<br />

move more than 850 pallets per hour<br />

The warehouse should be as airtight as<br />

possible to avoid the entry of air currents<br />

with a higher percentage of oxygen. This<br />

means that all the merchandise that enters<br />

and exits via the electrified monorails<br />

passes through a sealed area with double<br />

doors or airlocks that can never be opened<br />

at the same time.<br />

These spots are often bottlenecks in an<br />

unattended installation – consequently in<br />

this case, which work via electrified monorails<br />

and where there are also very high<br />

flow rates – it was necessary to design several<br />

accesses with triple inner shuttle capacity.<br />

In other words, the shuttles of the<br />

electrified monorails pass three at a time.<br />

ERP<br />

SAP<br />

of Hayat<br />

Mecalux Easy WMS<br />

Easy WMS: the nerve centre<br />

of the logistics centre<br />

All the operations of the logistics centre are<br />

governed by the warehouse management<br />

system Mecalux Easy WMS and its Galileo<br />

control software; tasked with controlling<br />

the computers that run the transport and<br />

the storage of goods tasks.<br />

Easy WMS is also responsible for:<br />

- Management of goods input from its reception<br />

at the docks.<br />

- Locate pallets in the warehouse using<br />

rules previously parameterised, under<br />

the criteria of streamlining and maximum<br />

productivity.<br />

- Manages the stock and the warehouse<br />

layout (what and where the goods are).<br />

- Manages the warehouse outputs to the<br />

picking and/or dispatch areas.<br />

- Manages and controls the picking operations<br />

through radio frequency terminals,<br />

guiding the operator in the tasks to be<br />

performed and the order to follow to optimise<br />

routes.<br />

- Allows the checking of the status of different<br />

parts of the logistics centre, and the<br />

various equipment that operate in it, via<br />

query and reporting tools.<br />

The Easy WMS (Warehouse Management<br />

Software) is in permanent and bi-directional<br />

connection with Hayat Kimya’s SAP<br />

ERP system.<br />

<strong>Best</strong> <strong>Practices</strong><br />

27


Case Study I Hayat Kimya<br />

Advantages for Hayat Kimya<br />

- High storage capacity: 161,000 pallets, 800 x 1200 mm in size and each weighing a maximum of<br />

700 kg can be warehoused, in a surface area of 12,500 m 2 .<br />

- Production cost savings: they have built four overpasses connecting the factories and the front<br />

of the warehouse. Each day an average of 6,500 pallets come into the warehouse, peaking at<br />

400 pallets per hour.<br />

- Total control of the automated warehouse: thanks to the Mecalux Easy WMS (Warehouse<br />

Management Software), Hayat Kimya controls all the processes and operations that take place<br />

inside the warehouse, from the moment the product leaves packaging lines until it is delivered.<br />

- Remote support, remote maintenance: Mecalux is available to give technical support to Hayat<br />

Kimya 24 hours a day, seven days a week.<br />

Technical data<br />

Length of the warehouse<br />

120 m<br />

Width of the warehouse<br />

105 m<br />

Height of the warehouse<br />

46 m<br />

Storage capacity<br />

161,000 pallets<br />

No. of storage aisles 15<br />

No. of docks 24<br />

No. of double cradle stacker cranes 15<br />

Extraction system<br />

double-depth<br />

Total electrified monorails<br />

> 900 linear metres<br />

No. of shuttles in the installation 55<br />

Total in overpasses<br />

> 420 linear metres<br />

Total number of lifts 12<br />

Total number of shuttles 4<br />

Live channels for picking 118<br />

Live preloads 17<br />

Total live preload channels 51<br />

Automatic unloading platform 1<br />

Pallet input per day 6,500<br />

Maximum pallet input per hour 400<br />

Pallet output per day 7,000<br />

Maximum pallet output per hour 450<br />

Average truckloads <strong>issue</strong>d per day > 200<br />

Weight of the warehouse structure 10,000 t<br />

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

28 <strong>Best</strong> <strong>Practices</strong>


Case study: Gioseppo<br />

Two million pairs of shoes: Mecalux builds<br />

Gioseppo a clad-rack solution for footwear<br />

Location: Spain<br />

The installation that Gioseppo has in Elche (Spain) is composed of an automated<br />

clad-rack warehouse for pallets, with live racks and a specific area for picking.<br />

The warehouse management system Mecalux Easy WMS was supplied, which is<br />

responsible for managing all the centre’s processes.<br />

<strong>Best</strong> <strong>Practices</strong><br />

29


Case Study I Gioseppo<br />

Who is Gioseppo?<br />

Founded in 1991, Gioseppo is a family<br />

busi ness from the Elx region, dedicated to<br />

designing and marketing medium to highend<br />

shoes for men, women and child.<br />

After almost 25 years, Gioseppo is currently<br />

a well-established brand whose<br />

products are marketed in more than 60<br />

countries worldwide.<br />

Its growth and track record has led<br />

Gioseppo to be included in the prestigious<br />

‘Forum for Renowned Spanish Brand’s’, an<br />

alliance made up of companies and leading<br />

brands from their respective sectors.<br />

Logistical needs<br />

The objectives presented by Gioseppo to<br />

Mecalux were very specific: build a warehouse<br />

to increase its storage capacity to locate<br />

all products coming from production,<br />

and automate the internal transport of<br />

goods with the purpose of managing a<br />

greater number of SKUs in the most efficient<br />

way possible.<br />

With this, the company would take a qualitative<br />

leap forward on a logistical level that<br />

could reduce production costs, while improving<br />

warehouse productivity<br />

Based on these requirements, Mecalux designed<br />

an integrated solution in which automated<br />

storage processes were more profitable<br />

for Gioseppo.<br />

30 <strong>Best</strong> <strong>Practices</strong>


Case Study I Gioseppo<br />

Construction needs<br />

Another premise that Mecalux had to keep<br />

in mind was to pay careful attention to the<br />

public image of the company. It was of utmost<br />

importance to limit the impact constructing<br />

a clad-rack warehouse would<br />

have on the landscape of the Gioseppo<br />

“Love Work Place” logistics centre, an<br />

environmentally friendly space near the<br />

Mediterranean Sea.<br />

Accordingly, the dimensions of the logistics<br />

centre could not exceed a certain height.<br />

So, it was necessary to find a solution that<br />

offered high storage capacity, while at the<br />

same time reducing the installation’s size.<br />

3<br />

It was paramount<br />

to reduce the impact<br />

constructing a clad-rack<br />

warehouse had on the<br />

landscape of Gioseppo’s<br />

‘Love Work Place’<br />

logistics centre<br />

2<br />

1<br />

Map data ©2015* Google<br />

<strong>Best</strong> <strong>Practices</strong><br />

31


Case Study I Gioseppo<br />

A clad-rack warehouse as a solution<br />

This 18.5 m high, 79 m long and 21.5 m<br />

wide clad-rack warehouse is composed<br />

of three aisles with double-deep racks on<br />

both sides, offering a storage capacity of<br />

5,844 pallets, weighing 500 kg each. To be<br />

clad-rack means that the structure of the<br />

building is formed by the racks themselves,<br />

and that the outer cladding is supported<br />

and attached to them.<br />

For structural calculations of clad-rack<br />

warehouses the following are taken into<br />

account: its own weight; the weight of the<br />

goods stored; the wind pressure both push<br />

and suction depending where it is built; the<br />

weight of the snow as indicated by the regulations;<br />

ramming by stacker cranes; and<br />

finally, the seismicity corresponding to the<br />

territory in which it is located.<br />

Its purpose, as explained above, was twofold:<br />

to optimise height in order to a chieve<br />

the largest possible storage capacity, and<br />

reduce landscape impact to preserve<br />

Gioseppo’s public image.<br />

In each aisle a stacker crane circulates,<br />

hand ling the movements of the pallets<br />

from the conveyors at the end of the aisle<br />

to its designated location.<br />

The use of stacker cranes helps increase<br />

productivity, at the same time decreasing<br />

the resources required to manipulate the<br />

goods.<br />

Gioseppo’s clad-rack<br />

warehouse is distinctive<br />

because they excavated<br />

a 6 meter deep trench<br />

where a large portion<br />

of the warehouse was<br />

installed<br />

3<br />

2<br />

1<br />

32 <strong>Best</strong> <strong>Practices</strong>


Case Study I Gioseppo<br />

<strong>Best</strong> <strong>Practices</strong><br />

33


Case Study I Gioseppo<br />

Inputs and outputs<br />

The inputs and outputs of palletised goods<br />

are done via a double shuttle that connects<br />

the main circuit of conveyors with<br />

the stor age aisles. The goods input area<br />

has an entry checkpoint, which is responsible<br />

for verifying that the size, weight, and<br />

condition of the pallets comply with the<br />

installation’s specifications.<br />

34 <strong>Best</strong> <strong>Practices</strong>


Case Study I Gioseppo<br />

<strong>Best</strong> <strong>Practices</strong><br />

35


Case Study I Gioseppo<br />

Picking functions<br />

This same transfer car is tasked with transferring<br />

the pallets from the aisles to the P&D<br />

stations. The picking area is organised star t-<br />

ing with six independent stations where<br />

operators take the boxes they need from<br />

the pallet and deposit them onto the box<br />

conveyor with the order sorter located on<br />

the back.<br />

In addition, and in order to facilitate work,<br />

each picking station has a lift table so that<br />

the pallets are kept at the ideal height for<br />

each operator, improving its ergonomic<br />

position.<br />

36 <strong>Best</strong> <strong>Practices</strong>


Case Study I Gioseppo<br />

The picking area<br />

has six independent<br />

stations that are<br />

set up with a lift table<br />

to improve ergonomic<br />

design<br />

<strong>Best</strong> <strong>Practices</strong><br />

37


Case Study I Gioseppo<br />

Live racks for orders completed and<br />

consumer products<br />

A block of 36 live rack channels has been<br />

installed both for storing orders prepared,<br />

as well as the stacks of idle pallets.<br />

This 8 m high, 9.5 m long and 11 m deep<br />

warehouse has a storage capacity of<br />

324 pallets 800 x 1,200 x 1,900 mm in<br />

size, each with a maximum weight of<br />

400 kg. Each channel receives nine pallets.<br />

The live racks are a compact storage system<br />

that allows maximum use of space and<br />

that are composed of roller channels on a<br />

slight incline. The pallets are inserted into<br />

the highest part of the rack and move via<br />

gravity to the lower end, being available to<br />

the operator. The pallet travel speed is controlled<br />

by roller brakes.<br />

Therefore, this storage system is ideal<br />

for lowering handling times and expedites<br />

picking, increasing the installation’s<br />

productivity.<br />

38 <strong>Best</strong> <strong>Practices</strong>


Case Study I Gioseppo<br />

Easy WMS: the nerve centre<br />

of the installation<br />

In Gioseppo’s new warehouse the warehouse<br />

management system Mecalux Easy<br />

WMS was implemented to manage and<br />

coordinate the different automated operations<br />

that take place within the installation:<br />

the input and output of goods, storage,<br />

picking and dispatches.<br />

This powerful management software has<br />

been customised to Gioseppo’s demands,<br />

being able to: locate pallets in the racks<br />

based on algorithms or parametrisable<br />

rules, manage outputs on the basis of traceability<br />

and FIFO criteria, check the stock,<br />

run standard and custom labelling of containers,<br />

group output orders in different<br />

modalities, etc.<br />

Easy WMS (warehouse management software)<br />

provides a competitive advant age<br />

to Gioseppo, since it involves cost savings,<br />

an improvement in service quality<br />

and consequently, maximising warehouse<br />

profitability.<br />

In addition, Easy WMS is in permanent<br />

communication with the SAP ERP,<br />

Gioseppo’s main management system, exchanging<br />

orders and the information that<br />

is essential for its overall management.<br />

<strong>Best</strong> <strong>Practices</strong><br />

39


Case Study I Gioseppo<br />

Advantages for Gioseppo<br />

- Increased storage capacity in a small space: Gioseppo’s clad-rack warehouse receives 5,844<br />

pallets in a surface area of 1,700 m 2 , quadrupling the capacity of the previous warehouse.<br />

- Limiting environmental impact: a 6 meter deep hole was excavated to obtain height and storage<br />

capacity, while the impact on the area’s landscape was minimised.<br />

- Cost savings: the automation of the clad-rack warehouse allows Gioseppo to increase efficiency<br />

and reduce personnel and logistics costs.<br />

- Complete control: the Mecalux Easy WMS controls all the processes and operations that take<br />

place inside the warehouse.<br />

Technical data<br />

Automated Warehouse<br />

Storage capacity<br />

5,844 pallets<br />

Maximum weight per pallet 500 kg<br />

Warehouse height<br />

18.5 m<br />

No. of stacker cranes 3<br />

Type of stacker crane<br />

twin-mast<br />

Fork type double-deep<br />

Construction system<br />

self-supporting<br />

Live racks<br />

Storage capacity<br />

Pallet size<br />

Maximum weight per pallet<br />

Warehouse height<br />

324 pallets<br />

800 x 1,200 mm<br />

400 kg<br />

8 m<br />

40 <strong>Best</strong> <strong>Practices</strong>


Case study: Ypê<br />

Wide prep area for orders: a key Mecalux<br />

design feature for Ypê warehouse in São Paulo<br />

Location: Brazil<br />

Ypê, a company dedicated to the<br />

development of cleaning products for<br />

the household and personal hygiene,<br />

has hired Mecalux to install a 29.5 m<br />

high automated clad-rack warehouse<br />

with a 24,168 pallet storage capacity<br />

in its logistical support centre in<br />

Amparo (São Paulo).<br />

<strong>Best</strong> <strong>Practices</strong><br />

41


Case study I Ypê<br />

Analysing the needs<br />

The main production centre of Ypê is located<br />

in Amparo, a town close to the city of<br />

São Paulo. The growing needs of the company<br />

required the construction of a large logistics<br />

centre next to the production plants,<br />

from which they could offer comprehensive<br />

service, and at the same time reduce costs.<br />

Mecalux installed the racks and structures<br />

of the warehouse, the automatic internal<br />

handling equipment, the construction<br />

of a picking area and Mecalux Easy WMS<br />

software deployment, the warehouse<br />

management system which governs and<br />

controls the operations of the logistics<br />

centre.<br />

The collaboration of<br />

Mecalux with Ypê has<br />

been very close from the<br />

development phase of the<br />

project to its execution<br />

42 <strong>Best</strong> <strong>Practices</strong>


Case study I Ypê<br />

<strong>Best</strong> <strong>Practices</strong><br />

43


Case study I Ypê<br />

Warehouse area<br />

reserved to expand the storage<br />

capacity of Ypê<br />

Solution adopted:<br />

clad-rack warehouse<br />

The most striking part of the project developed<br />

by Mecalux is the installation<br />

of a self-supporting construction warehouse<br />

with a total capacity of 24,168 pallets,<br />

1000 x 1200 mm in size, each with a<br />

weight of 1,300 kg.<br />

Being clad-racked, the racks are a fundamental<br />

part of the structure of the building<br />

and cladding is placed on them. In addition<br />

to its own weight, it must withstand the<br />

pallets stored, the force of the wind on the<br />

basis of the site characteristics, the pressure<br />

of the handling equipment and the<br />

seismic risk that corresponds to the zone in<br />

accordance with the country’s regulations.<br />

of eight storage aisles, with racks on both<br />

sides, of which five are double-depth and<br />

three single-depth.<br />

Each aisle is set up with a twin-mast stacker<br />

crane that automatically performs the<br />

movements between locations and the<br />

main conveyor circuit, placed at the header<br />

of the warehouse.<br />

The traditionally constructed buildings are<br />

adjacent to Ypê’s logistics centre, just besides<br />

the automated warehouse, where<br />

available space has been set aside for future<br />

expansion.<br />

At present, this 29.5 m high, 107.5 m long<br />

and 49.5 m wide warehouse has a total<br />

44 <strong>Best</strong> <strong>Practices</strong>


Case study I Ypê<br />

The warehouse is distributed into the following<br />

areas, as can be seen in the layout:<br />

A. Warehouse<br />

B. Input stations<br />

C. Main conveyor circuit<br />

D. Direct outputs station<br />

E. Picking channels<br />

<strong>Best</strong> <strong>Practices</strong><br />

45


Case study I Ypê<br />

The input of the pallets that go into the<br />

warehouse takes place via three stations<br />

readied with a gauge control and input<br />

checkpoint equipment. This space is located<br />

in the reception dock area for incoming<br />

goods, occupying one of the sides of<br />

the warehouse.<br />

A conveyor with accumulation capacity<br />

transports them to the header, where the<br />

main conveyor circuits are placed.<br />

A large percentage of the pallets that leave<br />

the warehouse do so designated for the<br />

picking area.<br />

As of now, there are five groups of live<br />

channels outfitted and one for pallets<br />

placed on the floor of the warehouse.<br />

Group of picking channels<br />

46 <strong>Best</strong> <strong>Practices</strong>


Case study I Ypê<br />

The installation<br />

that Ypê has in São Paulo,<br />

with a 24,168 pallet<br />

capacity, is expected to<br />

achieve a total flow of<br />

200 pallets/hour in inputs<br />

and outputs<br />

Each grouping contains 66 channels with<br />

a three pallet capacity. The feeding is performed<br />

via transfer cars that automatically<br />

move from specific positions of the header<br />

to the live channels. The slight tilt with<br />

which channels are mounted allows the<br />

pallet to move by gravity to the closest free<br />

position in work aisles.<br />

Among the five groups, there is a total of<br />

330 channels with a capacity for 990 pallets;<br />

each channel is intended for a single<br />

SKU. Apart from that, there are 138 positions<br />

for pallets placed on the floor, which<br />

are directly supplied by forklifts.<br />

The consolidation of orders, once the pallets<br />

have already passed by the balers, is<br />

carried out in the area allocated to preloads<br />

close to the loading docks.<br />

The logistics centre of Ypê also features live<br />

racks to store consumer products that do<br />

not enter into the automated warehouse.<br />

This area, next to the docks, works as crossdocking,<br />

the live racks acting as a buffer.<br />

Easy WMS: the nerve centre<br />

of the logistics centre<br />

Easy WMS is a powerful warehouse management<br />

system developed by Mecalux<br />

with which you can manage all the warehouse<br />

needs, stepping in from when the<br />

goods are received till the order has been<br />

dispatched.<br />

Among all the functions that Easy WMS is<br />

capable of performing, the most important<br />

are: the receipt and registration of<br />

the pallets that enter into the warehouse,<br />

the management of the locations on the<br />

basis of rules or parametrable algorithms,<br />

control of outputs in accordance with FIFO<br />

criteria and traceability, order preparation,<br />

consolidation, label issuing, documentation<br />

prior to delivery, etc.<br />

All of this with the major advantage of reducing<br />

the errors arising from manual management<br />

to a minimum.<br />

Furthermore, the Mecalux Easy WMS<br />

warehouse management software is continuously<br />

and directly connected to the<br />

ERP of Ypê, from which it receives the background<br />

information and that reports the<br />

outputs executed.<br />

<strong>Best</strong> <strong>Practices</strong><br />

47


Case study I Ypê<br />

Advantages for Ypê<br />

- High storage capacity: the clad-rack warehouse of Ypê enables them to locate 24,168 pallets, 1,000 x<br />

1,200 mm in size each with a weight of 1,300 kg, in a 5,200 m² area.<br />

- Cost savings: automation of the different storage processes helps Ypê to boost efficiency while reducing<br />

operational costs.<br />

- Flexibility for future growth: an area to the side of the automated warehouse has been prepared in<br />

order to expand storage capacity based on the future needs of the company.<br />

- Complete control: thanks to the Mecalux Easy WMS, Ypê controls all the processes and operations that<br />

take place inside the warehouse.<br />

Technical data<br />

Storage capacity<br />

24,168 pallets<br />

Dimensions of the pallet<br />

1,000 x 1,200 mm<br />

Maximum weight per pallet 1,300 kg<br />

No. of stacker cranes 8<br />

Type of stacker crane<br />

twin-mast<br />

Fork type<br />

single and double-depth<br />

Live picking channels 330<br />

Pallets in picking positions 1,128 pallets<br />

No. of transfer cars 5<br />

Preload<br />

on the floor<br />

48 <strong>Best</strong> <strong>Practices</strong>


Case study: Takeda<br />

Turnkey pharmaceutics: automated warehouse<br />

by Mecalux for Japanese partner Takeda<br />

Location: Poland<br />

<strong>Best</strong> <strong>Practices</strong><br />

49


Case Study I Takeda<br />

Takeda, one of the most important<br />

pharmaceutical companies in the<br />

world, has entrusted Mecalux to<br />

build a turnkey warehouse in its<br />

new Lyszkowice production plant,<br />

near the Polish city of Lowicz.<br />

The solution was to construct a<br />

temperature controlled, 32.5 m<br />

high clad-rack warehouse with<br />

a capacity to store more than<br />

6,500 pallets. It is equipped<br />

with a cold storage system and<br />

an ‘oxygen reduction system’<br />

for fire prevention. They were<br />

also supplied with a warehouse<br />

management system, the Mecalux<br />

Easy WMS, which is responsible<br />

for managing all the centre’s<br />

processes.<br />

Who is Takeda?<br />

Takeda Pharmaceutical Company Limited,<br />

with its headquarters in Osaka (Japan), is<br />

a global company specialising in the invest<br />

igation of pharmaceutical products. In<br />

the mid-twentieth century, it experienced<br />

massive growth, making it a world leader<br />

in the pharmaceutical industry and the<br />

larg est of its kind in Japan.<br />

A clad-rack warehouse as a solution<br />

When Takeda moved forward with the expansion<br />

of its production centre, it was very<br />

clear that the warehouse should be automated.<br />

This would allow for perfect control<br />

of stored goods, in addition to being<br />

able to achieve the maximum permissible<br />

height, given that the space available for<br />

warehouse construction was limited.<br />

The solution proposed by Mecalux was the<br />

construction of a 32.5 m high clad-rack<br />

warehouse located next to the manufact<br />

uring facilities and the bay assigned to<br />

delivery preloading. In this type of cons-<br />

The company has a commercial pre sence<br />

in more than 70 countries, most significantly<br />

those in Asia, North America and<br />

Europe and emerging markets such as<br />

Latin America, Russia and China.<br />

truction, the racks themselves make up<br />

the structure of the warehouse.<br />

The installation consists of two aisles, in<br />

which two automatic stacker cranes move<br />

independently, handling the pallets stored<br />

in double-deep racks (two pallets in depth<br />

on each level). Thanks to the optimal space<br />

utilisation, the Takeda warehouse has a<br />

storage capacity of more than 6,500 pallets<br />

in a surface area of only 950 m 2 .<br />

The warehouse was equipped with a<br />

HVAC system (Heating Ventilation Air<br />

Conditioning) which keeps the temperature<br />

between 16 and 24 °C and prevents<br />

the humidity level from exceeding 70%,<br />

which is something that could affect<br />

goods stored.<br />

3D computer graphic of the Takeda clad-rack warehouse<br />

50 <strong>Best</strong> <strong>Practices</strong>


Case Study I Takeda<br />

Warehouse aisle<br />

<strong>Best</strong> <strong>Practices</strong><br />

51


Case Study I Takeda<br />

32,382 mm<br />

14,505 mm<br />

Layout: elevation, floor and<br />

profile of the Takeda warehouse<br />

85,657 mm<br />

65657 mm<br />

An innovative fire protection system (inerting)<br />

has also been used, which reduces the<br />

amount of oxygen in the atmosphere to<br />

15% to avoid fires.<br />

The pipes of the air’s humidity and temperature<br />

control system have been installed<br />

above, targeting the aisles and placed in<br />

the free space between trusses in the facility.<br />

For structural calculations of clad-rack<br />

warehouses the following are taken into<br />

account: its own weight; the weight of the<br />

goods stored; the wind pressure both push<br />

and suction where it is built; the weight of<br />

the snow as indicated by the regulations;<br />

thrusts by stacker cranes; and finally, the<br />

seismicity corresponding to the territory<br />

where it is located.<br />

This 32.5 meter high clad-rack warehouse has a storage<br />

capacity of 6,584 pallets, 800 x 1200 mm in size,<br />

with a maximum weight of 800 kg<br />

Due to the slenderness of the building<br />

(14.5 m wide and 32.4 m high), a highly reinforced<br />

structure was built. Also, many<br />

large sized anchorages have been placed<br />

with the aim of absorbing maximum wind<br />

pressure.<br />

Outside view of the warehouse<br />

52 <strong>Best</strong> <strong>Practices</strong>


Case Study I Takeda<br />

Twin-mast stacker crane<br />

19800<br />

19,800 mm<br />

Cooling tube<br />

Reinforced racks<br />

<strong>Best</strong> <strong>Practices</strong><br />

53


Case Study I Takeda<br />

Inputs and outputs are practically unified<br />

and are constructed very simply, they are<br />

suitable for forklifts and stackers use. The<br />

entry conveyor has a checkpoint, which<br />

ensures top condition of all the pallets that<br />

are put into the automated warehouse.<br />

The connection with the inside of the<br />

warehouse is done using a double conveyor<br />

circuit (inputs and outputs) that passes<br />

through doors with double vertical<br />

screens.<br />

Entry and exit of the warehouse<br />

The space between the two screens<br />

amounts to what is needed for a single pallet,<br />

being that the system sends alternating<br />

open and close signals, limiting temperature<br />

changes inside.<br />

In order to avoid capacity loss, a superior<br />

platform was set up for doing secure maintenance<br />

with one access per aisle.<br />

Entry and exit of the warehouse<br />

The stacker cranes<br />

are double-mast<br />

and incorporate a<br />

maintenance cabin,<br />

which is located<br />

on the lifting cradle<br />

itself<br />

Main conveyor circuit<br />

54 <strong>Best</strong> <strong>Practices</strong>


Case Study I Takeda<br />

Plant’s maintenance access<br />

Easy WMS:<br />

The management, synchronisation and<br />

control of the entire warehouse, including<br />

parts that interact with the maintenance<br />

equipment, work thanks to the<br />

Mecalux Easy WMS (Warehouse Management<br />

Software).<br />

The main functions of Easy WMS are:<br />

- Receiving and recording the pallets that<br />

come into the warehouse.<br />

- Pallet location in the racks based on algorithms<br />

or parametrical rules.<br />

- Management of outputs based on FIFO<br />

criteria and traceability.<br />

- Via the Galileo software, all movements<br />

of the mechanical parts run and optimised<br />

the internal routes.<br />

- Connection to the warehouse door<br />

control program so that it acts<br />

automatically.<br />

In addition, Easy WMS is in constant communication<br />

with the SAP ERP, Takeda’s<br />

main management system, exchanging<br />

orders and information that is essential to<br />

its overall management.<br />

Maintenance access<br />

<strong>Best</strong> <strong>Practices</strong><br />

55


Case Study I Takeda<br />

Turnkey warehouse<br />

Takeda wanted all development and construction<br />

phases of the warehouse, including<br />

the supply of the software needed to<br />

properly manage all internal operations,<br />

carried out by a single company.<br />

That is why Mecalux was commissioned to<br />

run the turnkey project from beginning to<br />

end.<br />

Stages of warehouse implementation:<br />

- Land preparation via pilings: due to<br />

the low bearing capacity of the soil, and<br />

the large static demands, a deep foundation<br />

was made on pilings.<br />

- Installation of a reinforced concrete<br />

foundation slab: first a reinforced top<br />

and bottom was built with steel rods, and<br />

subsequently the ground was filled with<br />

concrete.<br />

- Finish: the foundation was finished and<br />

hardened with the objective of obtaining<br />

dust free paving.<br />

- Rack assembly: regarding clad-rack<br />

warehouse, the racks themselves make<br />

up the actual structure.<br />

- Assembly of warehouse cladding:<br />

in clad-rack warehouses wall panelling<br />

and ‘sandwich type’ roofs are fastened<br />

directly to the rack structure. In Takeda’s<br />

case, and having used an inerting system,<br />

it was necessary for the outside cladding<br />

to be as watertight as possible.<br />

- Introduction of maintenance teams:<br />

conveyors and stacker cranes were<br />

assembled inside the warehouse.<br />

56 <strong>Best</strong> <strong>Practices</strong>


Case Study I Takeda<br />

- Installation of the inerting system:<br />

implementation of a fire protection system<br />

that allows you to inject nitrogen into<br />

the warehouse so that the oxygen concentration<br />

is reduced to less than 15%.<br />

- Installing the HVAC air conditioning<br />

system: it controls the temperature that<br />

should be maintained between 16 and<br />

24 ºC.<br />

- Assembly of the electrical and lightning<br />

protection systems.<br />

- Assembly of the drainage system.<br />

- Airlock construction: the separation of<br />

the portion of the warehouse equipped<br />

with the inerting system to the adjoining<br />

building that work under normal environmental<br />

conditions.<br />

<strong>Best</strong> <strong>Practices</strong><br />

57


Case Study I Takeda<br />

Advantages for Takeda<br />

- High storage capacity in a small space: the clad-rack warehouse enables you to place 6,584, 800 x<br />

1,200 mm sized pallets each weighing 800 kg in a surface area of 980 m 2 .<br />

- Product security: pharmaceutical products stored by Takeda are protected and isolated thanks to the<br />

automatic warehouse installation. Only authorised people can access the warehouse.<br />

- Turnkey warehouse: Mecalux was responsible for the development phases, the construction of the<br />

warehouse, the supply of storage, cooling, and fire safety systems, as well as the implementation of the<br />

WMS (Warehouse Management Software).<br />

- Complete control: thanks to Mecalux Easy WMS, Takeda controls all the processes and operations that<br />

take place inside the warehouse, from the time the product leaves the packaging lines to its delivery.<br />

Technical data<br />

Warehouse capacity<br />

6,584 pallets<br />

Maximum weight per pallet 800 kg<br />

No. of stacker cranes 2<br />

Type of stacker crane<br />

twin-mast<br />

Fork type<br />

double-deep<br />

Height of the warehouse 32 m<br />

58 <strong>Best</strong> <strong>Practices</strong>


Case study: Nufri<br />

Nufri has put its confidence in Mecalux yet<br />

again by installing Movirack mobile pallet<br />

racking in its headquarters in Catalonia<br />

Location: Spain<br />

Mecalux supplied and installed a Movirack mobile racking system in Nufri,<br />

business leader in processing fresh fruits and vegetables with more than<br />

40 years’ experience in the sector. This new warehouse in its logistics centre in<br />

Mollerussa (Lleida) allows the storage of more than 6,100 pallets.<br />

Needs and the proposed solution<br />

Nufri handles around 400 million tons of<br />

fresh and processed materials, selling to<br />

more than 40 countries worldwide. To<br />

guarantee quality, personalized service,<br />

Nufri needed a warehouse in which it<br />

could access all its stored products in a<br />

straightforward manner, all the while<br />

maximizing surface area and the volume<br />

of the installations.<br />

In response, Mecalux opted to install<br />

Movirack mobile pallet racks of 12 m high,<br />

converting it into one of the tallest solutions<br />

of this kind and perfectly adapting it<br />

to the needs presented by Nufri.<br />

The warehouse is divided into two wellmarked<br />

areas: the first, which is smaller<br />

in size, is set up to store products and<br />

packag ing at ambient temperature, while<br />

the remainder of the area is cold storage<br />

used to store extracts, juices and purees.<br />

<strong>Best</strong> <strong>Practices</strong><br />

59


Case Study I Nufri<br />

Block 3: ambient<br />

temperature area<br />

Ambient temperature area<br />

It is set up to supply production areas, from<br />

cylindrical containers of enormous dimensions,<br />

including the products necessary to<br />

complete its range of processing.<br />

This area, with a storage capacity of<br />

1,200 pallets that are 1,200 x 1,200 mm<br />

in size and have a maximum weight of<br />

2,100 kg each, is available with seven mobile<br />

bases and two non-moving racks.<br />

Being located beside the cold storage<br />

allows combined supply, removal and storage<br />

of processed goods, significantly optimising<br />

the internal movements inside the<br />

installation.<br />

Providing for the future needs of the company,<br />

an area has been set up where five<br />

more mobile pallet racks can be installed.<br />

To that end, the floor has been fitted from<br />

the beginning to facilitate possible progressive<br />

growth.<br />

The utilization of<br />

Movirack mobile pallet<br />

racking provides the<br />

maximum installation<br />

streamlining<br />

BLOCK 3<br />

BLOCK 1<br />

2<br />

3<br />

BLOCK 2<br />

60 <strong>Best</strong> <strong>Practices</strong>


Case Study I Nufri<br />

Blocks 1 and 2: cold storage unit<br />

The racks have mesh shelves in them for low strength<br />

pallets or those that are not standard size<br />

Cold storage<br />

There are a total of 31 double mobile bases<br />

and four non-moving racks which give<br />

a storage capacity of 4,930 pallets 1,200 x<br />

1,200 mm in size, and have a maximum<br />

weight of 2,100 kg each, which conserves<br />

processed materials at a controlled<br />

temperature.<br />

The racks are arranged in two large blocks<br />

separated by a main gangway. Each block<br />

has a wide work aisle that opens up between<br />

racks. To automatically open it, the<br />

operator must only push a button via the<br />

remote control.<br />

For the purpose of ensuring the security of<br />

its operators and the installation in general,<br />

the Movirack system has the following<br />

devices: external optical safety barriers,<br />

longitudinal photocells placed on both<br />

sides of the bases, proximity sensors, preprogrammed<br />

activation protocols and<br />

emergency stop and reset buttons.<br />

The forklifts that are used in the refrigerated<br />

storage area are the retractable type<br />

that makes it possible to work in an aisle<br />

less than 3 m high. The last load level is<br />

plac ed at 10.6 m high, and the maximum<br />

load height would reach 12 m high.<br />

<strong>Best</strong> <strong>Practices</strong><br />

61


Case Study I Nufri<br />

Advantages for the customer<br />

- Storage capacity is increased using a Movirack mobile pallet rack system.<br />

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

- Products are maintained in optimal condition facilitated by the parking function, which keeps<br />

the racks slightly apart maintaining better air circulation.<br />

- Flexibility for future expansion.<br />

Technical data<br />

Storage capacity<br />

6,130 pallets<br />

Pallet size<br />

1,200 x 1,200 mm<br />

Maximum weigth per pallet 2,100 kg<br />

No. of mobile bases 38<br />

Rack height<br />

10.6 m<br />

Total height with load<br />

12 m<br />

Work aisle length<br />

23 m<br />

Warehouse temperature ambient / refrigerated<br />

62 <strong>Best</strong> <strong>Practices</strong>


Case study: MGA<br />

MGA has an efficient automated miniload<br />

warehouse coupled with conventional<br />

pallet racking<br />

Location: France<br />

For the new logistics center located in Saint-Quentin Fallavier, a town close<br />

to the city of Lyon, MGA chose Mecalux as provider of all management and<br />

storage systems, including an automated miniload warehouse with a capacity<br />

of 15,872 boxes.<br />

MGA is an important spare parts distributor<br />

with regional warehouses in different<br />

cities within France. The priority of the<br />

company is to offer express delivery to its<br />

customers, generally automobile replacement<br />

part wholesalers.<br />

In this logistics center, Mecalux has in stalled<br />

an automated miniload warehouse with a<br />

specific picking area and a warehouse for<br />

pallets placed on conventional type racks.<br />

It has also included the implementation of<br />

a Mecalux Easy WMS (warehouse management<br />

software), tasked with handling<br />

all operations, from the entry of goods till<br />

dispatch, previously passing through the<br />

storage and picking phases.<br />

<strong>Best</strong> <strong>Practices</strong><br />

63


Case Study I MGA<br />

Warehouse interior<br />

Conventional pallet racks<br />

The conventional pallet rack warehouse<br />

is intended for bulkier products and items<br />

with greater turnover (A type) placed<br />

upon pallets. Racks have two inferior levels<br />

to conduct direct picking from the pallets,<br />

while reserves are placed on superior<br />

levels.<br />

This storage system is characterised by<br />

its simplicity and capacity to adapt itself<br />

to the needs of the company. In addition,<br />

conventional pallet racks make it possible<br />

to directly access each pallet, storing the<br />

maximum number of unit loads in a safe<br />

and organised way.<br />

The miniload warehouse<br />

A miniload warehouse with four aisles,<br />

and two double­deep racks (one per side),<br />

was installed, allowing storage of a total<br />

of 15,872 plastic euro­boxes, 600 x 400 x<br />

320 mm in size. The height of the racks is<br />

12.3 m and the total admissible weight per<br />

box is 50 kg.<br />

All medium and small sized products are<br />

located in the miniload warehouse, generally<br />

B and C type items. These products<br />

are handled by four stacker cranes, three<br />

picking stations and a replenishment<br />

station.<br />

Connection between the warehouse and the picking area<br />

Warehouse for pallets: ‘A’ and bulky type product picking<br />

64 <strong>Best</strong> <strong>Practices</strong>


The MGA<br />

miniload warehouse<br />

can store 15,872 plastic<br />

euro-boxes<br />

The construction of the miniload<br />

warehouse was done in two phases, in<br />

accordance with the needs of MGA. The<br />

first included three storage aisles with<br />

three stacker cranes and three picking<br />

stations, while in the second they installed<br />

four aisles, set up a new stacker crane and<br />

completed the replenishment station.<br />

Case Study I MGA<br />

If we analyse the parts that the installation<br />

is composed of, represented by<br />

the images on this page, you will see the<br />

following:<br />

A. An automated warehouse<br />

B. Automated warehouse conveyors<br />

C. Three picking stations<br />

D. A replenishment station<br />

Four stacker cranes<br />

<strong>Best</strong> <strong>Practices</strong><br />

65


Case Study I MGA<br />

Two box extractions<br />

Double-mast stacker cranes were installed;<br />

the extraction system placed in the<br />

cradle is a double box and double-deep,<br />

being capable of handling two boxes at a<br />

time.<br />

The extractor is formed by a fork and two<br />

independently moving belts that allow<br />

them to interchangeably pick boxes from<br />

one or another side, first moving to the<br />

contrary side where you are going to make<br />

the second extraction.<br />

The conveyor system has been sized to<br />

move great quantities of boxes that may<br />

coincide with times of higher demand,<br />

while the travel speed, and mainly the stacker<br />

crane’s lifting speed, were adjusted to<br />

the characteristics of this warehouse.<br />

Miniload with conveyors inside the warehouse<br />

66 <strong>Best</strong> <strong>Practices</strong>


Case Study I MGA<br />

Interior of the stacker crane aisle<br />

Access doors to the stacker cranes<br />

Thanks to the four<br />

stacker cranes<br />

and the high number<br />

of boxes that they<br />

operate with, MGA<br />

ensures the liquidity<br />

of the flow of<br />

movements<br />

In addition, a cantilevered structure has<br />

been made above the loading and unloading<br />

stations, managing to increase<br />

capacity by 320 more boxes.<br />

In the rear, equipped with a large maintenance<br />

area, there are reference devices<br />

for the position of the stacker crane. The<br />

whole space is enclosed with mesh panels<br />

and safety doors that will individually<br />

disconnect the machines in case they are<br />

opened.<br />

Cantilevered storage levels<br />

Rear area of the warehouse<br />

<strong>Best</strong> <strong>Practices</strong><br />

67


Case Study I MGA<br />

Main picking area circuit<br />

Picking stations<br />

The enclosure where the main warehouse<br />

is located is independent of other buildings<br />

and, in particular, from the picking<br />

station, which was installed on the side of<br />

the warehouse.<br />

The picking stations, in the shape of a “U”,<br />

are located terraced perpendicularly to the<br />

main conveyors.<br />

These conveyors are comprised of a double<br />

circuit that allows both the re­circulation<br />

of boxes, as well as the connection<br />

to the warehouse and the replenishment<br />

station. Moving boxes to either of the two<br />

main conveyors is direct, thus avoiding unnecessary<br />

movements.<br />

Each station, with capacity for three boxes<br />

on hold plus the one which is being processed,<br />

is run by an operator, who in turn<br />

is able to prepare waves of six orders at the<br />

same time. To that end, there is a computer<br />

connected to the Mecalux Easy WMS<br />

(warehouse management software) and<br />

different support devices for picking. For<br />

example, put to light devices placed on top<br />

of the containers of each order, indicating<br />

to the operator which order each item<br />

corresponds to.<br />

On the pallets/containers of each order,<br />

the item location in the pallet racks has<br />

been previously introduced, that is to say,<br />

this same zone serves as an order consolidation<br />

area. In this way, fast and agile<br />

order preparation has been achieved.<br />

Control computers and picking stations<br />

Three picking stations,<br />

a replenishment station<br />

and the consolidation<br />

area were set up<br />

throughout the facility<br />

68 <strong>Best</strong> <strong>Practices</strong>


Case Study I MGA<br />

Conveyors in the picking station<br />

Put to light device<br />

Easy WMS<br />

The Mecalux Easy WMS is the nerve center<br />

that manages all the necessary functions<br />

for the general operations of any type of<br />

warehouse, regardless of its complexity.<br />

Easy WMS (Warehouse Management<br />

System) controls: all the inbound processes,<br />

the warehouse locations, stocks, location<br />

rules, storage and extraction, the<br />

pallets that have to go to picking stations,<br />

the picking itself, returns to the warehouse,<br />

etc. It is also able to analyze the<br />

state of distinct parts or areas via query<br />

and reporting tools, as well as the devices<br />

that operate in it.<br />

Easy WMS is in<br />

bidirectional and<br />

permanent connection<br />

with the customer’s<br />

SAP ERP<br />

<strong>Best</strong> <strong>Practices</strong><br />

69


Case Study I MGA<br />

Advantages for MGA<br />

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

- Increased productivity: thanks to the high level of warehouse automatization, the speed of order preparation<br />

has increased.<br />

- Perfect stock control: thanks to the Mecalux Easy WMS, the company MGA can manage all movements,<br />

processes and operations that take place within their warehouse.<br />

Technical data<br />

Storage capacity<br />

15,872 boxes<br />

Maximum weight per box 50 kg<br />

No. of stacker cranes 4<br />

Type of stacker crane<br />

double-mast<br />

Extraction system<br />

double-deep,two boxes<br />

Miniload warehouse height 12.3 m<br />

Picking stations 3<br />

Replenishment stations 1<br />

Pallet capacity<br />

1,480 pallets<br />

Maximum weight per pallet 1,000 kg<br />

70 <strong>Best</strong> <strong>Practices</strong>


Case study: Luís Simões<br />

Mecalux equips Luís Simões’ new<br />

installations in Portugal with Pallet Shuttle<br />

and conventional pallet racking<br />

Location: Portugal<br />

This warehouse, separated into<br />

two distinct areas and built under<br />

the “multi-client” concept, covers<br />

a surface area of 17,500 square<br />

metres and can supply more than<br />

33,000 pallets.<br />

Luís Simões performs all of its<br />

business-related activities from<br />

this installation, including storage<br />

and picking, mass and capillary<br />

distribution.<br />

What is Luís Simões:<br />

what are its needs?<br />

Luís Simões is a comprehensive transport<br />

and logistics services operator that began<br />

operating in 1948 in the portuguese city<br />

of Loures.<br />

The firm has operated in Spain for over<br />

25 years, and is currently the market leader<br />

in trade flows between the two countries,<br />

with a fleet of 2,000 vehicles (owned and<br />

outsourced) and over 1,500 employees.<br />

According to its storage facilities expansion<br />

and modernisation plan, the company<br />

commissioned Mecalux to equip<br />

two large, newly built sites, with almost<br />

10,000 m 2 of surface area each.<br />

Luís Simões needed to speed up the flow<br />

of incoming and outgoing pallets in the<br />

warehouse while, at the same time, increasing<br />

storage capacity. This was needed<br />

to efficiently meet the demands of both<br />

existing and potential customers.<br />

<strong>Best</strong> <strong>Practices</strong><br />

71


E<br />

E<br />

E<br />

E<br />

1<br />

E<br />

E<br />

38<br />

F<br />

F<br />

F<br />

F<br />

A<br />

A<br />

A<br />

A<br />

G<br />

G<br />

G<br />

G<br />

C<br />

C<br />

C<br />

C<br />

A<br />

A<br />

A<br />

A<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

C<br />

1<br />

45<br />

C<br />

C<br />

Case Study I Luís Simões<br />

Mecalux’s proposed solution<br />

After analysing all the operations, and Luís<br />

Simões’s needs and flows, Mecalux proposed<br />

a separate solution for each building,<br />

which are interconnected and share<br />

the same management and control centre.<br />

Moreover, the new logistics centre has<br />

34 loading and unloading docks, as well<br />

as three spacious order consolidation preloading<br />

areas.<br />

Warehouse A<br />

In Warehouse A, a semi­automatic compact<br />

Pallet Shuttle system combined with<br />

conventional racks was installed, giving<br />

rise to two distinct storage areas, each<br />

serv ed by reach trucks.<br />

Seven double and one single conventional<br />

pallet racks were installed, along with<br />

two compact racking units with the Pallet<br />

Shuttle system. They feature six load levels<br />

and the capacity to deep­store 15 pallets<br />

per level.<br />

The lower level of the conventional pallet<br />

racking was prepared to perform picking<br />

functions, because a high percentage of<br />

Luís Simões’s orders require it. Moreover,<br />

a spacious area was provided for subsequently<br />

consolidating the orders.<br />

The docks, located on either side, have their<br />

own preloading channels on the ground;<br />

these allow access to the pallets from both<br />

sides, thus optimising truck loading.<br />

Warehouse A<br />

1<br />

2<br />

The conventional pallet racking has the<br />

3<br />

capacity for 10,386 pallets, and with the<br />

Pallet Shuttle system the capacity is 5,544.<br />

4<br />

5<br />

P R OT E C Ç ÃO L AT E R AL DE B AS T IDOR<br />

P R OT E C Ç ÃO L AT E R AL DE B AS T IDOR<br />

P R OT E C Ç ÃO L AT E R AL DE B AS T IDOR<br />

P R OT E C Ç ÃO LAT E R AL DE B AS T IDOR<br />

MUR O MS M1<br />

1<br />

2<br />

3<br />

4<br />

5<br />

72 <strong>Best</strong> <strong>Practices</strong>


Case Study I Luís Simões<br />

Warehouse B<br />

Warehouse B consists of twenty rows of<br />

single­deep conventional pallet racking<br />

enabling direct access to the merchandise<br />

with maximum flexibility. The rows of<br />

rack ing, which are 130 m long, are served<br />

via 10 storage aisles along which the reach<br />

truck runs.<br />

The height layout can be seven, eight or<br />

nine levels, depending on the product to<br />

be stored and the unit load measurements,<br />

which may be Euro­pallets (800 x 1,200 mm)<br />

or US pallets (1,000 x 1,200 mm).<br />

Three transverse aisles cross the racking to<br />

facilitate the movement of operators; they<br />

can also be used as emergency es cape<br />

routes.<br />

Because of their significant length, and in<br />

order to travel the shortest possible distance<br />

during maintenance tasks, eight loading<br />

docks with their own pre­loading area<br />

were set up at both ends of the warehouse.<br />

Warehouse B’s total storage capacity is<br />

19,503 pallets.<br />

Warehouse B<br />

The combination of capacity and flexibility enables<br />

Luís Simões to offer its customers quality service<br />

and short delivery times, strengthening the firm’s<br />

position as a top provider of logistics services<br />

in the Iberian Peninsula<br />

<strong>Best</strong> <strong>Practices</strong><br />

73


Case Study I Luís Simões<br />

Conventional pallet racking<br />

This storage system, which was installed in<br />

both warehouses, has two major advantages:<br />

direct access to any pallet, and the<br />

ability to devote the lower level to picking<br />

orders.<br />

The machines used are high-lift reach<br />

trucks that can operate in a 3-metre wide<br />

aisle.<br />

The WMS (warehouse<br />

management system),<br />

an essential element<br />

in these types of<br />

warehouses, enables<br />

“chaotic” storage<br />

to be used, achieving<br />

high occupancy of all<br />

locations<br />

The last level of storage is 12 m high. To<br />

facilitate handling, avoid impacts and<br />

properly centre the pallets and/or forks,<br />

observation cameras were fitted on the<br />

upper part of the forklift.<br />

Moreover, and as a safety precaution, protectors<br />

were fitt ed on all the rack uprights<br />

facing the aisles.<br />

Conventional pallet racking<br />

74 <strong>Best</strong> <strong>Practices</strong>


Pallet Shuttle System<br />

Mass market consumer products, which<br />

have a greater number of pallets per item,<br />

are stored with this high­density storage<br />

system. The movements inside the rack are<br />

independent and follow the in structions<br />

that the operator transmits using a Wi­Fi<br />

tablet; this significantly reduc es the need<br />

for loading and unloading goods.<br />

In warehouse A, two blocks with six load<br />

levels were installed. The channels are<br />

13.2 m deep and have a unit capacity of<br />

15 pallets. The installation has 378 channels<br />

that are served by six Pallet Shuttles.<br />

Pallet Shuttle<br />

Case Study I Luís Simões<br />

Racking with the Pallet Shuttle system<br />

<strong>Best</strong> <strong>Practices</strong><br />

75


Case Study I Luís Simões<br />

The racks using Pallet Shuttle are operated<br />

as follows:<br />

1. Using the forklift, the operator introduces<br />

the Pallet Shuttle into the corresponding<br />

channel.<br />

2. With the pallet loaded, the Pallet Shuttle<br />

moves horizontally until it reaches the<br />

first free location, where it leaves the<br />

pallet.<br />

3. While the Pallet Shuttle moves and<br />

places the pallet into its location, the<br />

opera tor places another pallet in the original<br />

position in the channel.<br />

Thus, when the shuttle returns to the<br />

beginning of the lane it can successively<br />

repeat the same movement.<br />

When loading in the channel is completed,<br />

the Pallet Shuttle is moved on to the next<br />

one. Extraction is done by reversing these<br />

steps.<br />

Pallet Shuttle Racking<br />

76 <strong>Best</strong> <strong>Practices</strong>


Case Study I Luís Simões<br />

Observation camera<br />

Interface for operating the shuttle<br />

Battery charging station<br />

The program to control the Pallet Shuttle is<br />

installed on each tablet. Various functions<br />

can be performed, including:<br />

­ Selecting the Pallet Shuttle to be used.<br />

­ Automated movements.<br />

­ Manual movements for maintenance.<br />

­ Compacting or relocating pallets, bringing<br />

them closer to the exit point.<br />

­ Inventory: counts the number of pallets<br />

stored in each channel.<br />

­ User management: this funcionality<br />

manages shuttle user permissions for<br />

autho rised personnel.<br />

­ Battery charge status.<br />

The observation camera facilitates operations<br />

conducted at heights.<br />

A battery­charging station was installed<br />

that can charge the batteries of six Pallet<br />

Shuttle simultaneously. Batteries can also<br />

be charged independently of the shuttles,<br />

that is, the battery can be removed from<br />

the shuttle and replaced with a previously<br />

charged one. In this way, all the shuttles<br />

will always be operational to fulfil the orders<br />

needed.<br />

<strong>Best</strong> <strong>Practices</strong><br />

77


Case Study I Luís Simões<br />

Advantages for Luís Simões<br />

- Optimal use of space: the flexibility of conventional pallet racking and the high-density storage provided<br />

by the Pallet Shuttle enables a total capacity of 33,150 pallets.<br />

- Increased productivity: the Pallet Shuttle increases the flow of pallets per hour and allows for greater<br />

diversification by enabling items to be grouped by channel.<br />

- Strategic positioning: this new logistics platform has given an important competitive advantage to<br />

Luís Simões, positioning the firm as a leading logistics centre on the Atlantic coast and bolstering its drive<br />

towards internationalisation.<br />

Technical data<br />

Conventional pallet racking<br />

Pallet capacity 1,000 x 1,000 mm 26,000<br />

Pallet capacity 1,200 x 1,200 mm 1,600<br />

Total storage capacity<br />

27,600 pallets<br />

Maximum weight per pallet<br />

1,000 kg<br />

Maximum height of last level<br />

12.3 m<br />

Type of reach truck<br />

retractable<br />

Pallet Racking with Pallet Shuttle<br />

Pallet capacity 800 x 1,000 mm 5,550<br />

Maximum weight per pallet<br />

1,000 kg<br />

Number of channels 378<br />

Channel depth<br />

13.2 m<br />

Channel pallet capacity 15<br />

Maximum height of last level<br />

12.5 m<br />

Number of Pallet Shuttle 6<br />

Type of control<br />

wifi<br />

Number of tablets 4<br />

Type of reach truck<br />

retractable<br />

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

78 <strong>Best</strong> <strong>Practices</strong>


Case study: DHL<br />

Mecalux installs a new logistics centre<br />

for DHL on the outskirts of Madrid<br />

Location: Spain<br />

The warehouse, with a capacity<br />

for more than 90,000 pallets, has<br />

two areas allocated for palletised<br />

products. Another, formed by a<br />

two level high mezzanine floor, is<br />

earmarked for hanging garments.<br />

Its strategic location allows DHL<br />

to respond quickly to all its main<br />

customers’ stores within the Iberian<br />

Peninsula (Spain and Portugal).<br />

<strong>Best</strong> <strong>Practices</strong><br />

79


Case Study I DHL<br />

Storage of products on pallets<br />

Due to the fact that the majority of orders<br />

delivered by DHL to these stores are full<br />

boxes and they move very few pallets with<br />

a single item type, it was necessary to allocate<br />

the bottom level of the conventional<br />

pallet racks for picking activities. Reserve<br />

palletised goods are stored on higher<br />

levels.<br />

Handling equipment used to place the<br />

pallets on the racks are reach trucks.<br />

However, during order preparation, specific<br />

machines are used that have the<br />

ca pacity to transport up to two pallets at<br />

a time.<br />

80 <strong>Best</strong> <strong>Practices</strong>


Case Study I DHL<br />

Operators maximise streamlining routes<br />

inside the logistics centre thanks to<br />

the WMS (Warehouse Management<br />

Software), which divides the warehouse<br />

so that each operator is responsible for a<br />

single zone. This means that an order can<br />

be prepared by several people at the same<br />

time. Once their part of the order is finished,<br />

each operator will transfer it to one of<br />

the consolidation areas according to the<br />

assigned dock.<br />

Full use of the racks was made to install fire<br />

protection system pipelines and sprinklers.<br />

These coincide with the rack beams or girders<br />

to waste the minimum space possible.<br />

Conventional pallet<br />

racks are an ideal system<br />

to quickly replenish<br />

locations that have been<br />

left without product<br />

<strong>Best</strong> <strong>Practices</strong><br />

81


Case Study I DHL<br />

Assembly by phases<br />

Mecalux adapted to the company’s needs,<br />

thus they decided to build the warehouse<br />

in phases. So, DHL could make a tailored,<br />

gradual investment as it ran each project<br />

phase.<br />

Aisle length forced them to build intermediate<br />

passageways wide enough to<br />

give two pieces of handling equipment<br />

the ability to cross each other at the same<br />

point.<br />

Each sector of the warehouse has its own<br />

loading docks in order to avoid large displacements<br />

and significantly reduce operating<br />

costs. The warehouse is also compartmentalised<br />

for security reasons.<br />

The breadth of consolidation areas, and<br />

the laying of pre-loads on the floor just<br />

in front of their assigned dock, allows for<br />

speedy loading of transport vehicles.<br />

82 <strong>Best</strong> <strong>Practices</strong>


Case Study I DHL<br />

The total storage capacity<br />

of more than 90,000 pallets and more<br />

than 30,000 metres of profiles used<br />

to hang garments on the racks<br />

<strong>Best</strong> <strong>Practices</strong><br />

83


Case Study I DHL<br />

The garment hanging area<br />

Racks specifically for hanging garments<br />

are on the mezzanine floor and are two,<br />

fully interconnected, levels high. On each<br />

floor, a space has been left without racks<br />

to allow for the circulation and classification<br />

of garments.<br />

Thanks to the mezzanine floor, the productive<br />

surface area was multiplied, adding<br />

two extra floors that are perfectly suited to<br />

the space available.<br />

The connection of the operators with the<br />

different warehouse floors is done via a<br />

pedestrian access staircase. On the other<br />

hand, conveyors have stairs and spaces<br />

specifically for automatic access to overhead<br />

carriage that transports hanging<br />

garments.<br />

The Sigma profiles<br />

used for the mezzanine<br />

floor construction system<br />

join all the uprights in the<br />

installation, as well as<br />

attach the rails<br />

of the overhead conveyor<br />

system to the hanging<br />

garments<br />

84 <strong>Best</strong> <strong>Practices</strong>


Case Study I DHL<br />

The tubes used for hanging garments<br />

on the racks are located at an optimum<br />

height from an ergonomic point of view<br />

and, although they have bearings every<br />

2.2 m, the hangers slide and are grouped<br />

by items without producing any kind of<br />

interference.<br />

Both the fire safety system tubes, sprinklers<br />

and the warehouse lighting are attached to<br />

the structure. The overhead shuttle transportation<br />

rails that are situated in the central<br />

area of the aisles hang there upon.<br />

Spaces between<br />

pedestrian aisles<br />

are protected<br />

to avoid garments<br />

falling from one floor<br />

to another<br />

<strong>Best</strong> <strong>Practices</strong><br />

85


Case Study I DHL<br />

Advantages for DHL<br />

- Streamlining the space: the DHL warehouse is set up to store more than 90,000 pallets and more<br />

than 30,000 m of hanger profiles.<br />

- Increased productivity: the compartmentalisation of items, the breadth of consolidation areas and<br />

the location of pre-loading zones are some of the factors that help increase the volume and efficiency<br />

of the movement of goods.<br />

- Cost savings: each sector has its own loading dock, thus avoiding large displacements and notably<br />

reducing operation costs.<br />

- Efficient service: thanks to this new logistics center, DHL has met the high level of service demanded<br />

by its customers and is capable of offering fast delivery without errors in the goods sent.<br />

Technical data<br />

Conventional pallet racking<br />

Storage capacity<br />

Pallet size<br />

Maximum weight per pallet<br />

Handling equipment<br />

Order picker<br />

90,000 pallets<br />

800 x 1,200 mm<br />

1,000 x 1,200 mm<br />

1,000 kg<br />

reach truck<br />

ground floor with<br />

forks for 2 pallets<br />

Hung garment area<br />

Surface area occupied 3,000 m 2<br />

Surface area of the 3 floors 9,000 m 2<br />

Hanger profiles<br />

> 30,000 linear metres<br />

86 <strong>Best</strong> <strong>Practices</strong>


Case study: PAVI‐Groupauto<br />

Conveyor belts as the axis of a picking<br />

installation distributed over several floors<br />

Location: France<br />

PAVI‐Groupauto, a major<br />

supplier of auto spare parts from<br />

France, hired Mecalux<br />

to install the necessary equipment<br />

in its warehouse in Saint‐Priest,<br />

a town near the city of Lyon.<br />

The supply included two levels of mezzanines,<br />

racking, conveyor belts and automatic<br />

sorters, as well as the Mecalux Easy<br />

WMS warehouse management system.<br />

<strong>Best</strong> <strong>Practices</strong><br />

87


Case Study I PAVI‐Groupauto<br />

Analysing the needs<br />

The needs of PAVI-Groupauto required<br />

the construction of a warehouse capable<br />

of storing a large number of SKUs of<br />

varying dimensions and characteristics, as<br />

well as being low consumption.<br />

To do this, a storage system was needed<br />

that offered optimal use of the surface<br />

area, as well as being highly flexible and<br />

allowing direct access to any product.<br />

The main objective of the company was<br />

thus met: rapid service for its customers.<br />

Solution adopted: a conveyor circuit<br />

The need to maximise the size of the warehouse<br />

and the fact that most of the orders<br />

consist of very few units and different<br />

SKUs led Mecalux to propose and install<br />

the following solution:<br />

- Construction of a structure capable<br />

of integrating two raised floors on a<br />

2,000 m 2 area, which would allow the<br />

floor space to be tripled.<br />

- Installation, on each of the floors, of<br />

racking with different sizes and types of<br />

distribution in order to suit the different<br />

products.<br />

- Implementation of a continuous and<br />

automatic transport system connecting<br />

all the floors. This means operators can<br />

prepare orders by area, and transport<br />

them to the specific sorting and consolidation<br />

area after completion. The circuit<br />

is also used to send empty boxes from<br />

the lower level to the order preparation<br />

stations.<br />

- Replenishment of the goods directly<br />

from the receiving container to their locations.<br />

On each floor, pallet unloading<br />

docks have been installed on the other<br />

side of safety swing doors.<br />

88 <strong>Best</strong> <strong>Practices</strong>


Case Study I PAVI‐Groupauto<br />

- Swivel modules have also been located<br />

at strategic points along the transport<br />

circuit for the passage of operators.<br />

- Installation of access stairs between<br />

floors, enabling access and rapid evacuation<br />

during possible emergencies.<br />

All of this is controlled using the Mecalux<br />

Easy WMS warehouse management<br />

system.<br />

<strong>Best</strong> <strong>Practices</strong><br />

89


Case Study I PAVI‐Groupauto<br />

Ground floor<br />

The ground floor is dedicated to bulkier<br />

products with direct picking and does not<br />

require the use of conveyors.<br />

Also, the high consumption products are<br />

stored here, for which picking stations<br />

have been prepared adjacent to the conveyor<br />

belts.<br />

On the ground floor<br />

the conveyor belt<br />

borders the installation<br />

on two sides<br />

and is connected<br />

to the first floor<br />

via a ramp located<br />

on the third side<br />

90 <strong>Best</strong> <strong>Practices</strong>


Case Study I PAVI‐Groupauto<br />

1 37<br />

1200<br />

1200<br />

1200 1200<br />

1 6<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200<br />

1200<br />

1200 1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1 9<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1 12<br />

1 13<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200 1200<br />

1200 1200<br />

1 3<br />

1 3<br />

1200<br />

1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1 12<br />

1 13<br />

1200<br />

1200<br />

1200<br />

1200<br />

1 9<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200 1200<br />

1200 1200<br />

1 8<br />

1 6 1 6<br />

1200<br />

1200<br />

1200<br />

1200<br />

1 37<br />

1200<br />

1200<br />

Second and third floors<br />

The second and third floors of the PAVI-<br />

Groupauto warehouse have a very similar<br />

distribution and products of identical size<br />

are stored on both of them.<br />

1200 1200<br />

1 6<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1 9<br />

1200 1200<br />

1200 1200<br />

1 13 1 12<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200<br />

1200 1200<br />

1200 1200<br />

1 3<br />

1 3<br />

1200<br />

1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1 12<br />

1 13<br />

1200 1200<br />

1200 1200<br />

1 9<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1200 1200<br />

1 8<br />

1200 1200<br />

1200 1200<br />

1200<br />

1200<br />

In addition, the conveyor circuit on these<br />

two floors runs along the main aisle, with<br />

the order picking finishing on the top floor.<br />

<strong>Best</strong> <strong>Practices</strong><br />

91


Case Study I PAVI‐Groupauto<br />

Preparation and consolidation<br />

of orders<br />

Roller tables have been set up and attached<br />

to both sides of the conveyors on different<br />

parts of each floor in order to collect<br />

the boxes containing unfinished orders<br />

and serving at the same time as picking<br />

stations.<br />

Throughout the three floors, ten picking<br />

stations have been set up, each one corresponding<br />

to a different area or sector in the<br />

warehouse.<br />

The boxes, once the part of the order assigned<br />

to a zone has been put together or<br />

completed, are placed on the main conveyor<br />

circuit to be transferred to the stations<br />

in other areas or to the sorting area.<br />

The circuit descends along conveyor belts<br />

from the third floor to the bottom floor,<br />

where the classification and consolidation<br />

of orders is performed.<br />

In this area, the operators check, pack and<br />

draw up the packing list and the shipping<br />

labels of the orders.To complete the operation,<br />

there are packing boxes of different<br />

sizes, prep tables, computers and printers.<br />

Once the orders are<br />

completed, they are<br />

sent to the staging areas<br />

located opposite the<br />

loading docks to be sorted<br />

into dispatch routes<br />

92 <strong>Best</strong> <strong>Practices</strong>


Case Study I PAVI‐Groupauto<br />

The conveyor belts<br />

allow height differences<br />

to be overcome and<br />

movements to be<br />

carried out at different<br />

levels, while the swing<br />

conveyors allow<br />

the passage of<br />

the operators<br />

Easy WMS:<br />

Warehouse Management System<br />

The Mecalux Easy WMS (Warehouse<br />

Management System) is responsible,<br />

among other things, for managing all<br />

the incoming processes, choosing the<br />

location where the goods are received,<br />

controlling the stock, designating the<br />

picking functions to be performed by each<br />

operator, executing the movement of the<br />

boxes and sending the orders via computer<br />

terminals.<br />

The program for controlling the conveyors<br />

is connected to the WMS itself in order to<br />

ensure the efficient transport and allocation<br />

of boxes, eliminating human error and<br />

reducing PAVI-Groupauto’s personnel<br />

costs.<br />

<strong>Best</strong> <strong>Practices</strong><br />

93


Case Study I PAVI‐Groupauto<br />

Advantages for PAVI‐Groupauto<br />

‐ Excellent use of space: it was possible to increase storage capacity and triple the floor space through<br />

the construction of two raised floors.<br />

‐ Integrated warehouse: each of the parts that make up the warehouse are integrated with each other.<br />

‐ Adjustable storage needs: the distribution of the racking can be changed if the turnover rate of a product<br />

varies or if the future needs of PAVI­Groupauto so require.<br />

‐ Elimination of internal movement: as a result of the installed conveyor circuit and the optimal placement<br />

of the racking, it has been possible to eliminate part of the internal movement made by the operators.<br />

In this way productivity is increased and human errors are minimised.<br />

‐ Fast order picking: the storage system installed is highly flexible and allows the operator to have direct<br />

access to any product.<br />

‐ Efficient picking: operators can prepare orders by area using the continuous and automatic conveyor<br />

belt circuit that connects all the floors.<br />

‐ Perfect control of the stock: using the Mecalux Easy WMS, PAVI­Groupauto can manage all the flows,<br />

processes and operations that take place within its warehouse.<br />

Technical data<br />

No. of floors 3<br />

Surface area per floor 2,000 m 2<br />

Total surface area occupied 6,000 m 2<br />

Access stairs 6<br />

Conveyor length<br />

800 m<br />

Picking stations 10<br />

Automatic order sorters 4<br />

Total No. of SKUs stored 50,000<br />

94 <strong>Best</strong> <strong>Practices</strong>


Case study: Hemosa<br />

Multi-system Mecalux solution:<br />

Hemosa’s preparation centre beefs<br />

up automation<br />

Location: Spain<br />

Hemosa, a company specialised in the supply of fresh meats and pork-based<br />

products, has entrusted Mecalux to fit out its new warehouse with the latest<br />

automation technologies and computerisation of its manufacturing processes.<br />

For this reason, and with the objective of offering maximum quality products,<br />

they have installed various storage systems ranging from an automated<br />

warehouse with Pallet Shuttle and stacker cranes to drive-in<br />

and live pallet rackings.<br />

<strong>Best</strong> <strong>Practices</strong><br />

95


Case Study I Hemosa<br />

Automated warehouse with Pallet<br />

Shuttle: finished products<br />

The Pallet Shuttle system is a version of<br />

compact solutions that offers maximum<br />

storage capacity, with the added advantage<br />

of having load channels with variable<br />

depths. Pallets are transported internally<br />

through the channels using autonomous<br />

shuttles, hence the system name.<br />

A totally automated version of Pallet Shuttle<br />

has been installed which uses a stacker crane as its<br />

transport equipment that lends to great speed<br />

and efficient stock control<br />

The version installed in the Hemosa warehouse<br />

is totally automatic and uses stacker<br />

cranes as its primary transport equipment<br />

between warehouse entry/exits and channel<br />

locations, lending to great speed and<br />

efficient control of both stock and operations<br />

done. The total capacity of this warehouse<br />

is 1,050 pallets, 1,200 x 1,200 mm<br />

in size with a maximum weight of 700 kg.<br />

The Mecalux Easy WMS is a system which<br />

manages all operational basis in a warehouse;<br />

starting with entry, next placement<br />

based on parametrizable criteria and ending<br />

with subsequent dispatch.<br />

Pallet Shuttle<br />

Stacker crane<br />

96 <strong>Best</strong> <strong>Practices</strong>


The Pallet Shuttle is housed on the cradle<br />

of the stacker crane in a position, slightly<br />

inferior to the pallet support level; said<br />

level is made up of two motorized chains<br />

which pick up and drop off the pallet in<br />

the entry/exit positions. When the stacker<br />

crane is positioned in front of the assigned<br />

location, the shuttle raises with the pallet<br />

on it and introduces it into the channel.<br />

It is placed on top of the support rail in<br />

the available location furthest from the<br />

aisle. The profile is also prepared to make<br />

movements guided by the Pallet Shuttle.<br />

Extractions are done in inverted order.<br />

The Pallet Shuttle is autonomous and<br />

charg es its battery in the cradle of<br />

the stacker crane in an automatic and<br />

straightforward manner. Each shuttle has<br />

eight wheels which provide the correct<br />

distribution of the weight upon the profile<br />

and which help it move smoothly from the<br />

stacker crane into the channels. On each<br />

side of the aisle, rails allow centering elements<br />

to facilitate the movement of the<br />

shuttle.<br />

Case Study I Hemosa<br />

In the warehouse the following elements<br />

have been installed:<br />

- Racks<br />

- Stacker cranes<br />

- Pallet Shuttles<br />

- Entry conveyors<br />

- Exit conveyors<br />

This image represents<br />

a solution similar to the<br />

one used in the Hemosa<br />

installation.<br />

<strong>Best</strong> <strong>Practices</strong><br />

97


Case Study I Hemosa<br />

Pallet entry and exit<br />

Two entry and one exit doors have been<br />

enabled. In each of these, a conveyor is<br />

entrusted to pick up and drop off pallets in<br />

the position which coincides with the aisle<br />

where the stacker crane circulates.<br />

Moreover, the doors are protected by<br />

rapid action vertical curtains that only<br />

open via a signal sent by the Easy WMS<br />

when the pallet passes through, avoiding<br />

changes in the internal temperature of the<br />

cold-storage.<br />

When the stacker crane is positioned in<br />

front of the conveyor, it sends a signal both<br />

to the corresponding conveyor, as well as<br />

to the one it carries in the cradle, in order<br />

to act in unison and move the pallet from<br />

one to another. It also emits a signal to the<br />

same Pallet Shuttle when it is positioned<br />

in front of the channel where it must perform,<br />

ordering its displacement and the<br />

operation to be done.<br />

The two located profiles on both sides of<br />

the channel are shaped to allow for double<br />

supporting functions both to the pallets<br />

and the guide rail, ensuring that the<br />

shut tle moves along safely.<br />

From the moment the operator drops off<br />

the pallet in one of the entry points and<br />

the system is indicated which reference it<br />

contains, Easy WMS takes over control of<br />

it and its internal management.<br />

The warehouse is a cold storage unit with<br />

temperatures kept slightly above 0 ºC, which conserves<br />

products deposited there in optimal condition<br />

98 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hemosa<br />

<strong>Best</strong> <strong>Practices</strong><br />

99


Case Study I Hemosa<br />

Live Pallet Racking:<br />

semi-prepared fresh products<br />

This type of racking, as well as the Pallet<br />

Shuttle, is incorporated within the compact<br />

storage systems and also maximises<br />

space. The peculiarity of this warehouse<br />

is that it is composed of storage channels<br />

with a slight incline. Each channel has rollers<br />

on which the pallet, introduced into<br />

the more inclined side, moves along via<br />

gravity until the first position on the con­<br />

trary side. The velocity of pallet movements<br />

of is controlled via roller brakes.<br />

Choosing said storage solution has to do<br />

with the type of products stored. Racks<br />

used for pallets with semi-prepared fresh<br />

products that need a perfect product<br />

turn over (FIFO). In order to achieve efficient<br />

turnover, live pallet racking is ideal<br />

be cause the first pallet to enter the channel<br />

is the first to leave.<br />

Live pallet racking,<br />

which is 5.5 m in height,<br />

has the capacity to store<br />

188 pallets, 800 x<br />

1,200 mm in size and<br />

weighing a maximum<br />

of 600 kg<br />

100 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hemosa<br />

Drive-in system: semi-prepared<br />

frozen products<br />

Racks are put together having internal<br />

lanes of variable depth, in which forklifts<br />

enter with pallets raised to the corresponding<br />

height. At each level and on both<br />

sides, profiles are ready to support the<br />

pallets.<br />

Moreover, conventional pallet racking has<br />

been supplied to store other small volume<br />

products for internal consumption.<br />

The system installed in Hemosa is meant<br />

to store pallets of semi-prepared frozen products<br />

and large volume consumables, like packaging<br />

Easy WMS<br />

This is a powerful, tried and true warehouse<br />

management system developed<br />

by Mecalux. It controls all internal operational<br />

basis in any warehouse, from reception<br />

to verification and location assigned<br />

within the warehouse, picking functions<br />

and final dispatch based on rules and parametrizable<br />

criteria.<br />

In the case of Hemosa and in regards to the<br />

automated warehouse, the execution of<br />

movements is ordered via the Galileo control<br />

module. This software takes charge of<br />

controlling all actions which must be done<br />

by each moving device.<br />

The connection with ERP SAP or the general<br />

management system of Hemosa is permanent<br />

and bi-directional, exchanging information<br />

and instructions that permit the<br />

total control of all operations done.<br />

<strong>Best</strong> <strong>Practices</strong> 101


Case Study I Hemosa<br />

Advantages for Hemosa<br />

- High-density storage: the storage capacity demanded by Hemosa has been achieved thanks to a<br />

combination of distinct systems installed.<br />

- A place for each product: a storage solution has been enabled which best adapts to the characteristics<br />

and needs of each product that Hemosa works with, attaining perfect turnover and increased<br />

productivity.<br />

- Total control of the automated warehouse: Easy WMS from Mecalux controls all processes and<br />

operations that take place within a warehouse, from the moment the product leaves the packaging<br />

line, up until dispatch.<br />

Technical data<br />

Automated warehouse<br />

Storage capacity<br />

1,050 pallets<br />

Maximum weight per pallet 700 kg<br />

Warehouse height<br />

10 m<br />

No. of stacker cranes 1<br />

Type of stacker crane<br />

single mast + Pallet Shuttle<br />

Constructive system<br />

Pallet Shuttle – traditional<br />

construction<br />

Live pallet racking<br />

Storage capacity<br />

Maximum pallet weight<br />

Channel depth<br />

Maximum height<br />

Drive­in pallet racking<br />

Storage capacity<br />

Maximum pallet weight<br />

Maximum lane depth<br />

Maximum height<br />

188 pallets<br />

600 kg<br />

6.2 m<br />

5.5 m<br />

426 pallets<br />

1,000 kg<br />

5 m<br />

6.8 m<br />

102 <strong>Best</strong> <strong>Practices</strong>


Case study: Zbyszko Company<br />

A high profit automated warehouse:<br />

200 pallets/hour and 18,000 pallets stored<br />

Location: Poland<br />

Aiming to keep pace with its growing<br />

business, the company Zbyszko<br />

wanted to expand the capacity and<br />

agility of their warehouse in addition<br />

to integrating their production and<br />

storage processes. In order to meet<br />

this demand, Mecalux built them an<br />

automated warehouse connected to<br />

the production plant via a 100 m long<br />

overpass equipped with conveyors.<br />

All this is coordinated and controlled<br />

by the warehouse management<br />

system Mecalux Easy WMS software.<br />

<strong>Best</strong> <strong>Practices</strong> 103


Case Study I Zbyszko<br />

Zbyszko Company<br />

and their needs<br />

Zbyszko Company, a company specialised<br />

in the production of carbonated drinks,<br />

soft drinks and flavoured waters, was<br />

creat ed by Zbigniew Bojanowicz in 1993 in<br />

the Polish city of Białobrzegi.<br />

In just 10 years, the Zbyszko Company has<br />

experienced spectacular growth that has<br />

made it one of the most successful Polish<br />

manufacturers within the natural beverages<br />

market.<br />

In the face of its incessant headway,<br />

Zbyszko Company has relied on Mecalux<br />

to provide it with a new storage centre to<br />

centralise all the company’s logistical activities<br />

and which is equipped with the<br />

newest, most innovative technologies in<br />

order to deal with high production rates<br />

and save on logistics costs. Present and future<br />

growth demand it.<br />

Speeding up internal transport was also a<br />

crucial prerequisite of the project, creating<br />

a direct connection between the warehouse<br />

and the production area. This was<br />

done via maximum automation of the storage<br />

processes in order to increase Zbyszko<br />

Company’s market competitiveness.<br />

The Zbyszko Company hired<br />

Mecalux to construct its newest warehouse<br />

located in the Polish city of Radom<br />

104 <strong>Best</strong> <strong>Practices</strong>


Connecting the production area<br />

and the warehouse<br />

Mecalux has set up an automated warehouse<br />

that connects the production area<br />

via a 100 m long overpass through which<br />

already palletised goods circulate on a circuit<br />

of roller conveyors.<br />

The checkpoint, located at the beginning<br />

of the circuit and within the same production<br />

area, verifies that the dimensions and<br />

the quality of each pallet are appropriate.<br />

The conveyors have two lines – one in each<br />

direction – working independently despite<br />

being placed in parallel.<br />

Inside the warehouse two levels of conveyors<br />

are arranged. The upper level is allocated<br />

to the input of goods, while the lower<br />

level has been reserved for outputs.<br />

There is also the possibility that outside<br />

goods, destined for the warehouse or the<br />

production area, can enter at this level. Not<br />

to mix operations, they have set up a conveyor<br />

just above the docks for inputs into<br />

the warehouse, with a lift placed at the end<br />

that raises the pallets to the upper level.<br />

On the ground floor, so that throughput is<br />

as high as possible, a circuit of electrified<br />

monorails capable of transporting SKUs<br />

at more than 100 m/min – and which links<br />

the warehouse with the preload area – was<br />

installed.<br />

This system is ideal for connecting distant<br />

points of the installation at a steady pace,<br />

eliminating unnecessary movements between<br />

rack areas.<br />

Case Study I Zbyszko<br />

The Zbyszko Company<br />

warehouse is connected<br />

with the production<br />

area via a 100 m long<br />

overpass fitted with<br />

roller conveyors<br />

<strong>Best</strong> <strong>Practices</strong> 105


Case Study I Zbyszko<br />

Inside the warehouse<br />

The warehouse occupies a 7,000 m 2 surface<br />

area and is built in a facility only 11 m<br />

high.<br />

The installation of stacker cranes makes it<br />

possible to warehouse up to 18,000 pallets<br />

despite this limited height.<br />

Having few SKUs, they chose to place<br />

double­depth racks, a very common method<br />

in automated logistics centres that<br />

require a large storage capacity.<br />

The racks are served by eleven, fully automated<br />

stacker cranes, which move quickly<br />

along their respective aisles handling<br />

pallets weighing up to 1,000 kg each.<br />

Level 5 metres high<br />

Overpass<br />

106 <strong>Best</strong> <strong>Practices</strong>


Case Study I Zbyszko<br />

The seven stacker<br />

cranes that are located<br />

in the middle zone<br />

are 11 m high,<br />

while the remaining<br />

four left at either<br />

end of the warehouse<br />

have been retrofitted<br />

to the shape of the<br />

building, with a height<br />

of 9 m<br />

Ground floor<br />

<strong>Best</strong> <strong>Practices</strong> 107


Case Study I Zbyszko<br />

Dispatches<br />

The stacker cranes are responsible for automatically<br />

extracting stored goods from<br />

the production area and bringing them to<br />

the corresponding output conveyor. Once<br />

on the conveyor, the electrified monorails<br />

directed each pallet to their assigned preload<br />

area.<br />

1<br />

There are numerous options for creating<br />

an electrified monorail circuit. In Zbyszko<br />

Company’s case it was decided that a simple<br />

loop circuit, operated by 21 individually<br />

controlled shuttles, was the most costeffective,<br />

seamless solution.<br />

The software that controls the machines<br />

is connected with the WMS (Warehouse<br />

Management Software) throughout the<br />

warehouse, and to the customer’s ERP.<br />

The image on the right is differentiated into<br />

the following areas:<br />

­ Warehouse<br />

­ Inputs into the upper level<br />

­ Electrified monorails<br />

­ Preloads area<br />

­ Input conveyors from the docks<br />

3<br />

The pallets are loaded<br />

onto the shuttles<br />

on one side of the circuit<br />

and are unloaded<br />

in the consolidation<br />

area located<br />

on the opposite side<br />

Input conveyor on upper floor<br />

Shuttle depositing goods in preloads<br />

108 <strong>Best</strong> <strong>Practices</strong>


Case Study I Zbyszko<br />

2<br />

5<br />

4<br />

Warehouse Management System:<br />

Mecalux EASY WMS<br />

Zbyszko Company uses the warehouse<br />

management system Mecalux Easy WMS<br />

to check each and every one of the movements<br />

that takes place in the logistics centre,<br />

and thus efficiently manage their storage<br />

space.<br />

Easy WMS communicates with the<br />

customer’s ERP SAP in order to be able to<br />

carry out the dispatch, reception, distribution,<br />

transfer processes, and other tasks<br />

related to the logistics centre.<br />

This powerful system ensures the proper<br />

operation of the machines that are used in<br />

the automation of the warehouses, which<br />

simplifies transportation, eliminates human<br />

errors and reduces staffing costs.<br />

Overpass between production and the warehouse<br />

<strong>Best</strong> <strong>Practices</strong> 109


Case Study I Zbyszko<br />

Advantages for Zbyszko Company<br />

- Maximum space utilisation: the warehouse, only 11 m high, has an 18,000 pallet storage capacity in<br />

a 7,000 m 2 surface area.<br />

- Cost savings: the overpass that connects the warehouse to the production area allows Zbyszko to<br />

save in logistical costs.<br />

- Increased productivity: order preparation is fast and efficient thanks to the speed of the stacker cranes,<br />

the conveyor circuits and the electrified monorails installed, which can <strong>issue</strong> up to 200 pallets/hour.<br />

Technical data<br />

Storage capacity<br />

18,000 pallets<br />

Maximum weight per pallet<br />

1,000 kg<br />

Height of the warehouse<br />

11 m<br />

Warehouse surface area 7,000 m 2<br />

No. of stacker cranes 11<br />

Fork type<br />

double-depth<br />

No. of shuttles on the electrified monorails 21<br />

Length of the overpass<br />

100 m<br />

110 <strong>Best</strong> <strong>Practices</strong>


Case study: DAFSA<br />

A single warehouse in choice surroundings<br />

Location: Spain<br />

Mecalux builds DAFSA an automated<br />

clad-rack warehouse, in the scenic<br />

countryside near Valencia, whose<br />

outer finish was carefully made<br />

to be environmentally friendly. The<br />

new warehouse, with a capacity for<br />

more than 23,000 pallets, is integrated<br />

with production outputs via a two<br />

level overpass. Mecalux Easy WMS<br />

(Warehouse Management System)<br />

was supplied, which is responsible for<br />

managing all the warehouse processes.<br />

<strong>Best</strong> <strong>Practices</strong> 111


Case Study I DAFSA<br />

Who is DAFSA?<br />

DAFSA, manufacturer of juices, vegetable<br />

purees and horchata, was established<br />

in 2006 as an exclusive provider to<br />

Mercadona, Spain’s top supermarket.<br />

Strong growth experienced in recent years<br />

has made DAFSA one of the most active<br />

companies within its sector. They turn on<br />

more than 250 million litres a year.<br />

In 2014, with the start­up of the new production<br />

plant in Segorbe (Castellón), that<br />

has a 66,000 m 2 total surface area, it became<br />

their sector’s most advanced and<br />

sustainable production, processing and<br />

packaging factory in Europe. Within the<br />

premises, is the most noteworthy automated<br />

warehouse built by Mecalux.<br />

The collaboration between the two companies<br />

dates back to DAFSA’s beginnings.<br />

Since then, Mecalux has built different<br />

warehouse solutions adapted to the<br />

company’s ever changing needs.<br />

Current warehouse<br />

of DAFSA and the area<br />

reseved for future<br />

expansion.<br />

112 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

DAFSA has a reserved<br />

space with which they<br />

can double current<br />

storage capacity<br />

A clad-rack warehouse:<br />

today and beyond<br />

The attached picture shows the design<br />

of the warehouse installed and the space<br />

reserved for future growth, which is intended<br />

to multiply storage capacity up to<br />

40,000 pallets if needed.<br />

In a clad-rack warehouse like this, the racks<br />

are the building’s structure and the wall<br />

and roof cladding is placed on them. In<br />

addition to the building’s own weight, the<br />

racks must bear the pallets stored and the<br />

external forces indicated by regulations, including<br />

wind.<br />

<strong>Best</strong> <strong>Practices</strong> 113


Case Study I DAFSA<br />

The warehouse is 39 m high, 31 m wide<br />

and 102 m long and has four storage aisles.<br />

One of these aisles was isolated from the<br />

rest in order to store refrigerated products.<br />

To achieve this, a specific type of construction<br />

was required aimed at integrating the<br />

aisle into the same facility, but without having<br />

to install components that act as coldbridging.<br />

The equipment supplied by Mecalux and<br />

the warehouse management system Easy<br />

WMS is responsible for palletised product<br />

movement at the end of production lines,<br />

achieving total integration between the<br />

factory and the warehouse. This minimises<br />

the human intervention needed to move<br />

the goods between different areas.<br />

Thanks to<br />

the warehouse design,<br />

the second phase<br />

could be built without<br />

interrupting DAFSA’s<br />

production or installation<br />

operations<br />

114 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

<strong>Best</strong> <strong>Practices</strong> 115


Case Study I DAFSA<br />

Entrance into the warehouse:<br />

upper level<br />

The warehouse, located on one side of the<br />

plant, is linked to production output via a<br />

two level overpass, leaving the middle area<br />

for future growth.<br />

So pallets could enter the warehouse, elevators<br />

were enabled at the overpass’ end<br />

that raise the load to the top level. Then<br />

a circuit of automatic conveyors is responsible<br />

for transferring pallets up to the<br />

stor age aisle allocated by the Easy WMS<br />

(Warehouse Management Software).<br />

Various checkpoints and set ups ensure<br />

the size and excellent condition of the pallets<br />

coming into the warehouse. Quality<br />

control is essential, since 1,200 x 800 mm<br />

sized euro-pallets and medium sized 600 x<br />

800 mm pallets are deposited in the same<br />

warehouse.<br />

An entry point was provided, which is served by forklifts<br />

for products from other plants<br />

116 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

<strong>Best</strong> <strong>Practices</strong> 117


Case Study I DAFSA<br />

Inside the warehouse<br />

High platforms were installed that coincide<br />

with the overpass’ top level, on top of<br />

which the aisle input conveyors are placed.<br />

The warehouse is composed of four aisles<br />

where stacker cranes circulate. These are<br />

responsible for making movements between<br />

locations and the conveyors for the<br />

input and output of pallets. As mentioned<br />

previously, one of the aisles was isolated<br />

from the rest in order to store refrigerated<br />

products.<br />

Racks, double in depth, were readied on<br />

both sides of the aisles, with 16 storage<br />

levels adapted to store the two pallet formats<br />

which DAFSA uses.<br />

The refrigeration equipment, fire protection<br />

systems, the stacker cranes’ upper<br />

guides and the rest of internal equipment<br />

are supported and attached to the<br />

racks themselves forming an integral part<br />

thereof.<br />

118 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

The stacker cranes are twin­mast in nature<br />

and incorporate a mounted booth to facilitate<br />

maintenance work, as shown in the<br />

photo below and to the right.<br />

The installation is distributed in the following<br />

areas identified in the layout:<br />

1. Ambient temperature warehouse<br />

2. Cold storage aisle<br />

3. Connection overpass<br />

4. Entries from production<br />

5. Preloads deliveries<br />

6. Future expansion of the warehouse<br />

The warehouse’s capacity<br />

is for more than<br />

23,000 pallets,<br />

1,200 x 800 mm in size,<br />

1,700 mm high and<br />

weighing 1,050 kg each.<br />

If all the pallets were<br />

600 x 800 mm sized, the<br />

storage capacity would<br />

increase to more than<br />

46,000 pallets<br />

<strong>Best</strong> <strong>Practices</strong> 119


Case Study I DAFSA<br />

Pallet output: lower level<br />

Even though the overpass’ top level was intended<br />

for inputs only, on the lower level<br />

outputs coexist with inputs, allowing for<br />

duplicate flow of inputs.<br />

The main circuit, located on the overpass’<br />

lower floor, has dual conveyor strands to<br />

perform pallet input and output tasks.<br />

In bottom photo, of the overpass, you can<br />

see the access point to an ambient temperature<br />

aisle, followed by vertical access<br />

doors to the cold storage aisle.<br />

The main circuit of conveyors on the lower<br />

floor is connected via three doors with the<br />

conveyor circuit in the dispatch area, located<br />

in an adjoining building.<br />

Once there, two shuttles are tasked with<br />

depositing the pallets in one of the pallet<br />

flow channels available on the ground<br />

level.<br />

On the overpasses’ lower level is the consolidation area of the warehouse,<br />

where outputs and inputs exist side by side<br />

120 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

<strong>Best</strong> <strong>Practices</strong> 121


Case Study I DAFSA<br />

Deliveries<br />

Deliveries are also segmented depending<br />

on the product. Thereby, the part reserved<br />

for refrigerated products is built in a closed<br />

area that has a double preload capacity<br />

and vertical roll-up doors that automatically<br />

open for pallets to be deposited into the<br />

live channels.<br />

In all, seven preload groups and a quick exit<br />

have been provided. Each group consists<br />

of three live channels with a pallet capacity<br />

of 11 each. Between them the three full<br />

loads, 33 pallets in all, fill a lorry.<br />

The channels are prepared for the pallets,<br />

whose extraction is handled via electric<br />

pallet trucks.<br />

Preload outputs coincide with the lorry<br />

loading docks, as illustrated by the photographs<br />

on this two-page spread.<br />

A shuttle is<br />

responsible for<br />

connecting the output<br />

stations with different<br />

order consolidation<br />

channels<br />

122 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

<strong>Best</strong> <strong>Practices</strong> 123


Case Study I DAFSA<br />

Different pallets, different solutions<br />

The installation is outfitted to receive 800 x<br />

1,200 mm sized euro-pallets and medium<br />

800 x 600 mm sized pallets.<br />

The use of medium sized pallets is very frequent<br />

in the distribution sector, especially<br />

for high consumption products, because<br />

they go directly from production to linear<br />

supermarket shelves, avoiding interim<br />

handling.<br />

The facility was<br />

set up to handle and<br />

store medium sized<br />

pallets since the<br />

percentage, compared<br />

to euro-pallets, is<br />

higher<br />

800 x 600 mm medium pallet<br />

800 x 1,200 mm Euro-pallet<br />

To store 800 x 1,200 mm sized pallets of<br />

indiscriminate depth with the utmost security,<br />

cross-ties were put in the racks, as<br />

shown in the picture below on the right.<br />

The conveyors were also adapted for medium<br />

sized pallets. In the rollers, the separation<br />

between them is less than usual,<br />

while in the chain conveyors four strands<br />

are available. Furthermore, and in order<br />

to avoid confusion, checkpoints help to<br />

differ entiate the two pallet types.<br />

124 <strong>Best</strong> <strong>Practices</strong>


Case Study I DAFSA<br />

Easy WMS<br />

Easy WMS is the nerve centre that governs<br />

all operations from production outputs<br />

to their dispatch. This powerful warehouse<br />

management system developed by<br />

Mecalux performs, among others, these<br />

roles:<br />

- Management of the input of goods<br />

from production lines.<br />

- Pallet location in the warehouse using<br />

previously parameterised rules, according<br />

to the following criteria: product<br />

type, space optimisation and maximum<br />

productivity.<br />

- Stock management and the warehouse’s<br />

layout (what and where the goods<br />

are). Outputs to deliveries by batch<br />

and via FIFO criteria.<br />

- Preload fulfilment according to the order<br />

requested and subsequently loading<br />

the trucks.<br />

- Query the status of various parts of the<br />

warehouse and the machines that operate<br />

in them.<br />

Thanks to the Galileo control module, all<br />

movements of the different equipment<br />

that the installation is comprised of, as<br />

well as its safety measures, are managed.<br />

The communication between Easy WMS<br />

(Warehouse Management System) and<br />

the customer’s ERP is permanent and bidirectional,<br />

transferring the data both systems<br />

need to operate and to effectively<br />

manage the warehouse.<br />

<strong>Best</strong> <strong>Practices</strong> 125


Case Study I DAFSA<br />

Advantages for DAFSA<br />

- Enhanced storage capacity: the DAFSA warehouse has a capacity of more than 23,000 pallets,<br />

800 x 1200 mm in size. The facility has a space purposed for future expansion, which allows storage<br />

capacity to be multiplied up to 40,000 pallets.<br />

- Overall appearance: construction of a modern, high technology logistics centre, but at the same<br />

time integrated into the countryside in which it is located.<br />

- Increased logistical efficiency: DAFSA has improved its logistical efficiency thanks to the<br />

automation of in­house movements and the connection with production outputs.<br />

- Complete control: the Mecalux Easy MWS software manages all movements, processes and<br />

operations that take place inside the warehouse.<br />

Technical data<br />

Storage capacity<br />

23,232 pallets<br />

Maximum weight per pallet 1,050 kg<br />

Height of the warehouse 39 m<br />

Type of stacker cranes<br />

Double-deep, twin-mast<br />

No. of stacker cranes 4<br />

No. of shuttles 2<br />

Preload channels 21<br />

Capacity per channel 11<br />

Construction system<br />

Self-supporting<br />

126 <strong>Best</strong> <strong>Practices</strong>


Case study: Havi Logistics<br />

Mobile racks for continued growth<br />

at Havi Logistics<br />

Location: Italy<br />

Since its creation in Germany in<br />

1981 as a small family business, Havi<br />

Logistics has expanded its market to<br />

become one of the leading suppliers<br />

of integrated logistics services, with<br />

48 distribution centres in Europe<br />

and more than 5,000 employees. Its<br />

customers range from restaurant<br />

chains like McDonald’s to BP service<br />

station kiosks. The company is<br />

growing so fast that it has had to<br />

expand its facility in Lodi, Italy, and it<br />

has entrusted this project to Mecalux.<br />

Minding the essentials<br />

Havi’s logistics centre in Lodi, Italy, was<br />

opened in 2009 with a capacity for 4,566<br />

pallets. Given the company’s continuous<br />

growth and expanding customer base –<br />

and therefore the number of products to<br />

be stored and distributed – it quickly outgrew<br />

the facility. There was thus a clear<br />

need: to multiply the useful storage space<br />

by expanding the 4,870 m 2 available in the<br />

original warehouse.<br />

Furthermore, the characteristics of Havi<br />

Logistics’s activity had to be considered.<br />

Havi manages the supply chain for perishable<br />

and non-perishable products for a<br />

wide range of customers: frozen goods,<br />

fruits and vegetables, meat, dairy produce<br />

and cleaning products, amongst others.<br />

This made it necessary to conserve storage<br />

and handling areas with four different<br />

temperature ranges, with a particular focus<br />

on preserving the cold chain throughout<br />

the entire process to ensure optimal<br />

safety and conservation of the food that<br />

Havi stores and distributes daily.<br />

This project began with a very clear need:<br />

to reduce storage costs, especially in<br />

order to accommodate new customers.<br />

The result has been the combination of<br />

conventional pallet racks with mobile racking.<br />

By combining these two kinds of<br />

racks the size of the building needed to<br />

work with a given volume of pallets can be<br />

reduced.<br />

<strong>Best</strong> <strong>Practices</strong> 127


Case study I Havi Logistics<br />

The answer<br />

Mecalux’s technical team calculated the<br />

facility’s expansion and remodelling down<br />

to the tiniest detail. Since the customer’s<br />

priority was to multiply its storage capacity<br />

the Movirack mobile racks stole the<br />

show. These racks boast optimal performance<br />

at all temperatures. The immediate<br />

result was to expand from the original storage<br />

capacity of 4,566 pallets to the current<br />

capacity of 12,500 pallets, enlarging<br />

4,870 m 2 of surface area to 10,000 m 2 .<br />

As required by the customer, the four distinct<br />

zones with different temperatures at<br />

the Havi Logistics centre in Lodi were conserved,<br />

but the layout of each one was<br />

changed by implementing various storage<br />

solutions tailored to the specifications of<br />

the different products:<br />

- Dry or ambient temperature zone:<br />

370 linear metres of Movirack mobile<br />

racks were installed in this zone to a<br />

height of 9 metres. This system eliminates<br />

unnecessary storage aisles, as<br />

the operator selects the aisle that he or<br />

she needs to use, whether manually or<br />

by remote control, and the mobile racks<br />

move laterally on rails embedded in the<br />

floor. This leaves the space required for<br />

loading, unloading or picking access on<br />

the selected racks. Push-back racks for<br />

accumulative storage and conventional<br />

pallet racking were also installed. In this<br />

way, high occupancy was achieved and<br />

goods handling time was reduced.<br />

- Refrigerated zone: Movirack mobile<br />

racks combined with Push-back racks<br />

were installed here as well. This system<br />

allows four pallets per level to be placed<br />

in deep storage and uses the LIFO load<br />

management method (the last pallet<br />

in is the first out). The combination of<br />

both systems saves a significant amount<br />

of space and achieves high storage density<br />

while speeding the picking and replenishment<br />

of goods, which is essential<br />

in fresh food supply.<br />

- Freezing zone: in the cold storage area<br />

the Movirack mobile racks make it possible<br />

to reduce the volume that must<br />

be stored at low temperatures, thereby<br />

saving energy. Roller and trolley pushback<br />

racks and drive-in pallet racks were<br />

installed to round off this area.<br />

- Cool dock zone: this is a lengthwise<br />

loading and unloading zone linking<br />

the three storage areas described. Its<br />

function is to allow the goods to be handled<br />

without breaking the cold chain,<br />

which is kept at a temperature between<br />

1 and 4 degrees. This mode ensures that<br />

all products reach their destination in<br />

perfect condition.<br />

- Picking area without capacity loss:<br />

in this area there is a mix of conventional<br />

pallet racks, located on the sides,<br />

with Moviracks placed inside. The mobility<br />

and accessibility that the Movirack<br />

system offers frees up a wide aisle so that<br />

a forklift working with pallets can enter.<br />

It also opens all aisles so that operators<br />

carry out picking. Thereby, the area is set<br />

up to function both with pallets or smaller<br />

products that require picking.<br />

Mecalux has<br />

implemented a<br />

made-to-measure project<br />

that has allowed the<br />

Havi Logistics group<br />

to double the useful<br />

storage space and reap<br />

the benefits of a Movirack<br />

system on mobile bases<br />

128 <strong>Best</strong> <strong>Practices</strong>


Case study I Havi Logistics<br />

Push-back system with shuttles<br />

Push-back system with rollers<br />

Conventional pallet racking<br />

Movirack Mobile pallet racking<br />

Drive-in pallet racks<br />

<strong>Best</strong> <strong>Practices</strong><br />

129


Case study I Havi Logistics<br />

A<br />

B<br />

The first diagram (A) shows the solution where<br />

only one aisle is freed up to operate with a forklift.<br />

In the second (B), this option displays when<br />

two aisles are opened up to do picking.<br />

Advantages for Havi Logistics<br />

- Increased storage capacity: the Havi Logistics warehouse has almost tripled the storage capacity,<br />

from 4,566 pallets to 12,500 pallets, doubling the surface area from 4,870 m 2 to 10,000 m 2<br />

- Profitable model: the distribution centre Havi Logistics has in Lodi has become a model of profitability<br />

and efficiency that will allow the company to manage future growth in a flexible manner.<br />

- Cost savings: with the remodelling and expansion of this installation, logistics costs have been<br />

reduced without affecting the service quality of the company and maintaining a high level of<br />

productivity.<br />

Technical data<br />

Storage capacity<br />

12,500 pallets<br />

Length of the warehouse 152 m<br />

Width of the warehouse 62,5 m<br />

Height of the warehouse 12 m<br />

No. of racks 60<br />

No. of aisles 33<br />

No. of load levels 3, 4 and 5<br />

No. of Movirack mobile racks 12 double<br />

No. of push-back racks 9<br />

No. of drive-in racks 3<br />

No. of fixed conventional racks 20<br />

Pallet size<br />

800 x 1,200 x 1,650 / 2,300 mm<br />

Maximum weight per pallet<br />

1,000 kg<br />

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

130 <strong>Best</strong> <strong>Practices</strong>


Case study: Hepco Motion<br />

Mecalux installs a special mobile cantilever<br />

rack solution for metallic profiles<br />

Location: United Kingdom<br />

Hepco Motion, a world leader in<br />

the field of linear motion systems,<br />

has expanded its storage facility in<br />

Tiverton (Devon), with the aim of<br />

expanding their production growth<br />

and cutting down order fulfillment<br />

and delivery times. To optimize<br />

their warehouse capacity they put<br />

their trust in Mecalux, who installed<br />

cantilever racks on Movirack mobile<br />

bases for them.<br />

<strong>Best</strong> <strong>Practices</strong> 131


Case Study I Hepco Motion<br />

The needs of the customer<br />

Hepco Motion, a British company that is<br />

part of the Hepco business group, has branches<br />

and accredited distributors throughout<br />

the world and more than 40 years of<br />

experience. The company offers a wide<br />

range of products that are constantly being<br />

updated to meet the demands of their<br />

customers within the automation and<br />

other industrial sectors, offering all kinds<br />

of innovative linear move ment solutions.<br />

Due to their continued growth rate, Hepco<br />

has recently launched an expansion of<br />

its production and storage facility headquarters<br />

in Tiverton, UK.<br />

Given that the old warehouse was used<br />

to expand production area, storage processes<br />

were moved to a new premises adjacent<br />

to the factory. In other words, the<br />

main goal put forward by Hepco Motion<br />

has been to optimise this new space, which<br />

is 53 m x 13.5 m x 6.5 m in size.<br />

Given product<br />

characteristics and<br />

the need to maximise<br />

storage capacity,<br />

the solution proposed<br />

by the Mecalux<br />

delegation in the UK<br />

(located in Birmingham)<br />

was to install cantilever<br />

racks on Movirack<br />

mobile bases<br />

The company entrusted Mecalux with the<br />

development and implementation of this<br />

storage project, so in addition to sorting<br />

out space requirements, it also took into<br />

consideration the specific nature of the<br />

product: profiles of various lengths.<br />

Another project requirement has been the<br />

reuse of stationary cantilever racks from<br />

the old warehouse, so that they could be<br />

integrated into the new facility.<br />

132 <strong>Best</strong> <strong>Practices</strong>


Case Study I Hepco Motion<br />

The solution proposed by Mecalux<br />

In all, nine Moviracks were installed,<br />

grouped in 3 blocks of 3 racks each. Each<br />

Movirack cantilever is 11 m long, which<br />

allows you to make full use of the 13.5 m<br />

wide warehouse.<br />

The three blocks of mobile rack were interspersed<br />

with the stationary cantilever<br />

racks for heavy loads that came from the<br />

old warehouse: two single, one on each<br />

end of the warehouse, and 5 double, with<br />

access on both sides.<br />

A cantilever system is the best option for<br />

the storage of different length profiles,<br />

because the cantilever arms that support<br />

load units allow for easy, safe handling. In<br />

addition, it is possible to adapt them to the<br />

size, stiffness, tolerance, weight, etc. of<br />

the goods.<br />

In respect to the Movirack mobile base system,<br />

its main feature is the automatic sideways<br />

movement along rails embedded into<br />

the floor. This takes up less space by eliminating<br />

unnecessary aisles, but without losing<br />

direct access to the products stored in<br />

the warehouse.<br />

Consequently, each of the 3 blocks of<br />

3 Moviracks installed only needs a single<br />

work aisle, instead of the 4 that would be<br />

needed in a conventional system.<br />

Taking into account that rack length is 11 m<br />

and aisle width is 2.6 m, this amounts to an<br />

overall space saving of more than 250 m 2 ,<br />

which has resulted in significant cost savings<br />

in the construction of the new building.<br />

The dimensions<br />

of the warehouse<br />

have been adjusted<br />

to the storage system,<br />

lining up the entry<br />

doors with the work aisles<br />

of the Movirack units<br />

<strong>Best</strong> <strong>Practices</strong><br />

133


Case Study I Hepco Motion<br />

Advantages for Hepco Motion<br />

- Higher productivity: the installation of mobile bases allows faster processing of inbound and<br />

outbound goods, optimising product placement and workflow.<br />

- Cost savings: the high-density nature of the mobile bases has made it possible to reduce the size<br />

of the new industrial building, requiring less surface area to achieve the desired storage capacity.<br />

The opportunity of combining mobile and stationary cantilever systems, by reusing old racks, has<br />

also resulted in cost savings.<br />

- Optimal warehouse management: the above benefits will improve the management of<br />

warehouse processes.<br />

Technical data<br />

Length of the warehouse<br />

Width of the warehouse<br />

Height of the warehouse<br />

Rack length<br />

Rack width<br />

Rack height<br />

53 m<br />

13.5 m<br />

6.5 m<br />

11 m<br />

2.4 m for each mobile base<br />

5.3 m<br />

No. of Movirack racks 9<br />

No. of rack units 3<br />

No. of possible aisles<br />

4 per rack unit<br />

Aisle width<br />

2.6 m<br />

No. of load levels 7<br />

Height of the load levels<br />

variable<br />

134 <strong>Best</strong> <strong>Practices</strong>


Case study: Iron Mountain<br />

Earthquake-proof racking: an installation<br />

with conventional racking on the Pacific Rim<br />

Location: Chile<br />

The Mecalux racks installed in Warehouse 11 of Iron Mountain, a leading<br />

records management and archiving company, were the only ones which were<br />

able to withstand the 8.8 magnitude earthquake in 2010 that devastated the<br />

Chilean regions of Maule and Bio Bio. After the earthquake, Iron Mountain<br />

commissioned Mecalux to rebuild its many damaged buildings and to build two<br />

new warehouses with similar characteristics.<br />

<strong>Best</strong> <strong>Practices</strong> 135


Case Study I Iron Mountain<br />

The collaboration between the two companies<br />

began five months before the earthquake,<br />

when Iron Mountain hired Mecalux<br />

to build Warehouse 11, which holds more<br />

than 1.4 million boxes.<br />

As soon as Mecalux took over the project for<br />

Warehouse 11, the design went through a<br />

structural review that took a variety of considerations<br />

into account, such as local seismic<br />

regulations and fire protection, electrical<br />

protection and safety systems. The conventional<br />

pallet racking is designed with a focus<br />

on the seismic resistance of the shelves.<br />

Before starting the installation of the warehouse,<br />

the racks also went through a preliminary<br />

design phase, so they would be<br />

capable of absorbing the force generated<br />

by any potential earthquakes. The warehouse,<br />

divided into four floors in order<br />

to allow manual handling of the goods,<br />

is made up of tall, high-resistance racks<br />

with shelves at different levels on which the<br />

boxes containing the files are deposited.<br />

Access to the various floors of the warehouse<br />

is performed by means of stairs, lifts<br />

and walkways.<br />

136 <strong>Best</strong> <strong>Practices</strong>


Case Study I Iron Mountain<br />

The Iron Mountain<br />

warehouse in Chile is<br />

located in the Ring<br />

of Fire on the Pacific Rim,<br />

one of the regions with<br />

the most seismic activity<br />

in the world. Therefore,<br />

Mecalux prioritised the<br />

safety of the installation<br />

and built a reinforced<br />

system that would be<br />

capable of withstanding<br />

potential earthquakes<br />

The conventional pallet racks put in<br />

place were designed from the inside<br />

out – first the shelves and then the building<br />

envelope.<br />

Longitudinal rigid frames to reinforce the<br />

beams and columns on the four floors of<br />

the warehouse were also installed, along<br />

with the creation of a 4 m wide central<br />

aisle that enables comfortable handling<br />

of the load at the different locations. The<br />

central frames were fixed on a base plate<br />

calculated with sufficient thickness to provide<br />

maximum absorption of the shocks,<br />

since according to the calculations made,<br />

the seismic waves would travel longitudinally<br />

through the frames.<br />

The land on which Warehouse 11 was built<br />

was classified as Type 3, of the lowest possible<br />

quality, so extraordinary measures<br />

were taken to reinforce the entire building.<br />

The earthquake and the<br />

reconstruction<br />

On 27 February 2010, an earthquake measuring<br />

8.8 on the Richter scale struck the<br />

Chilean regions of Maule and Biobío with<br />

devastating consequences. The company<br />

lost seven of its facilities, but there was one<br />

that was indeed able to pass the test: the<br />

warehouse built by Mecalux, which was<br />

still only half-finished.<br />

Given this natural disaster, many businesses<br />

were looking to store their documents<br />

and files in more secure facilities such as<br />

those Iron Mountain had been proven to<br />

have.<br />

Even so, the company needed to relocate<br />

the many thousands of boxes that<br />

were scattered on the floor, so the second<br />

phase of construction was begun quickly<br />

with the aim of storing part of those<br />

loads. However, Iron Mountain not only<br />

needed to rebuild all its facilities, it also<br />

had to progress and keep growing. For<br />

this reason, the company commissioned<br />

Mecalux to build two warehouses similar<br />

to Warehouse 11, with a total capacity of<br />

more than 3 million boxes.<br />

With so little time to lose, Mecalux made a supreme<br />

effort to meet the deadlines and erect<br />

the new facilities at a dizzying speed, so that<br />

the company would be able to resume its<br />

activities as quickly as possible and relocate<br />

its personnel to their regular workstations.<br />

An efficient and safe project<br />

With this earthquake-resistant project,<br />

Mecalux demonstrated its high standards<br />

of quality, safety and commitment. The<br />

challenge of building a warehouse of this<br />

kind in such a powerful earthquake zone<br />

was overcome while complying with local<br />

seismic regulations and supplying an installation<br />

which was fully reinforced and prepared<br />

to protect the workers and stored<br />

goods against earthquake tremors.<br />

Mecalux also pledged to assist in the difficult<br />

tasks of reconstruction through the<br />

construction of two new warehouses<br />

which were equally resistant.<br />

<strong>Best</strong> <strong>Practices</strong> 137


Case Study I Iron Mountain<br />

Advantages for Iron Mountain<br />

- Security against earthquakes: installation is reinforced to withstand any seismic movement.<br />

- Higher capacity: the three warehouses built by Mecalux have a total capacity of more than<br />

3 million boxes, which far exceeds the needs of Iron Mountain.<br />

Technical data<br />

Warehouse No. 11 – Iron Mountain<br />

1st stage<br />

2nd stage<br />

Total capacity<br />

720,000 boxes<br />

Total capacity<br />

480,000 boxes<br />

Number of staircases<br />

4 levels<br />

Number of staircases<br />

4 levels<br />

Frame height<br />

12,600 mm<br />

Frame height<br />

12,600 mm<br />

Central aisles<br />

4 metres<br />

Central aisles<br />

4 metres<br />

Warehouse No. 12 – Iron Mountain<br />

Warehouse No. 77 – SA Storbox<br />

Total capacity<br />

980,000 boxes<br />

Total capacity<br />

823,000 boxes<br />

Number of staircases<br />

4 levels<br />

Number of staircases<br />

4 levels<br />

Frame height<br />

13,000 mm<br />

Frame height<br />

13,000 mm<br />

138 <strong>Best</strong> <strong>Practices</strong>


Case study: Benco Dental<br />

Uprooting Benco Dental: a customized<br />

warehouse to speed up picking<br />

Location: USA<br />

In January 2010, dental equipment supplier Benco Dental teamed up with<br />

Interlake Mecalux (IKMX) to create the nucleus of its rapidly swelling<br />

business: a new home office doubling as a distribution centre and lavish<br />

product showroom. After a decade that saw the Pennsylvania company open<br />

distribution centres throughout the USA, Benco Dental’s next step was to bring<br />

the corporation back home.<br />

The founder Ben Cohen put down roots<br />

in Pennsylvania in the 1930s and formally<br />

started Benco Dental in a modestly sized<br />

Wilkes-Barre Township office. Benco grew<br />

the business there for the next 30 years. In<br />

Wilkes-Barre, the enterprise was hampered<br />

by, among other things, limited and<br />

undersized pick locations, pockets of<br />

scattered secondary stock, and bins with<br />

inefficient replenishment.<br />

“The most bang-for-your-buck happens<br />

when companies receive product, stick it<br />

in its primary location and pick it,” said a<br />

Benco spokesperson. “That’s the philosophy<br />

we took when we designed the new<br />

facility.”<br />

In its latest move, Benco swapped a<br />

6,400 m² installation for over 14,900 m²<br />

just 11 km away in Pittston.<br />

<strong>Best</strong> <strong>Practices</strong> 139


Case Study I Benco Dental<br />

The fastest growing<br />

private dental distributor<br />

in the U.S. implemented<br />

a pick module as part<br />

of its expansion<br />

and legacy<br />

Mecalux steps in<br />

Bob Novak, Interlake Mecalux’s North East<br />

Market Manager, explained, explained<br />

that he first got involved with Benco Dental<br />

after one of its lift truck distributors came<br />

to him for help designing Benco’s pick module<br />

in Fort Wayne.<br />

He noted that after IKMX’s involvement<br />

with the Indiana installation, Benco Dental<br />

commissioned the well-known Spanish<br />

warehouse solutions provider to install<br />

racks in its future installations.<br />

As it often does, the evolution of this process<br />

started with Benco Dental’s conceptual<br />

drawings. After the sides volleyed<br />

their ideas back and forth, the concept was<br />

whittled down to a final design.<br />

“We went in as the experts on pick modules<br />

and have worked with Benco ever<br />

since,” said Novak. “It worked out pretty<br />

well,” top Benco managers replied, reflecting<br />

on both Benco’s reenlistment<br />

of Interlake Mecalux and the six-week<br />

installation.<br />

Customized V-shaped shelves above conveyors for quick storage of small items<br />

140 <strong>Best</strong> <strong>Practices</strong>


Case Study I Benco Dental<br />

Today, more than 400 employees work<br />

out of the Pittston facility – not just in the<br />

distribution warehouse, but in the offices,<br />

classrooms and showrooms built into the<br />

structure’s design. “We have the biggest<br />

single place in the U.S., where dentists can<br />

come see all kinds of working operatories,”<br />

a spokesperson continued. Twentysix<br />

office sets display the products and<br />

tech nologies Benco distributes.<br />

Challenge and success<br />

Relocating a company is a tough business,<br />

even if it only means moving 11 km<br />

away. The Pittston installation rests in a<br />

never-occu pied building within a storage<br />

park that was adapted by Interlake<br />

Mecalux (IKMX) according to Benco’s<br />

specifications.<br />

Benco Dental’s team realized how tricky<br />

the several months preceding the<br />

move were going to be. It meant having<br />

to manually move 34,000 items oneby-one<br />

from old pick slots to new ones.<br />

“Maintaining customer satisfaction during<br />

the move was the biggest challenge,”<br />

Benco management explained, “We didn’t<br />

shut down for one day.”<br />

<strong>Best</strong> <strong>Practices</strong> 141


Case Study I Benco Dental<br />

Benco Dental reinvented<br />

The design and size of Benco Dental’s installation<br />

ensures that it isn’t strained by<br />

constant restocking demands. Warehouse<br />

dimensions aside, the dental product distributor<br />

uses its space wisely by also building<br />

up and canvassing each square meter<br />

with efficient operations.<br />

Benco’s floor plan certainly fulfils all of its<br />

basic requirements, but it is the system’s<br />

bells and whistles that add a unique efficiency<br />

exclusive to that Pittston facility.<br />

In addition to the improvements the racks<br />

inherently create on the premises, the expert<br />

innovations and specialized flourishes<br />

of the Pittston location optimize<br />

production.<br />

Mobilizing Mecalux’s knowledge into innovative<br />

solutions is what helped solidify<br />

Pallets arrive on<br />

the outer decks of the<br />

module to be loaded<br />

on to the flow rails<br />

Benco. “I approached Interlake Mecalux<br />

with a basic design in mind, they tweaked<br />

it, and we both added some great features,”<br />

said a key Benco manager.<br />

Here are Pittston’s biggest customisations<br />

– and why they are necessary:<br />

Adjustable decks: make it easier for anyone<br />

to stock top shelves. The solution was<br />

to incline the deck on the higher end of the<br />

carton flow module by several inches and<br />

install multiple catwalks connecting the<br />

two. The end result is a seamlessly equal<br />

reach for personnel on both sides.<br />

An overpass: in addition to the catwalks,<br />

Novak and the IKMX design crew<br />

were able to create an overpass connecting<br />

the second floor of the pick module<br />

with a structural mezzanine for greater<br />

throughput.<br />

Extra shelf picking area: the design also<br />

called for shelf pick areas allowing for<br />

maximised order fulfilment or just-in-time<br />

shipping. Shuffling the product out<br />

the door or back into the system is easier<br />

to do the more shelf picking areas one has.<br />

Once a pallet is unloaded onto the dock,<br />

lift trucks transport the pallets to their locations<br />

throughout the module.<br />

Steel-encased flow rail: the ground level<br />

pallet flow rails were last-minute additions<br />

designed to maintain a productive picking<br />

speed of oversized products. It keeps product<br />

both stored and out of the way, and<br />

protects against possible damage done by<br />

lift trucks.<br />

V-shaped shelves: Benco Dental wanted<br />

their smaller, slower-moving products<br />

to be accessible to the pick area without<br />

going to great lengths to retrieve them – a<br />

common wish among facilities with similar<br />

products. For this, the group designed<br />

V-shaped shelves. The 20-inch deep units<br />

hang above the conveyor – accessible, but<br />

out of the way.<br />

Bonus storage: adding more storage space<br />

to each level meant that Benco would<br />

have extra floor space where pallet storage<br />

would have been.<br />

The extra floor space can be used by forklifts<br />

to unload additional goods faster.<br />

The stocking area rises 10 inches between<br />

the picking side and the charge side.<br />

142 <strong>Best</strong> <strong>Practices</strong>


Case Study I Benco Dental<br />

Pick module safety<br />

How Interlake Mecalux worked with<br />

Benco Dental to ensure safety.<br />

1<br />

1 Safety straps. The operator is hooked<br />

into a harness, as well as a safety strap.<br />

The strap rides along a trolley line that<br />

runs the length of each module level<br />

(other than the ground floor).<br />

2 Galvanized safety deck. Once a pallet<br />

is fully picked, personnel relocate the<br />

pallet. The galvanizing ensures an easy,<br />

undamaged course of the pallet to a return<br />

lane, and the safety of personnel<br />

below from wood shards.<br />

2<br />

3 Safety netting. The netting extends<br />

past the safety deck in order to deter<br />

personnel from approaching the edge<br />

of the pick module, and to protect them<br />

if they do.<br />

The safety of the<br />

picking installation was<br />

fundamental throughout<br />

the design process<br />

3<br />

The extra shelf picking areas ensure<br />

constant quick turnaround.<br />

Added height for pallets and steel-encased<br />

flow rail keep product safely housed.<br />

<strong>Best</strong> <strong>Practices</strong> 143


Case Study I Benco Dental<br />

CYCLING THROUGH A RESPONSIVE REPLENISHMENT METHOD<br />

Benco Dental has made it a company practice to saturate its distribution centers with efficient production strategies<br />

including its just-in-time replenishment method. JIT is a means to reduce stored inventory by optimizing system<br />

performance. Here is how Interlake Mecalux helped ensure Benco Dental’s efficiency:<br />

1. Product is<br />

received within<br />

24 hours<br />

Reduce store inventory by<br />

optimizing the time it sits in the<br />

factory, eliminating “change<br />

overtime” that would normally<br />

cause delays at the beginning of<br />

the process.<br />

2. Expedited<br />

product is sent<br />

straight to order<br />

fulfillment<br />

Schedules are synchronized with<br />

demand. If there is not product<br />

demand, personnel is placed<br />

else where, making multi-skilled<br />

employees more useful.<br />

6. Product is<br />

unloaded to dock<br />

Fewer pieces mean fewer delays.<br />

3. Remaining stock<br />

is stored<br />

With less inventory, there is<br />

decreased risk of product damage<br />

or expiration.<br />

5. Employee effort,<br />

emphasis is spent elsewhere<br />

Supplier relationships are enhanced as a company<br />

with limited inventory will do whatever it takes to<br />

avoid part shortages.<br />

4. Fulfilled orders loaded<br />

and shipped<br />

When production demand and supply is<br />

synchronized and goods move directly from<br />

receiving to order fulfillment, less space is necessary<br />

for storage.<br />

144 <strong>Best</strong> <strong>Practices</strong>


Case Study I Benco Dental<br />

Advantages for Benco Dental<br />

- Design and dimensions: special design features and the large-scale installation ensure that they<br />

are able to supply the continuous demands of restocking products.<br />

- Space optimization: Dental Benco uses the available space intelligently, taking advantage of<br />

every square meter for efficient operations that contribute to the strong performance of the<br />

installation.<br />

- Development of made-to-measure products: the customization of the system, in accordance<br />

with the needs and requirements of the client, gives the installation unique efficiency. The application<br />

of Mecalux’s technical knowledge, in regards to innovative solutions, has helped Benco to<br />

stand out among their competitors.<br />

- Enhanced productivity: as a result of the incorporation of massive picking modules from<br />

Interlake Mecalux and other systems in the Pittston installation, Benco estimates that has increased<br />

its productivity by 12% in comparison to what it earned in its previous facilities.<br />

<strong>Best</strong> <strong>Practices</strong> 145


Our experts I Software<br />

Logistics software: the cloud is the future<br />

Due to the continuous evolution of technology, our business<br />

landscape is changing at a high speed. One of the most important<br />

paradigm changes that has taken place in recent years has been<br />

caused by the software industry, with the creation of cloud-based<br />

applications. The logistics operations of companies have quickly<br />

adapted to this change, demanding that software applications be<br />

implemented which are increasingly compatible with the cloud.<br />

This paradigm shift has been led principally<br />

by the needs of the clients themselves,<br />

who in light of periods of crisis have opted<br />

for the type of solutions that only the cloud<br />

can offer: controlled expenditure, versatility<br />

and portability.<br />

However, it is also important to take into<br />

account the fundamental influence that the<br />

evolution of technology has brought upon<br />

us, which has made it possible to increase<br />

the connection capacity both within locally<br />

or mobile based communications. The<br />

social changes caused by globalisation, the<br />

sharing of information and the need for<br />

continuous access to information can also<br />

not be ignored.<br />

What do we mean when we talk<br />

about “the cloud”?<br />

There are many definitions for such a broad<br />

term and that, in the here and now, is part of<br />

almost any solution. Perhaps the one that comes<br />

closest says that it is a “consumer technology<br />

model” (applications, computing<br />

and storage) as a service through a network<br />

(usually the Internet), without the need for<br />

investments, securely and accessible from<br />

anywhere. This virtual set up makes data<br />

control and management more obtainable.<br />

Key advantages<br />

The main features that have led to this<br />

growth in cloud based solutions are:<br />

• Savings in the initial investment of<br />

any project of software deployment.<br />

The hardware infrastructure to house the<br />

solution is eliminated, and only the equipment<br />

in use is required. Nor is the initial cost<br />

of licensing necessary, since a payment by<br />

use and monthly service (SaaS) is applied.<br />

• Automatic and secure application<br />

updates. There is no need to spend several<br />

weeks to update a company’s applications,<br />

with problems that can result in loss of data,<br />

downtimes, etc. Updates are completely<br />

transparent and without any form of<br />

intervention.<br />

• Savings in maintenance costs. By<br />

adopting a SaaS model, the maintenance of<br />

the application and the housing of the solution<br />

lies with the provider. Who is the one<br />

responsible for hardware upkeep.<br />

146 <strong>Best</strong> <strong>Practices</strong>


Our experts I Software<br />

CLOUD<br />

HOST<br />

LAN<br />

WAN<br />

LAN<br />

ON-PREMISE<br />

• Flexibility. This model is ideal for businesses<br />

with fluctuating growth over time,<br />

so that it is always possible to increase or<br />

decrease the service you are receiving.<br />

• Access to information from any location.<br />

Only an Internet connection is required<br />

to be able to work remotely.<br />

• Reduction of the implementation<br />

times when performing a solution rollout<br />

because it is unnecessary for clients to install<br />

software to access the computer program<br />

from an Internet browser.<br />

• Security. The cloud does not depend on<br />

computer equipment, so that data is not<br />

lost in the event of portable devices being<br />

misplaced, or because of any type of breakdown<br />

in a client’s computer. That is to say,<br />

because the data is stored in the cloud, you<br />

can access the information in the company,<br />

regardless of anything that happens to your<br />

computer.<br />

Some “cons”<br />

All these features are advantages that currently<br />

lead more than 60% of medium-sized<br />

companies to use cloud-based services.<br />

But there are also drawbacks to working in<br />

the cloud:<br />

• Dependence of network connections.<br />

For this reason, before deciding to step into<br />

the cloud, you should verify that your network<br />

infrastructure, that will support these<br />

services, is adequate enough and even be<br />

sure to have a contingency plan for network<br />

breakdowns. This way, you will get a solid<br />

system.<br />

• Loss of data control. This is the biggest<br />

drawback that many companies face when<br />

making the leap into the cloud. To upload<br />

information into a server hosted in the cloud<br />

that can be replicated in any other secure<br />

backup in the recovery of a system, relocation<br />

of the information is clear and this<br />

makes many businesses fearful. This distrust<br />

is based, in part, on the perception that data<br />

is more secure in their own facility, when the<br />

truth is that it is easier for data leaks to occur<br />

at a domestic level. The possibility of an incident<br />

within their own systems is much more<br />

likely than with any cloud hosted service.<br />

An example of evolution: Easy WMS<br />

Fundamentally, when analysing the pros<br />

and cons of using the cloud, it is obvious<br />

that the future of software and services<br />

lies within this new platform. In the coming<br />

years, companies will increasingly rely on<br />

adopting this technology.<br />

Responding to the changing needs of its<br />

customers and to this new paradigm, Mecalux<br />

Software Solutions – Mecalux’s software<br />

development division – has created a<br />

new version of its Easy WMS Warehouse<br />

Management Software, so that clients can<br />

operate as per the architecture that they<br />

desire to use:<br />

• Either in the cloud, offering a cloud service<br />

model, namely SaaS (Software as a<br />

Service).<br />

• Or the traditional client/server “on-premise”<br />

model, hosted in their facilities.<br />

This way it is the client who decides which<br />

option they feel more comfortable working<br />

with. And even if you prefer to start with the<br />

traditional model, you can then jump into<br />

the cloud or vice versa. Flexibility, is first and<br />

foremost. u<br />

<strong>Best</strong> <strong>Practices</strong><br />

147


Our experts I Clack-racks<br />

Clad-rack warehouses<br />

When racks also support the building<br />

This type of constructions are integrated buildings formed by the racks themselves, whose structure is<br />

coupled to both the roof and wall cladding. Clad-rack warehouses have achieved great importance in<br />

the last 30 years, mainly because of the need for space optimisation, and resulting in the construction of<br />

buildings that are taller than 45 m.<br />

In order to better understand the advantages<br />

offered by building a clad-rack<br />

warehouse, we should first consider some<br />

features of the traditionally built warehouses:<br />

• The building of a traditional warehouse<br />

is formed by a supporting structure, with<br />

its pillars, trusses, roof girders, side walls<br />

and roofing, on which external forces<br />

such as the wind, snow or earthquakes<br />

act against, depending on its geographic<br />

location.<br />

All the forces are transmitted to the<br />

ground through the pillars, which require<br />

the construction of load-redistribution<br />

footings.<br />

It is also essential to build a slab or floor<br />

with sufficient load capacity to be able to<br />

support the weight of the goods and handling<br />

equipment.<br />

• The warehouse, or one of its parts, is<br />

composed of racks that occupy the total<br />

height of the building’s interior.<br />

• There are usually heavy pallets stored on<br />

the racks, so calculations must be done to<br />

withstand all the stored goods.<br />

• The racks are metal structures that have<br />

a large number of pillars (frames/uprights)<br />

that distribute the weight evenly on the<br />

floor of the warehouse.<br />

• The forces that the racking units transmit<br />

to the ground are much higher than<br />

those that the pillars of the building transmit,<br />

although individually. Each upright<br />

transmits a much lighter load and which,<br />

above all, is distributed.<br />

• If the external forces that support the<br />

building were transmitted to the ground<br />

via the racks, it would add a relatively small<br />

percentage to each upright in comparison<br />

with the loads derived from the goods.<br />

Advantages of a clad-rack<br />

warehouse<br />

• Full use of the surface area: the warehouse<br />

is designed at the same time as the<br />

racks and only occupies the space required,<br />

without intermediate pillars that influence<br />

their distribution.<br />

• Optimisation of height: as with the<br />

surface area, the height will be only that<br />

which is required. At the same time, the<br />

upper trusses or girders require less height<br />

and incline being directly supported on<br />

the racking.<br />

• Maximum height of the construction:<br />

you can build to any height, it only<br />

depends on local regulations or the scope<br />

of the handling means which are used, being<br />

able to exceed 45 m high (which would<br />

148 <strong>Best</strong> <strong>Practices</strong>


Our experts I Clack-racks<br />

be complex and expensive in traditional<br />

construction).<br />

• Simpler construction: the entire structure<br />

is assembled on a concrete slab of suitable<br />

thickness to achieve uniform distribution<br />

of the forces on the foundation; there isn’t a<br />

high concentration of loads<br />

• Less time for completion: once the<br />

slab is built, the entire structure and cladding<br />

are progressively and concurrently<br />

installed.<br />

• Cost savings: As a general rule, the<br />

cost of a clad-rack warehouse is less than<br />

the more traditional racks. The greater the<br />

construction height, the more profitable<br />

the clad-rack system.<br />

• Easily removable: being a structure<br />

formed by standard rack elements that come<br />

pre-assembled or bolted, they can be<br />

dismounted with ease and a high percentage<br />

of components recovered.<br />

When installing a clad-rack<br />

warehouse<br />

The variety of applications of this type of<br />

warehouses are very broad, although it<br />

is particularly suitable solution in the following<br />

cases:<br />

• When the warehouse exceeds 12 m high.<br />

• When the construction is of a lower, but<br />

its use is temporary or pro-visional.<br />

• When the maximum optimisation of space<br />

and volume is required, regardless of<br />

the height of construction that is built.<br />

In the case of clad-rack warehouses which<br />

are less than 12 m high, the storage system<br />

which is often used is non-automated<br />

• Minimal civil works: it only requires<br />

the construction of the slab on the ground<br />

and, in some cases, a waterproof wall between<br />

one and two metres high. In which<br />

case the operations area needs to be expanded<br />

for receipt and dispatch, a traditional<br />

building can be built, but of sufficient<br />

height without reaching the total height of<br />

the warehouse.<br />

<strong>Best</strong> <strong>Practices</strong><br />

149


Our experts I Clack-racks<br />

9 8<br />

6 4<br />

2<br />

1. Frame<br />

2. Beam<br />

3. Footplates and<br />

anchor bolts<br />

4. Roof trusses<br />

5. Guide rails<br />

6. Roof joist<br />

7. Wall joist<br />

8. Roof<br />

9. Cladded walls<br />

7<br />

3<br />

5<br />

1<br />

the structure be respected (wind actions,<br />

roof overloads, seismic action, etc.), but<br />

also the specific regulations for the metal<br />

racking.<br />

compact (drive-in palletising, push-back,<br />

Pallet Shuttle and live by gravity).<br />

racks must also bear the forces that they<br />

transmit.<br />

On a European level, the following regulations<br />

are in force for all metal structures:<br />

The use of conventional pallet racking, either<br />

single or double-depth, is more common<br />

starting at this height. On the other<br />

hand, when above 15 m high handling<br />

machines should be automatic.<br />

As a general rule, in the case of automated<br />

warehouses, the best practice is to take advantage<br />

of the maximum height allowed<br />

by local regulations. This is provided that<br />

the amount of machines designed for the<br />

installation makes it possible to achieve<br />

the desired number of movements. To get<br />

same storage capacity, you can opt for a<br />

reduced height installation, but with more<br />

work aisles –which involves installing more<br />

machines–or opt for a warehouse with<br />

more height and less aisles, and therefore<br />

less machines.<br />

Basic components<br />

of a clad-rack warehouse<br />

The constructive system is very simple: the<br />

structure is composed by the racks themselves<br />

on which the upper trusses, roof<br />

girders and the side profiles are placed,<br />

which are used for attaching the panels<br />

that make up the walls and roofing.<br />

When the handling equipment are automatic<br />

stacker cranes, the upper guides<br />

are attached to the trusses, so that the<br />

How a warehouse clad-rack<br />

is calculated<br />

Apart from having to bear loads generated<br />

by the goods stored and the forces from the<br />

handling machines, clad-rack warehouses<br />

must also be designed to withstand the actions<br />

of a building, for example, the action<br />

of the wind, overburdened roofing (maintenance,<br />

snow, etc.), the weight itself and<br />

of the wall cladding – both covering and the<br />

facades – besides considering the seismic<br />

coefficient that corresponds to the zone<br />

where it is installed.<br />

As with any civil engineering structure,<br />

the clad-rack warehouse forms part of the<br />

building structure. However, this involves<br />

very specific constructions, because in<br />

addition to the peculiarities of a building<br />

used, the specifications of the racks must<br />

be taken into account.<br />

Thus, when calculating and designing the<br />

structure of a clad-rack warehouse, not<br />

only must each country’s rules of construction<br />

and the actions that can affect<br />

• EN 1990 / Basis of structural design.<br />

• EN 1991 / Eurocode 1: Actions on<br />

structures.<br />

• EN 1993 / Eurocode 3: Design of steel<br />

structures<br />

• EN 1998 / Eurocode 8: Design of structures<br />

for earthquake resistance.<br />

Logically, in each territory there are different<br />

climatic actions that involve deviations from<br />

the general rule. Moreover, certain countries<br />

require different calculation conditions<br />

(for example: more stringent security coefficients<br />

than those specified in European<br />

regulations).<br />

In regard to the European regulations specific<br />

to metal racking, the following are<br />

underscored:<br />

• EN 15512 / Steel static storage systems.<br />

Adjustable pallet racking systems. Principles<br />

for structural design.<br />

At the height of 12 m the inflection point between<br />

the costs of constructing a traditional warehouse and<br />

a clad-rack warehouse is usually found<br />

150 <strong>Best</strong> <strong>Practices</strong>


Our experts I Clack-racks<br />

Modelling for the calculation of<br />

the structure in 3D<br />

Modelling for the calculation of a cross section<br />

of the structure in 2D<br />

• EN 15620 / Steel static storage systems.<br />

Adjustable pallet racking. Tolerances, deformations<br />

and clearances.<br />

• EN 15635 / Steel static storage systems.<br />

Application and maintenance of storage<br />

equipment.<br />

The structure of a clad-rack warehouse is<br />

composed of thousands of junctions and<br />

rods, so you need powerful calculation<br />

programs to model and calculate this type<br />

of installation in three dimensions. 3D modelling<br />

is indispensable if we want to predict<br />

the torsional effects that a simplified<br />

analysis in two dimensions cannot reveal.<br />

Calculation programs allow.<br />

by regulation EN 15620 must also be substantiated<br />

in two dimensions.<br />

It is important to point out that the calculation<br />

of a clad-rack warehouse is an<br />

iterative process. Which means that the<br />

person calculating uses some profiles and,<br />

subsequently, checks and verifies their<br />

appropriateness. This process is repeated<br />

until getting the most finely-honed solution<br />

possible, that meets all safety requirements<br />

and that delivers maximum profitability.<br />

The iterative process will be longer<br />

or shorter depending on the experience of<br />

the person calculating.<br />

Civil works and assembly<br />

The basic civil work is minimal: only the<br />

slab on which the structure sits and the pipes<br />

for the drains are required. Likewise,<br />

depending on its use, a water-proof perimeter<br />

wall and an additional operations<br />

• To consider the actions on the structure.<br />

For example, the stored load is modelled<br />

as a load evenly distributed on the beams.<br />

It also takes into account the action of the<br />

wind, roof overloads...<br />

• To obtain the forces that the racks bear:<br />

bending, shearing and axil moments on<br />

each rod and each junction.<br />

• To obtain the deformations and displacements<br />

of all the structure’s components.<br />

• Check the suitability of the sections or<br />

profiles hypothesised in the calculation,<br />

applying the verification formulas outlined<br />

in the EN 1993 and 15512 regulations.<br />

EIn very tall facilities (25 m and upwards),<br />

it is not enough to ensure that the profiles<br />

are sufficiently resistant to the forces<br />

which they must absorb, but warehouse<br />

displacement within the range specified<br />

<strong>Best</strong> <strong>Practices</strong><br />

151


Our experts I Clack-racks<br />

area of appropriate height can be erected,<br />

as has already been mentioned.<br />

In the process of the structure’s assembly,<br />

the first job that is performed on site is the<br />

verification of the correct levelling of the<br />

slab, after which part of the anchor plates<br />

are placed in their final position (before<br />

putting up the structure). Once you have<br />

verified the correct levelling of the racks,<br />

you can fill the space between the plate and<br />

the ground with a non-shrink concrete.<br />

The next step is to assemble the structure.<br />

You can install any type of pallet storage<br />

system, both single and double-depth, with<br />

live racks, with or without Pallet Shuttle and<br />

in combination with stacker cranes or transfer<br />

cars. It is also possible to install clad-rack<br />

warehouses for boxes, particularly suited in<br />

combination with the miniload automated<br />

system (stacker cranes for boxes).<br />

The assembly usually starts at the head of<br />

the warehouse and, after putting up the<br />

first racks and part of the cladding (the<br />

coverings and facades), the handling machines<br />

are introduced. Then, the structure<br />

is finished being assembled and the rest of<br />

the cladding is placed.<br />

The requirements of clad-rack warehouse<br />

can vary depending on several factors. For<br />

example, when used as cold storage, two<br />

The slab must have suitable strength and thickness<br />

for bearing the weight of the structure plus the goods<br />

stored, as well as to withstand the forces produced by<br />

external factors<br />

slabs are built – one on top of the other –<br />

and you install insulation between them.<br />

At the same time, the bottom slab incorporates<br />

a ventilation system, or a circuit<br />

of pipes, to prevent the foundation from<br />

freezing.<br />

Another determining factor is height.<br />

When more height is required than is<br />

allowed by applicable regulations, there<br />

is the possibility of building part of the<br />

warehouse in a trench. In these cases,<br />

provisions for a hatch or door must be<br />

made for maintenance workers and the<br />

installation of access ladders, drains and<br />

over-flow water pumps.<br />

On other occasions, height will be determined<br />

by factors such as the wind or<br />

the seismicity that affects the zone. The<br />

repercussions of this factor will be greater<br />

the higher the warehouse, the vertical<br />

bracing has to transmit forces produced<br />

in the structure along to the concrete slab<br />

that makes up the floor.<br />

152 <strong>Best</strong> <strong>Practices</strong>


Our experts I Clack-racks<br />

Integration<br />

of the warehouse<br />

In general, warehouses are built next to<br />

other production processes. When the<br />

constructive system is self-supporting,<br />

even more so if the handling machines<br />

are automatic, the height is usually much<br />

higher than the rest of the buildings<br />

and the site it is located at has been well<br />

analysed.<br />

It is essential to install the warehouse in a<br />

strategic zone, to simplify the flows between<br />

the different areas that have been<br />

connected as much as is possible. This will<br />

be easier when it is a part of a totally new<br />

plant, and according to the experience<br />

and know-how of the designer.<br />

Although the majority of the warehouses<br />

are joined to the production buildings, there<br />

are situations in which the warehouse<br />

will be more distant: for logistical needs,<br />

or future expansion, or to not eliminate inner<br />

lanes. To connect the warehouse with<br />

other buildings, you may resort to any of<br />

these options:<br />

1. Have shuttle trucks that connect the production<br />

centres with the warehouse. The<br />

logical thing to do in this case is that the<br />

vehicles and the warehouse are ready to<br />

perform unloading automatically.<br />

2. Build an underground tunnel to connect<br />

the two areas via conveyors.<br />

3. Build an overpass on a raised structure.<br />

Conclusion<br />

The possibility of configuring the warehouse<br />

with different types of storage systems<br />

for pallets and for boxes, both manual<br />

and automatic, allows you to respond<br />

to all types of loading units, operations<br />

and necessities.<br />

In any case, only companies Mecalux’s<br />

experience and service quality can undertake<br />

this type of construction and offer<br />

the best solution based on the demands,<br />

the intended utility, the location and the<br />

height of the construction while acting as<br />

the sole interlocutor throughout the process.<br />

Furthermore, Mecalux is committed<br />

to the development of the engineering of<br />

projects with its own team of technicians,<br />

whether it be in the mechanical, electrical,<br />

electronics or software specialist. This<br />

helps to ensure the fulfilment of all the<br />

technical and legal rules applicable to the<br />

installations.<br />

Clad-rack warehouses implemented by<br />

Mecalux have demonstrated their effectiveness<br />

in diverse sectors such as food,<br />

automotive, pharmaceutical, spare parts,<br />

petroleum, ceramics, metallurgy, chemical<br />

and cosmetics products, plastic products,<br />

logistics operators, etc. This solution is also<br />

recommended for cold or frozen storage,<br />

in particular when combined with automated<br />

handling systems. Thus, transforming<br />

know-how and cold-storage into profitability<br />

u<br />

<strong>Best</strong> <strong>Practices</strong><br />

153


Our experts I Structural Calculation<br />

How to calculate the structure<br />

of a conventional pallet rack<br />

What forces must be pondered when designing metal pallet racks? How do we verify that the structure<br />

will be suitable to withstand all loads? These and other <strong>issue</strong>s are those which should be taken into<br />

account in the design of this type of rack, with the goal of ensuring its stability and resistance, and<br />

therefore the overall security of the installations.<br />

The European EN 15512 norm, according<br />

to its definition, specifies the requirements<br />

for structural design applicable to conventional<br />

pallet racking (selective racks)<br />

manufactured from steel components,<br />

designed to store palletised unit loads and<br />

subject to essentially stationary loads. It<br />

has become the main benchmark on this<br />

matter, and provides additional technical<br />

information required for the implementation<br />

of the Eurocodes.<br />

In addition, designers must also provide<br />

for the EN 15620, EN 15629 and EN 15635<br />

standards as guides for the specifications<br />

of the storage system, the required tolerances<br />

during assembly and the safe operation<br />

of the installation.<br />

Likewise, conventional racks for palletised<br />

loads are metal structures, generally<br />

formed by components made out of thin,<br />

cold-formed, steel sheet metal. They are<br />

able to withstand heavy loads, while the<br />

installation is designed to be as lightweight<br />

as possible; consequently the rack’s own<br />

weight rarely exceeds 5% of the load stored<br />

in the facility’s interior.<br />

On the other hand, it is imperative that this<br />

type of installations for palletised loads be<br />

versatile, to be able to adapt to different<br />

load types. For this reason, the connections<br />

between the main parts of the structure<br />

must be adjustable, and quick and<br />

easy to assemble.<br />

The uprights of these structures usually<br />

have perforations along the entire profile,<br />

while the beams include connectors provided<br />

with hooks that fit into the perforations<br />

of these uprights.<br />

Basic structural<br />

components<br />

• Frames: are vertical pieces composed<br />

of two uprights joined together by beams<br />

and cross-ties forming a lattice.<br />

Close up of the<br />

joining of an upright<br />

and a beam<br />

• Uprights: these tend to be cold-profiled<br />

components of thin sheet metal, with<br />

open sections and are always perforated,<br />

which makes them prone to distortion and<br />

torsional type sagging.<br />

• Beams: are horizontal pieces that bear<br />

the burden of the pallets. These tend to<br />

be cold-profiled and have connectors on<br />

their ends for attaching them to frame<br />

uprights.<br />

• Connectors: are parts welded onto<br />

the ends of beams to attach them to the<br />

uprights. They are equipped with hooks<br />

that fit into the perforations of the<br />

uprights.<br />

154 <strong>Best</strong> <strong>Practices</strong>


Our experts I Structural Calculation<br />

Calculation types: general and<br />

individual<br />

The calculation is carried out in two<br />

stages:<br />

1. General analysis of the structure<br />

Normally filiform, two-dimensional (2D)<br />

models with second order calculations<br />

applying the finite element method are<br />

used. In some types of installations, calculations<br />

are also frequently done via 3D models<br />

in accordance with the EN 1993-1-1.<br />

This analysis must incorporate the modelling<br />

of the actual behaviour of the connection<br />

between the upright-beams and<br />

the frame-ground.<br />

Example of down‐aisle analysis<br />

2. Individual verification of pieces<br />

Once the overall analysis is performed, it is<br />

vital to check the correctness of the design<br />

by verifying the buckling and the tensions of<br />

the pieces that make up the racking.<br />

Basically, the following items are verified:<br />

- General stability of the installation.<br />

- Stress state of frames: uprights and<br />

diagonals.<br />

- Base plates: pressure on the slab and<br />

anchorage.<br />

- Beams: buckling and stress state.<br />

- Connectors.<br />

General analysis: structural model<br />

For general analysis, it is usual to consider<br />

two, two-dimensional (2D) structures in<br />

concurrent vertical and perpendicular layouts<br />

with respect to the storage aisles.<br />

In the model calculation, the following requirements<br />

are observed:<br />

General analysis<br />

• Filiform model.<br />

• System lines through the CG (centre of<br />

gravit y) of the gross sec tion, or also through<br />

the CG of the actual cross section.<br />

Overall analysis of a 2D structure<br />

Example of cross‐aisle analysis<br />

• Terms of section corresponding to the<br />

gross section of the pieces (or also of the<br />

actual cross section).<br />

In this analysis the aim is to obtain:<br />

- The internal forces on the different pieces<br />

for their subsequent verification,<br />

combining the down-aisle and crossaisle<br />

calculations.<br />

- Checking the overall stability of the<br />

installation.<br />

It includes two types of analysis:<br />

- Down-aisle analysis: analysis in 2D on a<br />

vertical layout parallel to the load aisles.<br />

This analysis also includes the semi-rigid<br />

connections of the upright-beam and<br />

upright-floor, obtained by testing.<br />

- Cross-aisle analysis: analysis in 2D on a<br />

vertical layout perpendicular to the load<br />

aisles. Usually involves the articulated<br />

upright-floor joint.<br />

In both cases, the global imperfection can<br />

be modelled as:<br />

- The tilt of the agreed uprights to the<br />

imperfection.<br />

- Horizontal forces at the height of<br />

the load levels corresponding to the<br />

imperfection.<br />

Type of analysis according to the<br />

classification of the structure<br />

This classification is based on the relationship<br />

of the expected load design in regards<br />

to the critical load of the structure. According<br />

to the coefficient obtained by this re-<br />

<strong>Best</strong> <strong>Practices</strong><br />

155


Our experts I Structural Calculation<br />

lationship, the need to perform a second<br />

order calculation will be determined.<br />

Individual analysis: verifying<br />

elements<br />

In the verification of the different elements<br />

that make up the structure the following<br />

concepts, among others, must be taken<br />

into account:<br />

Uprights - Frames - Anchorage plates<br />

- Upright mainly function by compression<br />

and flexion.<br />

- The use of the reduction factor for buckling,<br />

obtained by laboratory testing or<br />

by using theoretical formulas.<br />

- The internal forces obtained from the<br />

down-aisle and cross-aisle calculations<br />

will be jointly perpended.<br />

- Axil force on the diagonals of the<br />

frame.<br />

- Axil force and momentum on uprights’<br />

footplates.<br />

- Axil and shear force on fastening anchorage<br />

to the slab.<br />

Beams - Connectors<br />

- Working primarily with bending and<br />

shearing forces.<br />

- Buckling (deflection) is limited to a maximum<br />

of L/200. Occasionally, for certain<br />

installations smaller value deflections<br />

are required.<br />

So that the conventional<br />

pallet racking function<br />

safely, it is fundamental<br />

to know the structure<br />

you are working with,<br />

the preventive actions<br />

that exist and the safety<br />

measures to keep in mind.<br />

- Consideration of the cross-aisle forces<br />

of location.<br />

- Verifying the shear force and deflection<br />

in the endplate.<br />

Blocks of bracing - Vertical and horizontal<br />

bracing - Spacers<br />

- The brace diagonals work exclusively on<br />

axil force.<br />

- Verification of the deflection and shear<br />

forces on the elements that connect the<br />

diagonals of the vertical bracing to the<br />

frames (bracing spacers).<br />

- The actions of the bracing increases the<br />

forces on the uprights and beams that<br />

form part of the block of bracing or that<br />

are adjacent to it.<br />

- The eccentricity of the actions of the<br />

vertical bracing in respect to the racks<br />

requires a study of the torsion behaviour<br />

of the elements that form part<br />

of the block of bracing, as well as the<br />

racks.<br />

Actions<br />

There are different types of actions that<br />

may affect the strength and stability of<br />

the racks, so that it is also imperative to<br />

contemplate them when setting up an<br />

installation of this kind. The actions on the<br />

racking are classified into several groups:<br />

Permanent actions<br />

- Weight of the racks.<br />

- Permanent loads and various equipment<br />

supported by the racking.<br />

Variables actions<br />

- Weight of the pallets.<br />

- Weight and actions due to mobile loads<br />

on platforms and walkways.<br />

- Actions due to the location of the pallets<br />

(vertical + horizontal).<br />

- Actions on the positioning profiles.<br />

- Actions due to storage equipment<br />

guides.<br />

- Actions due to the imperfection in the<br />

elements and assembly.<br />

- Other actions arising from national regulations<br />

(wind, snow, etc.).<br />

- The weight of the pallets together with<br />

the general imperfection deemed as a<br />

156 <strong>Best</strong> <strong>Practices</strong>


Our experts I Structural Calculation<br />

structure’s parts subject to the corresponding<br />

unweighted actions (nominal loads) is<br />

studied:<br />

• Verifying the overall stability of the<br />

struc-ture.<br />

• Verifying beam deflection<br />

Ultimate Limit State (ULS)<br />

In each of the load cases the tensional<br />

state of components subjected to the corresponding<br />

weighted actions (affected<br />

by factors of security) is studied. In the<br />

verification formulas of the elements the<br />

combination of forces (down-aisle + crossaisle)<br />

must be considered.<br />

Variable actions like weight and actions due to moving loads on<br />

platforms and walkways.<br />

single action, which in turn is the most<br />

relevant (unfavourable).<br />

Accidental actions<br />

- Forklift blows.<br />

- Actions on security profiles.<br />

- Seismic actions.<br />

Load states and the combination<br />

of actions<br />

It is viewed as appropriate and sufficient<br />

to study the two load states listed below,<br />

considering the following actions or load<br />

cases:<br />

• Permanent actions + the most unfavourable<br />

variable action.<br />

• Permanent actions + 0.9 x (the totality<br />

of variable actions).<br />

• Permanent actions + variables + incidentals.<br />

State Service Limit (SSL)<br />

In each of the load cases the buckling of the<br />

It is also necessary to ponder the uncertainty<br />

as to the different actions that can<br />

affect the racking (described previously).<br />

To do this, there are established security<br />

coefficients considered, for both the load<br />

coefficient and the material, and which<br />

can range between 1.0 and 1.5.<br />

Some countries have specific national legislation<br />

which obliges you to use greater<br />

weighting coefficients in the facilities that<br />

are built on its territory (A deviations).<br />

Eccentricities<br />

When the design and/or handling of the<br />

storage system allows the pallets to syste-<br />

Vertical and horizontal actions due to the placement of pallets.<br />

<strong>Best</strong> <strong>Practices</strong><br />

157


Our experts I Structural Calculation<br />

En 15620. - Steel static storage<br />

systems. Tolerances, deformations<br />

and clearances.<br />

- Flatness of the slab and its buckling under<br />

load.<br />

- Clearance between pallets, and between<br />

the pallet and racks.<br />

- Clearance between racks and civil<br />

works.<br />

- Aisle width according to the load unit,<br />

the forklift type and the number of pallet<br />

locations per hour.<br />

The asymmetrical position of the pallets in respect to the beams.<br />

matically become off-centred, the increased<br />

load that causes this off-centring on<br />

beams and braces must also be taken into<br />

account in the design of the structure.<br />

Likewise, the eccentricities of the lines of<br />

the structural system must be observed, in<br />

the event that they are deemed excessive.<br />

Eccentricities in the positioning of<br />

the pallets<br />

- Asymmetric position of the pallets in regard<br />

to the beams.<br />

- Load is not evenly distributed on the<br />

pallet.<br />

- Load overflow in regards to the pallet.<br />

Thus, not only is it imperative for the manufacturer<br />

to carry out a good structural<br />

analysis and design of the installation,<br />

but it is also makes good use of the same,<br />

so that actions against the racking<br />

does not exceed those considered in the<br />

installation’s structural calculation. This is<br />

all the fruit of many years of experience,<br />

and studies and trials by FEM (Federation<br />

of European Maintenance) and other<br />

agencies.<br />

It is essential to keep in mind:<br />

En 15629. - Steel static storage<br />

systems. Specification of storage<br />

equipment.<br />

Individual responsibilities of the different<br />

system suppliers that make up the storage<br />

equipment.<br />

En 15635. - Steel static storage<br />

systems. Application and<br />

maintenance of storage equipment.<br />

- Designation of a person responsible for<br />

the security of the storage equipment.<br />

- Safe load sign.<br />

- Education and training of the warehouse<br />

staff.<br />

- Damage to the racks and assessment of<br />

the level of damage.<br />

- Regular inspections. u<br />

Eccentricities of the diagonals of the<br />

vertical bracing<br />

Although the diagonals of the vertical bracing<br />

are not physically connected to the<br />

racks on the junctions that form the neutral<br />

lines of the uprights and the beams,<br />

in the 2D calculations the diagonals can<br />

be viewed as attached to these junctions,<br />

provided that the eccentricities of the same<br />

are kept below certain values depending on<br />

the width of the brace and the edge of the<br />

beams. The same happens with the diagonals<br />

of the frames.<br />

Conclusion: the safety of the<br />

installation and responsibilities<br />

Lastly, we want to point out that in a large<br />

part of the incidents that occur in palletised<br />

installations, human error interferes<br />

and are primarily caused by scraping or<br />

impacts of forklifts against the racking.<br />

On the other hand, these impacts may<br />

represent higher than normal actions on<br />

the racks, than those established in the EN<br />

15512 norm.<br />

Software for the structural calculation of racks<br />

Currently, all the mentioned analysis throughout this article are done via<br />

computerised calculation programmes. Mecalux has applied their extensive<br />

experience in design, manufacture and installation of warehouse systems to the<br />

development of a powerful design software, capable of finding the best option<br />

for each warehouse layout, the dimensions of the storage structures and the most<br />

ideal profiles. In this way, optimization of capacity and cost of the warehouse is<br />

procured, with the utmost safety.<br />

158 <strong>Best</strong> <strong>Practices</strong>


HEAD OFFICE - BARCELONA (SPAIN)<br />

Tel. +34 932 616 913 – info@mecalux.com – www.mecalux.com<br />

EUROPE<br />

BELGIUM<br />

Tel. +32 2 346 90 71<br />

info@mecalux.be<br />

www.mecalux.be<br />

POLAND<br />

Tel. +48 32-331 69 66<br />

info@mecalux.pl<br />

www.mecalux.pl<br />

AMERICA<br />

ARGENTINA<br />

Tel. +54 (11) 4006-4444<br />

info@mecalux.com.ar<br />

www.mecalux.com.ar<br />

CZECH REPUBLIC<br />

Tel. +420 222 524 240<br />

info@mecalux.cz<br />

www.mecalux.cz<br />

PORTUGAL<br />

Tel. +351 21 415 18 90<br />

info@mecalux.pt<br />

www.mecalux.pt<br />

BRAZIL<br />

Tel. +55 19 3809-6800<br />

info@mecalux.com.br<br />

www.mecalux.com.br<br />

FRANCE<br />

Tel. +33 01 60 11 92 92<br />

info@mecalux.fr<br />

www.mecalux.fr<br />

SLOVAKIA<br />

Tel. + 421 220 545 117<br />

info@mecalux.sk<br />

www.mecalux.sk<br />

CHILE<br />

Tel. +56 (2) 2827 6000<br />

info@mecalux.cl<br />

www.mecalux.cl<br />

GERMANY<br />

Tel. +49 (0) 2133 5065 0<br />

info@mecalux.de<br />

www.mecalux.de<br />

SPAIN<br />

Tel. +34 932 616 913<br />

info@mecalux.es<br />

www.mecalux.es<br />

MEXICO<br />

Tel. +52 (664) 647 22 00<br />

info@mecalux.com.mx<br />

www.mecalux.com.mx<br />

ITALY<br />

Tel. +39 02 98836601<br />

info@mecalux.it<br />

www.mecalux.it<br />

TurKEY<br />

Tel. +90 216 706 10 15<br />

info@mecalux.com.tr<br />

www.mecalux.com.tr<br />

PERU<br />

Tel. +51 (1) - 422 6060<br />

info@mecalux.pe<br />

www.mecalux.pe<br />

Netherlands<br />

info@mecalux.co.nl<br />

www.mecalux.co.nl<br />

UNITED KINGDOM<br />

Tel. +44 0121 3336 602<br />

info@mecalux.co.uk<br />

www.mecalux.co.uk<br />

URUGUAY<br />

Tel. +598 2683-8879<br />

info@mecalux.com.uy<br />

www.mecalux.com.uy<br />

USA<br />

Tel. 1-877-632-2589<br />

info@interlakemecalux.com<br />

www.interlakemecalux.com<br />

MK- 00203309 - 02/16 - ©MECALUX,SA

Hooray! Your file is uploaded and ready to be published.

Saved successfully!

Ooh no, something went wrong!