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Construction of the tallest cold-storage warehouse in Europe - Timelapse

The tallest cold-storage warehouse in Europe

Step-by-step construction of a clad-rack warehouse

Discover how a clad-rack warehouse is built, step by step, from the assembly of the structure to the installation of the cranes and cladding. A feat of engineering that will leave you in awe.

Step-by-step construction of a clad-rack warehouse

Mecalux builds a clad-rack automatic warehouse ready for the future

Dafsa, an example of automation, integration and growth

Video transcription

Drink a juice, heat up a puree... very day-to-day activities. But behind each brick there are hundreds of miles from the garden to the supermarket shelves.

Dafsa is Mercadona’s exclusive provider for juices, nectars, smoothies, horchata and natural purees.

Its production, packaging and distribution plant in Segorbe, Castellón, is 66,000 m2 in size and is one of the most efficient and eco-friendly within Europe.y es una de las más eficientes y sostenibles de toda Europa.

A leading company needed a partner like Mecalux to be able to carry out the innovative automated warehouse project that provides service to one of Spain’s food giants.

What stands out about the project is the spectacular automated rack supported warehouse with a carefully finished exterior that minimizes the overall landscape impact.

Jorge Dosdà Oltra (AREA MANAGER FOR LOGISTICS AND AUXILIARY MATERIAL PURCHASING)
One of the points that made us decide that Mecalux was the ideal supplier for this project was that it could provide both the storage structures, as well as the computer management system that guarantees our entire tracking.
 

The pallets with the finished product arrive at the warehouse, using robotic pallet trucks, from the packaging area to the conveyors, located in the lower area.

A loading gauge validates the condition of each pallet.

The entries are carried out by means of a double vertical reciprocating conveyor that raises the pallets to the upper level. Four stacker cranes collect them to be placed in the rack location allocated to them.

For production needs, Dafsa interchangeably handles two types of load units: Euro-pallets and medium sized pallets.

To be able to handle medium sized pallets, Mecalux installed conveyors with less spacing between rollers, chain conveyors with four strands and three cross-ties in the racks for depositing the load with utmost security.

To store their products, Dafsa has organized the warehouse so that three stacker cranes are earmarked for ambient temperature products and a fourth for refrigerated, separated by a cold-storage panel with an automatic opening access door.

The warehouse is ready for future expansion and has enough space to install three new stacker cranes.

Jorge Dosdà Oltra (AREA MANAGER FOR LOGISTICS AND AUXILIARY MATERIAL PURCHASING)
Thanks to Mecalux we have doubled our storage capacity in a short time and thereby ensured the service to our customers
 

The stacker cranes deposit the pallets for their dispatch in the lower level and two shuttles take them to the pallet flow channels according to the loading dock to which they belong. There are seven groups of channels, five for products that are stored at ambient temperature and two that are temperature controlled to ensure the cold chain.

Each channel group allows for the exact number of pallets for a full truckload.

The channels incorporate a ground breaking system of foldable bays for easy cleaning.

The Easy WMS warehouse management software from Mecalux manages all processes, from entries to dispatch.

A company like Dafsa, who sets the bar high in the area of food quality and safety, required a warehouse that is compatible with their needs.

Jorge Dosdà Oltra (AREA MANAGER FOR LOGISTICS AND AUXILIARY MATERIAL PURCHASING)
Dafsa has high standards, which is also what we ask of our suppliers and what Mecalux is able to guarantee.
 

The rack supported warehouse, built and designed by Mecalux, stands out because of its high level of integration and automation of processes.

Mecalux sets up semi-automated controlled-temperature logistics centre

Salvesen has enhanced its productivity by maximising the use of space

Video transcription

Salvesen Logistics, a business leader in food distribution, has a controlled temperature logistics centre in Seville, Spain.

This project, designed and developed by Mecalux, has transformed a warehouse with an inefficient use of space, into a semi-automated logistics centre able to meet a high standard of service.

Mecalux has divided the space of the warehouse into two clearly differentiated areas: the automated warehouse, which occupies the old warehouse zone, and the area with push-back racks on rollers.

Because of the characteristics of the product that Salvesen distributes, the two warehouses are maintained at a temperature of between 4 and 7 ºC.

The project was carried out in stages and kept a stable inventory, which guaranteed the perfect operation of the installation during the assembly.

The warehouse has 6 automatic trilateral stacker cranes each 9.8 m high, serving six 48.5 metres long, single-depth racking aisles.

The group of six trilateral stacker cranes permits a combined pallet cycle of 100 in and 100 out per hour with a travel speed of 100 metres per minute.

This type of stacker crane does not require a top rail, which allows you to capitalise on the uneven height of the warehouse covered with gabled roofs, procuring five load levels.

Nor is it necessary that the floor has a high planimetry, because the equipment moves on rails.

ISRAEL PEREZ (Head of maintenance)
The automatic trilateral stacker crane by Mecalux, being able to place items almost at level zero, allows us to make maximum use of the space, apart from having total control over our stock.
 

The processes of entries, storage and dispatch are managed and optimised thanks to the Mecalux EASY WMS warehouse management software, which enables a higher amount of throughput per hour and a total traceability of goods.

This logistics centre is equipped with an automatic dock for unloading trucks. With this system an entire truck, with 33 pallets on it, can be unloaded in 2 minutes.

Before being transferred to the main conveyor system, pallets must pass through the control gauge, where their weight, size and quality are verified to meet established standards.

Two transfer cars, one on each end of the warehouse, deposit the pallets on a conveyor circuit and move them to the entrance of the high-rise warehouse.

The stacker cranes are responsible for picking them up and placing them on the racks.

Part of the conventional pallet racks from the old warehouse are allocated to the picking of high rotation products. In all, this provides an additional capacity of almost 1,500 pallets.

The capacity achieved in the automated warehouse is more than 2,600 pallets.

Mecalux has installed 20 gravity driven live channels in front of the loading docks. Up to 7 pallets deep can be deposited per channel enhancing the speed of dispatches.

The new area of the warehouse has high-density, push-back racks with rollers. These racks have 3 load levels and are 3 pallets deep per level.

When manoeuvring by push and gravity, loading and unloading times are reduced in respect to conventional pallet racks.

This area quadruples their capacity to 2,000 pallets.

A tunnel intended for picking passes through each block of racks as to not interfere with the loading process, which is performed on the front side with wire-guided, trilateral forklifts.

This solution from Mecalux allows a massive preparation of orders.

The area has its own loading and unloading docks, which eliminates unnecessary movements between the two warehouses.

TORIBIO GUMIEL (Salvesen Seville-Malaga Area Manager)
The immediate advantages obtained from the new warehouse have been the increase in productivity, cost optimisation and the dependability of receptions and loads being on time.
 

Salvesen has enhanced its productivity by maximising the use of space, achieving cost savings and a rapid return on investment. All this, thanks to the project designed and implemented by Mecalux, which has transformed Salvesen’s warehouse in Seville.

How do you ensure error-free management of 6,000 different references from the automotive industry?

Centres AutoEquip are now able to manage a multitude of different car parts, and provide any single one within minutes, thanks to Mecalux’s Warehouse Management Software EasyWMS.

Video transcription

Ignasi Mallol (Head of the software Technical office Mecalux)
Success always begins with good ideas, good management and plenty of hard work.
However, the key to solid growth depends on our ability to manage success.
That is why Autoequip entrusts its logistics operations to Mecalux's Easy WMS software.

CENTRES AUTOEQUIP is a company devoted to providing quick vehicle care and maintenance services, and is a specialist in tyre distribution.
You have to multiply the five basic tyres on a standard vehicle by all the possible brands, models, sizes, functions... Van or estate car? Land rover or taxi? Sports car or lorry? Mountain or city? Snow or sun? And so on...
That is why Autoequip manages a database with 6,000 different articles and more than 1,700 tyres in day-to-day use.

Javier Niño (Director of finance and operations Centres AutoEquip)
Autoequip began in a village very near here, Premià de Mar, with great hope and an obsession: to sell tyres at the most competitive prices and to provide the quickest service.
Today, we are leaders in Catalonia. Autoequip has 16 centres and operates two important new business lines: national distribution by Internet and international distribution—trading.

In 2009, in order to absorb demand and improve service, Centres Autoequip opened a new logistics distribution warehouse. The new facility has a total of 3,100 square meters, of which 2,700 are devoted to warehouse space.

Ignasi Mallol (Head of the software Technical office Mecalux)
The challenge was to find a system that would ensure optimum logistical management of the warehouse, integrating it into all the processes managed by the company's ERP.

Centres Autoequip set itself an objective: to automate warehouse processes in order to increase efficiency and achieve three goals:
- Ensuring that all orders are prepared as quickly as possible
- Capacity to manage a high and variable number of article types (more than 6,000)
- Optimisation of space and storage.

Ignasi Mallol (Head of the software Technical office Mecalux)
Thanks to its multiple functionalities, ease of communications between systems and simplicity in performing complex processes, our Easy WMS software was the option selected.

Javier Niño (Director of finance and operations Centres AutoEquip)
Because a customer can call me and say: I need just one wheel, and in five minutes I know where the wheel is, I go and get it and have it ready. Only Mecalux can give you that.

The warehouse was divided into seven different areas, and the system needed to manage these according to the processes defined at the study stage: conventional storage areas for containers and large cages; peak area with tyre picking shelves; floor area for cross-docking management; large amount of stock and quick reception buffers; car audio product storage area; and dock area.
The site is fitted with conventional shelves, tyre picking shelves and floor areas, with a total of 8 storage aisles, 2 reception docks and 5 dispatch docks.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
We have 7 forklift trucks that we use to move around 3,000 wheels a day.

Easy WMS operates on 8 radio-frequency terminals with a single workstation in the warehouse.
Once the study, configuration, launch and training stages had finished, an inventory was completed and the warehouse opened, performing the following operations:

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
Operators unload the lorry and, as the unloading process continues, one calls out the following information: reference, number of units and the container we are going to put the goods into. Once a container is full, we make a report from our ERP system to the Mecalux SGA system. The operators then take the Radio Frequency Terminal (TRF) and read the type of container. Once this has been read, they are known told where to place it.

The system performs cross-docking if there are lines of orders pending.

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
If not many units enter, what we do is, we consolidate it in another type of container and the TRF tells us where we should put the tyres,

They will be placed in the peak or full container zone through an article replacement or consolidation process, when these containers are filled up again with the same product. In this way, Mecalux's Easy WMS optimises container capacity and, in this way, warehouse space.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
It tells us exactly where to place and where to pick each type of tyre on all customer orders.

- The ERP sends orders automatically.
- The warehouse manager assigns orders to operators according to their workload and capacity.
- Waves of orders are generated so that orders can be prepared in blocks, optimising the route.
- The operator's route is optimised, beginning with the orange zone on, to create a natural route to the dispatch docks.
- The warehouse is divided into zones according to the down-up rotation of articles in order to minimise goods movements and ensure that operators have direct access to goods.
- Once the order has been served at the dispatch dock, the dispatch is automatically closed and confirmation of the prepared and dispatched order is sent to the ERP.
Easy WMS also allows other processes to be performed:
- Permanent inventory.
- Automatic product rotation calculation
- Generation of container and location labels
- Generation of customised reports and statistics

Ignasi Mallol (Head of the software Technical office Mecalux)
But results are the important thing. Let's see how Autoequip has benefited from Mecalux Easy software.

Javier Niño (Director of finance and operations Centres AutoEquip)
We have increased our capacity by 100 per cent, from 15,000 to 30,000 wheels.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
At first, we were handling a couple of lorries a week, more or less. Now, it's one or two a day.

Juan Carlos Astasio (Integral logistics manager Centres AutoEquip)
We have increased dispatches by 60 per cent, from 150 a day to 240.

Ignasi Mallol (Head of the software Technical office Mecalux)
Mecalux Easy has helped Autoequip to consolidate the company's success.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
The amount we have grown is... awesome.

Ignasi Mallol (Head of the software Technical office Mecalux)
The system has enormous potential, enabling us to increase the complexity of our warehouse management, opening up to the future.

Javier Niño (Director of finance and operations Centres AutoEquip)
We plan to increase the capacity of our warehouse here by approximately 70 per cent.

Carlos Tamayo (Warehouse Manager Centres AutoEquip)
In a year or less we will be moving double the number of tyres.

Javier Niño (Director of finance and operations Centres AutoEquip)
We could easily be talking in terms of 120 per cent growth in three years.

Pallet inspection: Size, weight and structure

This ensures that only pallets in optimum conditions get into the automated circuit. We can monitor the size, weight and condition of the pallet, to ensure that they are suitable.

Move pallets from rollers to chains

A conveyor that combines both rollers and chains, making it possible to transfer pallets from one system to another, while making changes of direction through 90°.

Pallet transfer between unaligned conveyors

The layout of transportation systems for pallets can vary greatly. This conveyor lets you cover angles of 45°, 60°, 90° and 180° in relation to the incoming direction.

Lifting pallets to different heights

Join two or more levels and turn the problems associated with transporting palletised unit loads into a thing of the past. This lifting system can be easily incorporated into warehouses of type.

Stacking and re-distributing surplus pallets in a transportation circuit

Telescopic lifting forks are used either to stack empty pallets one on top of the other, or unstack them. Used in specific circuit layouts.

Twin-mast cranes in single deep racks: Combined cycles

A combined cycle is the average time required to store and remove materials in a single movement.

Stacker cranes: Extractions in double-deep racks

Automated retrieval systems that work in double-deep racks, such as stacker cranes, offer a great balance between storage capacity and handling speed. Relocation is required when working with the second unit load.

Combined cycles in double-deep racks: Relocations

Ratios of combined cycles when double-deep racking systems are somewhat lower. Discover the relocation concept and boost storage capacity

Single-deep stacker crane: a single cycle

Automated warehouses with single-deep racks: Stacker cranes load or unload a single pallet on one side of the aisle and then return to their starting position.

High performance in compact pallet racking

When combined with fast handling equipment, Pallet Shuttle systems offer high-speed workflows, making your warehouse fully automatic.

Mecalux to centralise logistics at Nupik International

A new logistics centre installed in Polinyà has allowed Nupik International to centralise logistics operations, concentrating the activity of five warehouses into one fully-automated facility with an incredible capacity of 28,000 pallets.

Video transcription

Nupik Internacional, a leading company in the manufacture of single-use tableware, has consolidated 5 of its warehouses in its headquarters in Polinyà, Barcelona.

A fully automated warehouse with an area of 8,000 m2, that can respond to the order peaks generated by seasonal demand.

The new automated warehouse designed by Mecalux is comprised of one building for storage, picking and shipment of orders.

Next to this there is a tall, Rack-clad warehouse enabling a total storage capacity of 28,000 pallets.

The processes of storage, reception and shipment are fully automated and optimised using the Easy WMS warehouse management software from Mecalux, enabling permanent inventory and full traceability of merchandise

Reception of merchandise to the store may be carried out automatically and manually.

A zone in the shipment area has been prepared for the manual reception of pallets from other production or handling centres.

A tunnel links the production lines to the warehouse through an automatic transport system that enables a continuous flow of pallets. This is a two-way system as it also allows goods to be carried to the production area.

A total of 6 lifts smoothly and effectively connect the different warehouse levels, the production warehouse and the shipping area.

Pallets are grouped on friction accumulation conveyors and automatically move to the identification and control point.

A scanner does the reading and the Easy Warehouse Management software selects their placement.

If necessary, the pallet is wrapped in order to prevent uncontrolled movement of the load.

The reception identification point measures, weighs and verifies the perfect status of each pallet.

Within the facility, pallets may have different destinations: the storage area, the picking area or directly to shipping.

The Nupik automated warehouse is serviced by double-bottom stacker cranes with Shuttle Car, using the most advanced technology.

In the double bottom storage area a total of 5 stacker cranes are installed that place pallets to be sent to the picking area with average turnover references.

Telescopik forks are able to place and pick up a load located at the second deep.

The entry and exit of material may be carried out in a single movement, enabling 229 combined cycles per hour.

The automated warehouse is also equipped with 3 stacker cranes with a shuttle car, enabling the storage of a large number of pallets by reference and also those that are issued complete. This storage system maximises available space.

The stacker cranes lift the merchandise while moving longitudinally at the same time, improving location and collection times.

The shuttle car moves the pallets from the entry point to the placement position that the Easy WMS management system has specified.

By using the shuttle car, the operating time of each manoeuvre is reduced and the LIFO system is applied, in which the last pallet in is the first out.

A corridor physically connects and integrates the different areas: production, picking platform and storage area.

In the picking preparation area automatic and manual orders are carried out and a total of 32 simultaneous orders is possible.

In the central area, the pallets that the robot handles accumulate according to the requirements of the subsequent orders.

The monitor indicates which layers must be released and the operator cuts the protective film.

Subsequently, the robot or the shuttle places the empty pallets on preparation points.

The anthropomorphic robot can prepare three orders simultaneously and is capable of handling up to 150 layers/hour or, in other words, more than 1,000 boxes/hour.

The Easy WMS management software optimises the stackability and sequencing of loads, thus increasing effectiveness, saving time and minimising costs.

Some orders are carried out semi-automatically, the robot begins its preparation and the shuttle moves the pallet to the operator in order for the operator to complete it.

Manual picking consists of 2 platforms with a total of 16 preparation posts that enable the handling of many different references quickly and easily.

This process is always guided by interactive visual indications.

The system is equipped with safety measures ensuring the protection and integrity of installation personnel.

The shuttles take the prepared orders and transfer them to the wrapping area.

Merchandise is wrapped at a rate of 70 pallets/hour.

Finally, the pallets are labelled and transferred to the shipping area using lifts.

Complete pallets that do not pass through the picking area are labelled in the shipping area.

All pallets arrive at this area and are then transported to a double shuttle, which places them into dynamic channels, enabling grouping and sequencing of the merchandise.

The Easy WMS management software groups the merchandise by route, vehicle, customer, delivery order or other characteristics.

This automated warehouse management system is a high-level technological solution, which enables Nupik to provide rapid service to its customers and to consolidate its international expansion.

 

A LEADER IN ACTIVE LOGISTICS

Mecalux completes the Porcelanosa Group´s logistics complex

With the addition of this automated warehouse to Porcelanosa’s logistics complex, Mecalux completes one of the most advanced logistics infrastructures in the ceramic industry.

Video transcription

The heat of fire, the humbleness of sand… basic elements on which Porcelanosa has built a solid business group which covers all sectors of ceramics, from tiles to solutions for the most contemporary of architecture.

 

5 logistics centres in Castellón are the result of years of close collaboration with Mecalux, which has designed and implemented the best solutions for each project, providing “innovation, technology and excellence” in each one. Three words that sum up their working philosophy and turn them into the best allies of a large group like Porcelanosa.

 

Mecalux took its first steps in this great project with the Porcelanosa logistics centre in 2003, followed by the Ceranco centre. Six years later the l’Antic Colonial and Noken centres were built, and finally Venís in 2011.

 

Venís, a pioneering flooring company, with a wide variety of types and finishes, is the last of the 5 logistics centres built by Mecalux for the Porcelanosa Group. This centre is fitted out with the most recent technological developments present in each and every part of the circuit.

 

The cycle starts with the pallets with the finished product. These mostly come from the production centre, connected to the silo through an underground tunnel more than 1 kilometre long.

 

Monitored along their route by Mecalux’s Easy warehouse management software, they are lifted on the double lifts that allow two pallets of up to 1,600 kg each to be loaded until they reach the aisle entrances of the store.

 

In addition to the tunnel entrance, the store has another auxiliary entrance for pallets from other centres.

 

The pallets are moved on the roller and chain conveyors to the identification point, where Mecalux’s Easy warehouse management software controls any incident. Here each pallet is measured and weighed and it is made sure that they are in perfect condition.

 

The auxiliary entrance is also used for bringing in empty pallets. Both these and those from other centres comply with rigorous quality control.

 

 

Venís silo: 7,000 square metres, 31 metres high and with a capacity to store 65,000 pallets.

 

The silo structure comprises 10 aisles where 10 twin-mast stacker cranes circulate and lift the pallets to place them strategically following the orders of the Mecalux Easy warehouse management software.

 

The faster-rotating goods are placed closer to the aisle entrance.

 

The twin-mast stacker cranes operate at a speed of up to 180 metres per minute and are able to perform as many as 237 combined cycles.

 

The stacker cranes are capable of recovering an average value of 15% of the energy consumed for self-consumption.

 

This logistics centre project created by Mecalux especially in accordance with Venis’s needs, also has space for future extensions to be built.

 

Goods delivery has also required specific solutions from Mecalux, both for the more complex picking zone and for and that of full pallets.

 

Eight work posts have been set up in the picking zone, able to prepare a total of 31 orders at the same time.

 

Pneumatic arms allow operators to handle the load effortlessly, facilitating movements with weight and speeding up the whole process.

 

The tables are fitted with height-adjustable hydraulic systems for greater ergonomics for workers.

 

The Mecalux Easy warehouse management software controls the preparation and the dispatching, enabling 4 orders to be completed at a time at each picking post.

 

Two double shuttles run along the picking aisles, keeping the safety distance and distributing the loads on the output tables.

 

All details count in the Venís logistics centre. Mecalux built a tunnel in Venís to connect the picking zone with the dispatch area to avoid the shuttle circulation area.

 

The delivery zone has two areas for full pallets and another two for those coming from picking.

 

The full pallets are distributed along 6 lines on either side of the silo. Those coming from the picking zone are wrapped to be shipped.

 

The large variety of Porcelanosa products has generated specific requirements in some of the group’s logistics centres. This is the case of l’Antic Colonial, where the parquet flooring is stored in large, wrapped flat packs requiring double pallets for storage.

 

Mecalux has designed lifts, stacker cranes and picking posts especially for these unconventionally large items.

 

In the case of Noken, another of the companies of the Porcelanosa Group, which stores small products as a manufacturer of taps and bathroom units, Mecalux designed an automatic warehouse for boxes instead of pallets. A solution that provides greater agility in goods input and output.

 

This is the daily work of the logistics centres of the Porcelanosa Group, a company that has risen as a benchmark of quality and innovation at the service of logistics. A challenge taken on by Porcelanosa and Mecalux now more than 15 years ago materialised in the 5 automatic logistics centres built to date.

 

Mecalux and Porcelanosa. A long trajectory offering the best products to their customers. Mecalux technology and experience for the Porcelanosa Group.

Mecalux as a provider of global e-commerce solutions

The Easy WMS software allows Tradeinn to efficiently control its growing volume of data and stock.

Video transcription

Tradeinn is an internationally recognized e-commerce firm in the sale of sports equipment.

With its headquarters in Celrà, Girona, Tradeinn began doing business in 1997. Today it has 13 speciality online stores. Year after year, the company has been growing and developing, reaching some incredible numbers:

  • 13 Specialty online shops
  • More than 1,000,000 SKUs for sale
  • Sales in 220 countries
  • 1,000,000 customers
  • Averaging 2,000 orders per day

Since its inception Tradeinn has relied on Mecalux as a provider of global e-commerce solutions.

DAVID MARTIN (CEO at Tradeinn)
Mecalux has been an essential partner in our growth during the different stages that we have gone through these past 6 years, in which our sales have multiplied by 40. Because they have helped both in supplying racks for each warehouse we have been located in and also with the radio frequency software, Easy. The truth is that “Easy” has helped us enormously in managing the more than a million products that are in our catalogue and in reducing the costs of preparing a package, which is very important in the case of an e-commerce company.
 

The warehouse is 7,000 square meters in size, equipped with picking racks that are adjustable to any product size, from skis to wetsuits, and they are set up for future growth.

The management of the warehouse with the Easy WMS software allows Tradeinn to efficiently control its growing volume of data and stock.

Ramon Alvarez - CLO (Chief Logistics Officer)
Which meant the implementation of Mecalux Easy at Tradeinn was to "streamline", i.e. knowing at all times what we have, where we have it and how we have to prepare it. We now turn over the same amount of volume in a single month as we did in the whole of 2011. We realized that we had to integrate a warehouse management software at the time when we moved because traditional management was impossible.

 

Tradeinn’s objective is that when a user clicks the "Proceed to Checkout" button a process starts that is completed when they receive the correct product at their homes, on time.

The most important stages of this process are in the management of stock and the fulfilment of orders.

This involves different actions controlled by Easy WMS, such as:

  • Reception of material and new releases in the product master records…
  • Streamlining of the operator’s movements…
  • Inventory in real time…
  • And cross docking.

Ramon Alvarez - CLO (Chief Logistics Officer)
One of the developments made, which has been very successful, is the cross dock, which allows us to receive and dispatch material without it being put into the racks, minimising time, costs and operations.
 

Averaging 2,000 orders per day, the speed and accuracy in the preparation of orders is the most important process. Tradeinn defines its business as "a factory for preparing packages".

Ramon Alvarez - CLO (Chief Logistics Officer)
We can easily absorb the growth that the company is experiencing, as the software can withstand it, manage it and there is no problem. In terms of inputs, we are receiving 80% more than last year. In terms of outputs, we are shipping out 70% more than last year. The integration of stock in the last inventory was 99.98%. Easy has everything under control, all of these parameters, and helps us to be able to accomplish everything on time.
 

To be able to make large scale preparation of products, Tradeinn has reconfigured parcelling operations, distributing it onto tables. To further increase productivity, Easy WMS allows for working with orders in waves: they can currently launch 600 orders at the same time.

The features of EASY WMS also enable the management of point of sale stores, whether they have their own stock or not, as in the case of the store that Tradeinn has next to its logistics centre, which is treated as if it were another customer.

DAVID MARTIN (CEO at Tradeinn)
We chose Mecalux as a partner due to the reputation that the company has in the market. We started to work a bit at a time putting up parts of the racks, when we needed to install a software we examined several options and Easy was the one we liked the most. And as we already had good referrals and we had previously worked with Mecalux, we decided to go ahead with them.
 

By choosing this storage solution and the Mecalux Easy WMS management software, Tradeinn was provided with the flexibility, versatility and response capability necessary to adapt to the relentless innovation that the e-commerce sector experiences, becoming a business leader in continuous development and growth.

Mecalux delivers a turnkey installation to the highest producing Michelin tire plants in Europe

The solution by Mecalux has made the Michelin manufacturing centre in Vitoria a pioneer in its sector.

Video transcription

Michelin, 130 years manufacturing tires for any vehicle around the world.

One of the largest, highest producing Michelin tire plants in Europe is located in Vitoria, Spain. The facility’s elevated manufacturing flows required a fine-tuned logistics solution able to manage the business growth achieved in recent years, driven in part by the planned addition of a fourth production line.

 

The solution provided by Mecalux is designed with Michelin’s standard container dimensions and characteristics in mind. These metal containers flow through the entire installation and are set directly in the racks without needing a base pallet.

The automated clad-rack warehouse is 27 metres high and comprises 5 aisles where 5 single-mast stacker cranes operate. Divided into two floors, each level runs a different operation: inputs are carried out on the lower level, and outputs on the upper.
 

Double stacked containers arrive directly from the production plant. A full pallet stacker mounted at the entry point unstacks the containers and sets them on the chain conveyor, all pallet-free. Next, the conveyors shift the containers to the storage aisles; a stacker crane then collects and inserts them in their assigned location.

Inside the automated warehouse, the goods are stored as per the commands of the Easy WMS warehouse management system, designed by Mecalux. The Easy software has been adapted to the BSM communications system of Michelin, meaning output management is fully customised. Easy WMS controls product tracking through virtual instructions, and always knows where to find each and every container and if that container has exited or not..

The racks are specially designed to direct-store containers, thanks to cross-ties that support the container legs in a completely secure manner.

Outputs flow through the upper floor, serviced by a double transfer car that carries the containers to the dispatch zone. This transfer car can hold two containers at a time, making it possible to sequence the load and streamline workflows.

In this zone, 4 full pallet stackers restack the containers, to reduce loading times and optimise the space inside the transport vehicles.

Antonio J. García-Montalvo / Project Manager ASRS Z/VIT / Technical office / Michelin
This warehouse has a 4600 container capacity, which will accommodate the containers generated by 3 already up and running production lines, as well as a fourth prospective line, and it also has a capacity for 120 containers an hour. It was crucial to be able to retrieve containers off the lines and also supply containers to the delivery vehicle docks. Presently, everything is running very smoothly.
 

Mecalux also set up a fire safety system, enclosures and a cooling system that keeps the temperature between 10 and 27 degrees.

Mecalux has delivered a turnkey installation to Michelin that operates 24 hours a day, 7 days a week.

The solution by Mecalux has made the Michelin manufacturing centre in Vitoria a pioneer in its sector. Innovation and technology at your service.

Goods dispatch: The last step before leaving the warehouse

Through the use of outbound gravity-flow lanes and Warehouse Management Software, goods can be gathered in the dispatch areas, sorted by route, vehicle, customer, etc.

Video transcription

Goods are taken to the dispatching área

If necessary, pallets are labelled

Pallets are carried to a shuttle, which is doublé in this case.

The system can carry pallets of different weights.

Easy WMS management software groups goods by route, vehicle, client or other criteria.

Dynamic shelves allow grouping and sequencing goods without using electricity.

Brake rollers keep the moving speedconstant and maintain stability.