Mecalux Best Practices Magazine 01 - English

1r Quarter - Year 2016 - No. 1
Cases Studies
Benco Dental / DAFSA / DHL / Gioseppo / Havi Logistics
Hayat Kimya / Hemosa / Hepco Motion / Iron Mountain / Luis Simões
MGA / Nufri / PAVI-Groupauto / Takeda / Ypê / Zbyszko

3Best Practices
135135
111
9595
7979
Index
13 HAYAT KIMYA
One of the tallest warehouses in Europe
in an earthquake prone zone in Turkey.
29 GIOSEPPO
Automated clad‐rack warehouse with a
capacity of two million pairs of shoes.
41 YPÊ
High‐rise warehouse with massive
picking area for the Brazilian company
Ypê.
49 TAKEDA
Almacén automático llave en mano
para el gigante farmacéutico japonés
Takeda.
59 NUFRI
Racks on Movirack mobile bases for
their headquarters in Catalonia.
63 MGA
Efficient automated miniload
warehouse with conventional racks.
71 LUIS SIMÕES
The operator equips their installations
with a Pallet Shuttle system combined
with conventional racks.
79 DHL
New logistics centre for DHL on the
outskirts of Madrid.
87 PAVI-GROUPAUTO
Conveyors on several floors the axis of a
picking installation.
95 HEMOSA
Mecalux equips the processing plant for
Hemosa located in Madrid.
103 ZbYSZKO
The Polish manufacturer Zbyszko
Company entrusts Mecalux with the
connection of theproduction area with
a new automated warehouse.
111 DAFSA
A singular warehouse in choice
surroundings.
127 HAVI LOGISTICS
The logistics services business relies on
mobile bases to keep growing.
131 HEPCO MOTION
A special mobile racks with cantilevers
solution installed in the United
Kingdom.
135 IRON MONTAIN
Earthquake‐proof racks in the Belt of
Fire in the Pacific.
139 bENCO DENTAL
Interlake Mecalux speeds up the picking
at Benco Dental.
146 OUR ExPERTS
- Logistics software, the cloud is the
future.
- Clad‐rack warehouses: when the racks
also support the building.
- How to calculate the structure of
conventional pallet racking.

News I Mecalux
4 Best Practices
Safety in the warehouse is the foundation
onwhichtodevelopaninstallation’sday-to-
day work operations in an efficient and risk-
freeway.Therefore,Mecaluxinvestsasigni-
ficant part of its R&D resources to improve
the security devices of all its products.
The latest innovation in this respect is the
incorporation of a new junction system
between uprights and beams in Mecalux
pallet racks. This involves a connector with
a locking system, developed to provide
greater safety on the whole.
Its most outstanding contribution is the in-
tegration of a safety locking mechanism in
the actual connector, which results in two
key advantages: on the one hand, it is im-
possible for the safety device not to work
or to lose it accidentally; while on the other
hand, once it is assembled it is not possible
to remove it without the disassembly of the
entire beam. This prevents accidental or
deliberate manipulation of the connector –
with a blow by a forklift, for example – thus
avoiding the beam displacement and its
possibleconsequences,suchasthecollapse
of the load.
After successfully introducing this new
locking system into installations set up in
the United States, where Mecalux is a lea-
der in the pallet racking market, it is now
integrating it into all their projects within
Europe.
They are the only manufacturer on the
European continent to develop and incor-
porate this breakthrough device into their
storage solutions.
Keepingwithitscommitmenttoinnovation
and new technologies, Mecalux has com-
pletely updated its e-commerce portal for
Spain, offering a new design, new content
and a better user experience.
The new Mecalux Shop specialises in the di-
rect sale of metal shelving and related pro-
ducts to warehouses, workshops, offices,
archives, change rooms, etc., building on
the extensive knowledge and experience of
Mecalux within the sector.
Among the newly inte-
grated enhancements
are the following:
• Newcategoriesand
advanced search filters which allow
you to easily find any product.
• More information on each product:
description of main product features,
with more detailed technical information
and more pictures.
• Makingapurchaseisstreamlinedand
speedy with a user friendly design.
• Optimised design for smartphones and
tablets.
• Moreadvantagesforregisteredusers:
custom offers, easy personal data admin,
order tracking, purchase history access,
etc.
Another of the key points of Mecalux Shop
is its Customer Service, with professionals
who know the product and its applica-
Safe and sound: Mecalux introduces
an innovative safety locking mechanism
Mecalux Shop:
a new look, new
clickable content
tions and that, if necessary, can help the
user to choose between different storage
solutions.
With this rejuvenation and the inclusion of
better features and navigability, Mecalux
has updated its online sales gateway
witn the steady flow of technological
breakthroughs in the field of e-commerce
and in the shifts in user enthusiasm. The
end user will benefit from the esase of use.

News I Mecalux
5Best Practices
As one of the leading companies in storage
solutions for more than 50 years, Mecalux
invests significant resources in the develop-
ment of new products and the continuous
improvement of those which are already
part of their catalogue. It always aims to in-
corporate the latest in technological inno-
vations to deliver better profitability.
So, one of the solutions that has experien-
ced the greatest amount of development
is the semi-automated Pallet Shuttle. This
compact system uses an electric shuttle
instead of forklifts to handle pallets inside
the storage channels (that can reach 40 m
in depth), considerably reducing manoeu-
vring times and helping to streamline stora-
ge processes for all kinds of companies.
Among the new add-on innovations what
stands out is the adoption of Wi-Fi techno-
Maxi-innovation for Mecalux’s
semi-automated compact storage
logy, which mul-
tiplies the system
benefits: the forklift
operator communi-
cates the storage and
removal orders to the shuttle
using a control tablet with Wi-Fi
connection, with an intuitive, user
friendly interface.
Different key features:
• Input and removal of pallets: conti-
nuous or partial.
• Inventory functionality.
• High speed: 90 m/min without load and
lifting time of 2 s.
• Lithium batteries that provide up to
10 h of autonomous use, with a quick
connect battery compartment that elimi-
nates the need for cables.
• Pallet type selector (the shuttle sup-
ports various sizes).
• LIFO/FIFO setup to select the load ma-
nagement strategy.
• Positioncamerathatfacilitatestheope-
rator in centralising the pallet on the rails
(optional).
• Security scanner: controls access to
the rails while the shuttle is operating
(optional).
• Additional lock system that increases
the clamping of the electric shuttle to the
forklift blades.
• Compatibility with Mecalux Easy WMS
software, or other generic WMS used by
the customer.
• The lifting platform can receive pallets
with buckling of up to 25 mm.
• Tiltmeter: detects the incorrect position
of the shuttle within the channel
• Rescue: recovers the damaged shuttle
from within the channel
The result is a new generation of Pallet
Shuttle, which capitalises new technolo-
gies to enhance the warehouse performan-
ce and its profitability. It is an ideal solution
forcompanieswithalargevolumeofpallets
per SKU and high loading and unloading
activity.

News I Mecalux
6 Best Practices
Mecalux has had a significant presence in
Mexico for many years, with 8 sales offices.
Being local, together with the experience
of its team of professionals, has led nume-
rous Mexican companies to rely on the Easy
WMS Mecalux software, as a means to ma-
nage and capitalise their storage processes.
Among the rollout Easy WMS projects sig-
ned in Mexico in the past few months, the
following stand out:
• Grupo Acuícola Mexicano (GB-
PO). With Easy WMS they can au-
tomate the management of one of
its freezing chambers, controlling
the entries from the production li-
ne, and correct load management
using FIFO and expeditions.
• Distribución Hugo’ss. Within
its improved processes, they ha-
ve chosen the Easy WMS, which
communicates with their SAP
ERP, to speed up and streamline
their picking processes, elimina-
tingcustomerserviceerrors.
• Polioles. ELeader in the petrochemical
industry. Its main objectives are the reduc-
tion of costs and storage errors, to control
warehouse operations, product traceabili-
ty and cross-docking management.
• Diseños Labor. With Easy WMS they
can reconfigure their warehouse layout,
the improved inventory visibility, handles
information real time via bar codes and
radio frequency controls and, in general,
automate warehouse processes.
• Grupo Comrap. They use Easy WMS in
two warehouses, designed and built by
Mecalux, in Mexico DF to manage large
scale picking and fulfil their commitment to
offer excellent service to their customers.
Furthermore, two prestigious univer-
sities, the Autonomous University of
Queretaro (UTEQ) and the Auto-
nomous University of the State of
Mexico (UAEM) have acquired the
field license for Easy WMS Basic for
academic use in the Logistics degree
professorship.
The three university courses delivered in
2015, within the framework of the Mecalux
UPC classroom, were created through
the collaborative agreement between the
UPC (Universitat Politècnica de Catalunya),
the ETSEIB (Escola Tècnica Superior
d’Enginyeria Industrial) of Barcelona and
Mecalux, all being extremely reputable
parties.
Due to success, this new training modules
will be taught throughout 2016, which will
give new students the opportunity to dee-
pen their understanding of subjects such
as the development of structures, robotics
and the automation of storage facilities.
The objective of the UPC Mecalux Aula is
to train up tomorrow’s professionals and
provide them with the tools necessary to
make advances in R&D&I within the logis-
tics industry. To this end, Mecalux offers
scholarships covering course fees for UPC
master’s students, which fulfil the entry
Success, innovation & automation: the Mecalux UPC classroom
offers new courses in breakthrough logistics systems in 2016
requirements, in addition to putting the
Mecalux technological centres at their dis-
posal and offering them the possibility of
starting their career in the company.
New courses are scheduled to start in
Marchof2016,with30lecturehours,atthe
Mecalux UPC classroom premises.
Mecalux and the UPC
As a company that bases its leadership on
technological innovation, Mecalux has
for years been committed to fostering this
company-University relationship, collabo-
rating with the UPC and in particular
with the ETSEIB, since 1979. All this through
the Department of Material Resistance
(LERMA), with which it has developed an
Experimental Analysis of Characterisa-
tions program and another of Research and
Development.
Along these lines, the two entities have
promoted the creation the Mecalux UPC
Aula, as a means of consolidating long-
term collaboration in R&D&I activities and
the transfer of research results and scien-
tific dissemination within integral logistics
related topics.
For more information and to register
contact:
http://aulamecalux.upc.edu/
E-mail: aula.mecalux@upc.edu
Mecalux Easy Warehouse Management Software: a blockbuster in Mexico
Visit the Mecalux Mexico
stand in the upcoming industry
fairs at:
LogisticSummit&Expo,MéxicoDF,
onApril6th
and7th
,2016.
Expopack, México DF, from May
17th
to 20th
, 2016.

7
News I Our customers
Best Practices
In recent months, the markets of Argenti-
na and Peru have opted for the compact
storage system Pallet Shuttle by Mecalux.
This solution incorporates numerous inno-
vations to streamline the processes of the
entry and exit of goods in the warehouse. It
alsoprovidesgreatstoragecapacity,thanks
to an electric shuttle that loads and unloads
pallets in the interior of the racks, moving
autonomously along rails.
Among the projects recently carried out in
these countries, two constructions, in parti-
cular, stand out that have combined the be-
nefits of clad-rack warehouses with those
containing Pallet Shuttle racks.
In Argentina, Granja Tres Arroyos, one of
the major producers and exporters of fro-
zen chicken, has chosen this solution when
building their new frozen cold-storage. The
combination of a clad-rack warehouse with
the Pallet Shuttle system is particularly re-
commended in cold-storage, although, the
building is not of great height. In addition
to lowering manoeuvring times, it offers a
high storage capacity that reduces the vo-
lumetric area to be kept cool, resulting in
energy cost savings.
On the other hand, the Mecalux Peru team
has completed the construction of another
clad-rack warehouse with Pallet Shuttle for
Medifarma, one of the top 5 pharmaceuti-
cal laboratories in Peru. In this project, gi-
ven the diversity of the products marketed,
the versatility of the system proved essen-
tial, while also increasing the number of cy-
cles per hour compared to a conventional
system.
In both cases, it is worth noting that
although these clad-rack warehouses are
not very tall, they have also been the most
profitable option for both companies. This
is because the storage channels were cons-
tructed to the depth which was strictly ne-
Logistics chain
innovation in Argentina
and Peru: clad-rack
warehouses with Pallet
Shuttle to be built
cessary, calculated according to their requi-
red functionality.
The goal is to put new technologies and
approaches within reach all kinds of com-
panies,tomultiplytheproductivityandpro-
fitability of storage installations, achieving
maximum performance within the logistics
chain.
Mecalux, in their effort to provide up clo-
se and personal service to its customers, are
present in Argentina with two sales offices
inBuenosAiresanda21,000m2
production
centre, while there is also a delegation in
Lima, Peru. Overall, the strength of the cus-
tomer support is second to none.
Close up of the Granja Tres Arroyos warehouse in Argentina
Close up of the Mediafarma warehouse

8
Best Practices
All in the family: Mecalux expands
the Familia Group warehouse in Colombia
Familia Group, a company specialising in
personal care and hygiene products, will
expand its current clad-rack warehouse
to reach a capacity of more than 16,000
pallets.
In 2011, Mecalux erected Family Group one
of the first automated warehouses within Co-
lombia. The installation, with a capacity for
7,416 pallets and 31.2 m high, is managed by
threestackercranes.
A few years later, the company has again cho-
sen Mecalux to execute the Cájica warehouse
expansion. The objective: to reach 34.4 m in
height, increase capacity to include another
9,480 pallets, and install an additional three
stacker cranes. Moreover, recirculation is set
upthatallowsboththemanagementofinputs
fromoutsidesourcesandinternalproduction,
and also direct dispatch from the warehouse.
The warehouse management system, Easy
WMSsoftware,implementedbyMecaluxwill
alsobesupplied.
With this expansion, the Family Group ware-
housewillachievegreaterinputsandoutputs,
bringing it to the forefront of logistics within
thetissueandthepersonalhygienesector.
Çaykur’s, the biggest producer of
Turkish tea, new clad-rack warehouse
in Iyidere (Turkey) will be more than
40 m high and almost 160 m long.
Mecalux will provide a large, single aisle,
automated warehouse served by three
single-column stacker cranes and aided
by Pallet Shuttle that are responsible for
transporting 800 x 1200 x 2600 mm sized
pallets with a maximum weight of 600 kg
each.
In order to optimize accessibility to loca-
tions, Mecalux has developed a control
system and safe passageways that allow
the stacker cranes to enter the annex
zones. This is all controlled by the ware-
house management system Easy WMS and
the Galileo control software.
Mecalux will build
Çaykur a clad-rack
warehouse with
a capacity for more
than 29,000 pallets
In addition, input of goods will be done
at the side the warehouse via three raised
overpasses that connect the warehouse
with the docking area. The elevated over-
passes allow for workspace savings so
that the ground floor remains completely
available.

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

9
Best Practices
This company, specialised in the manu-
facture and marketing of caps and clo-
sures, will incorporate an automated
and asymmetrical, four tiered ware-
house into its Wiltz (Luxembourg)
plant.
The warehouse, with a capacity for more
than 5,000 pallets, will be managed by two
stacker cranes and a Pallet Shuttle that will
work with two types of pallets: 800 x 1,200
x 2,200 mm and 800 x 1,200 x 2,700 mm.
The warehouse management system,
Easy WMS, will also be supplied, tasked
with managing all the centre’s own ope-
rations. For the first time in its history,
Easy WMS will be permanently connected
to Axapta (Microsoft Dynamics AX), the
ERP system that the client uses.
UnitedCapsisaleaderinthedesignandpro-
duction of plastic caps and closures. With
their headquarters in Luxembourg, this
family business offers its innovative so-
lutions throughout the world and has its
own production plants in France, Belgium,
Germany, Hungary, Ireland, Luxembourg
and Spain. The company, which had an an-
nual turnover of 122.000.000 € in 2015,
employs more than 530 workers.
United Caps seals
the deal: Mecalux
to automate new
warehouse
The very popular Brazilian company,
specialised in the production of pre-
cooked, frozen potato products, has
entrusted Mecalux to design, ins-
tall and launch a clad-rack automa-
ted warehouse. This warehouse has
the capacity of storing more than
33,000 pallets, 1,000 x 1,200 mm in
size and each with a maximum weight
of 1,120 kg.
The warehouse, which is more than
25 m high, has three twin-mast stacker
cranes with Pallet Shuttle that allow for an
input or output of 105 pallets/hour. Thus,
the company’s required throughputs are
Bem Brasil is keeping cool with clad-rack:
Mecalux sets up automated storage in Brazil
attained. The stacker cranes, when work-
ing in deep lanes, are supported by a
Pallet Shuttle that is responsible for mo-
ving the pallet up to the location designa-
ted by the Mecalux Easy WMS software.
Additionally, in order to ensure the per-
fect condition of the goods, Bem Brasil’s
clad-rack frozen storage is expected to
work at a temperature of -30 ºC.
Founded in 2006, Bem Brasil produces
more than 100,000 tons of pre-cooked
frozen fries a year. It has become the na-
tional leader within the sector, and one of
the most consumed brands within Brazil.

10
Best Practices
The French company, dedicated to the
technological agribusiness sector, will
have an automated mainland ware-
house for boxes – with a capacity of
morethan10,000boxes –built.
The miniload warehouse is comprised of two
doubledepthaisleswhereastackercranewill
circulateandbetaskedwithexecutingthein-
putandoutputof400x600mmsizedboxes,
each weighing a maximum of 50 kg. In the
Agrarian giant Gregoire Besson announces new automated
miniload warehouse in France by Mecalux
header of the automated warehouse, three
P&D stations are set up to prepare orders of
smallerproducts.Inaddition,theinstallation
will be equipped with six conventional pallet
rack aisles with a capacity for 4,440 pallets
andacantileverrackforover-sizedproducts.
Thanks to the different storage solutions
provided by Mecalux, Gregoire Besson
will optimise space and, at the same time,
streamline order preparation.
GregoireBesson,withalmost200years’ex-
perience,isaleadingFrenchcompanyinthe
manufacture of agricultural machines and
in the implementation of technological so-
lutions designed to optimise land produced
resources.
Withalargerepresentationworldwide,their
ploughing machines are innovative, effi-
cient, robust and adaptable to the characte-
risticsofanytypeofarableland.
Home decor’s largest
warehouse: Mecalux
will equip Maisons
du Monde with new
installation
Thenewconventionalpalletrackware-
house, of the French company speciali-
sed in home decor, will be built within
a 96,000 m² logistical centre located in
Saint-Martin-de-Crau, a town in the
south of France.
Distrimag, the company responsible for dis-
tributing products to customers of Maisons
du Monde, has once again commissioned
Mecalux with supplying a warehouse for
pallets. Since 2007, Mecalux has built them
10 warehouses that are divided into 4 lo-
gistics centres (Saint Martin, Fos Distriport,
Feuillanne and Boussard) and that allow
the storage of a total of 304,000 pallets. In
this way, Distrimag commands 477,600 m2
of storage in strategic locations in the south
of France, extending its firm grip on the de-
corationmarket.
Founded in 1990 by Xavier Marie, Maisons
duMondehas260shopsspreadthroughout
France, Italy, Spain, Luxembourg, Switzer-
land, Germany and Belgium, and which em-
ploy more than 4,500 workers. The Group
has more than 40,000 high-quality pro-
ducts, making it one of the leading compa-
niesinhomedecorinFrance.

11
Best Practices
The new automated warehouse, to be
builtinthePolishtownofZarycanstore
more than 20,000 pallets, or 2.9 million
square meters of finished product.
Kronopol, one of the world’s leading pro-
ducers in wooden material manufacturing,
has commissioned Mecalux to construct
its new automated warehouse for pallets,
where the floor panels fabricated by the
company will be depo-
sited. The warehouse,
composed of four aisles
with double depth racks,
measures 30.3 m high,
32.9 m wide and 89.3 m
long. In each aisle a stac-
ker crane will circulate
that is able to move 840 x
1,410x1,200mmpallets,
with a maximum weight
of 1,075 kg each.
This installation, which
is scheduled for comple-
tion in the third quarter
Kronopol goes automated: Mecalux constructs custom
warehouse for timber products
of 2016, was the Kronopol organisation’s
most substantial investment in 2015. Its
construction,apartfromincreasingstorage
capacity by maximising available space, will
give the company a series of advantages.
Among these are complete automation,
an increase in the loading and unloading
speeds of vehicles, and the preclusion of
damagedgoodscausedbyforkliftusage.In
addition, the warehouse is also distinguis-
hed by being environmentally friendly be-
cause the solutions used will work via elec-
tricity, which will eliminate the emission of
gases.
The Polish company Kronopol, present in
more than 50 countries, has been part of
the Swiss Krono Group holding company
since 1994. Throughout this process, the
firm has become a worldwide leader in
their sector, thanks to the quality and va-
rietyoftheirtimberproductsearmarkedfor
the manufacture of interior finishings and
furniture.
This renowned Spanish food and be-
verage company has entrusted Meca-
lux in the semi-automation of trans-
port and delivery processes of Leche
Pascual, one of its leading brands, in
its packaging centre located in Gurb
(Barcelona).
After a thorough study, the technical team
at Mecalux opted for the installation of two
automatic conveyor circuits, one on each
floorofthefacility,andaliftwhichconnects
thetwolevels.Therefore,theygetthestrea-
mlining of product throughput and the best
use of available space on the warehouse’s
first floor.
The ground floor conveyor circuits will move
pallets from the end of the production area
to three possible destinations: the drive-in
racks situated on the same floor, the dis-
patch area, or the storage-ready area on the
firstfloor.
On the other hand, the conveyor circuit de-
signed for this upper floor will be reversible,
so that it can be used for both inputs and
outputs of pallets. The maximisation of this
space will make it possible for the Catalan
Pascualplanttodispensewithexternalware-
houses, with subsequent cost and time sa-
vings in the transport of goods between dis-
tantwarehouses.
Inadditiontotheliftwhichconnectsthetwo
levels of the warehouse, they complement
theequipmentwithapalletstackerandapa-
lletunstacker.
All movements of the equipment will be
monitored by the Mecalux Galileo con-
trol software, which is in communication
with the warehouse management soft-
ware currently used by the company in this
installation.
To sum up, the project that Mecalux will
set up in the upcoming months in the Gurb
packaging centre will provide Qualidad
Pascual with greater agility and accuracy in
product throughput and dispatches. This is
all part of the group’s commitment to offer-
ing excellent quality service, and the con-
tinuous improvement of both its products
and processes.
Throughput conveyed and supersized: Quality Pascual and
Mecalux collaborate on new conveyor system in Barcelona

12
Best Practices
Founded in 1983 by Jesus Gasca, STUA
in one of the most internationally recog-
nized Spanish contemporary furniture
design companies. Recently, its opera-
tions moved to a new facility in Astiga-
rraga (Guipúzcoa) in order to boost con-
tinuousgrowth.
After assessing various options for the imple-
mentation of a storage system that best re-
solved their needs, STUA finally chose the
project submitted by Mecalux, due to the
confidence that being made in Spain and
theirextensiveexperienceconveys.
STUA’s objectives are to gain perfect con-
trol of both their products and deliveries to
any part of the world, in addition to maximi-
se storage capacity. To fulfil these require-
ments, Mecalux has planned out a solution
consisting of an automated clad-rack ware-
house annex to the production building that
stands out for its slenderness, since it has had
to adapt to some unusual measurements:
80mlong,25mhighandonly9mwide.
The automatic warehouse is made up of
an aisle where a single-mast stacker crane
circulates, which serves the double depth
racks located on both sides. The racking has
10 levels of different heights in order to lo-
cate various sized load units – some larger
than usual – given the characteristics of the
product. The inputs and outputs of the auto-
mated warehouse have been dealt with a
circuitofconveyors.
Last but not least, to manage all warehouse
processes, Mecalux will implement its Easy
WMS warehouse management software,
which will allow the full control STUA stock
and real-time inventory, while also optimi-
sing and coordinating product throughput,
from its entry into the warehouse to its dis-
patchtotheendcustomer.
Thenewautomatedclad-rackwarehousewill
provide STUA with better efficiency and pro-
fitability in their logistics operations. This will,
in turn, give them a competitive advantage in
theirjobof innovatingandpromotingSpanish
design, which was recognized in 2008 with
theNationalPrizeforInnovationandDesign.
Design and efficiency go
hand in hand: a new automated
clad-rack warehouse designed
by Mecalux for STUA

13Best Practices
Casestudy:HayatKimya
Tallest warehouse in Europe constructed:
earthquake prone area in Turkey not an issue
for Mecalux and its partner Hayat Kimya
Location:Turkey
Hayat Kimya is the leading chemical company in the Turkish and Eurasian
market in the manufacture of cleaning and hygiene products. They entrusted
Mecalux in the construction of a spectacular 12,500 m2
, 46 m tall automated
logistics centre in the city of Izmit (Turkey).
Theyweresuppliedwithaplanthatinclud-
ed the warehouse management system
Mecalux Easy WMS, responsible for ma-
nagingallthecentre’sactivities.
ThesolutionimplementedforHayatKimya
has become a global benchmark for auto-
mated clad-rack warehouses, showcasing
Mecalux’sprofessionalfortitudeandskill.

14 Best Practices
Case Study I Hayat Kimya
Who is Hayat Kimya?
Founded in 1937, Hayat Kimya is the lead
ingchemicalcompanyintheTurkish,Asian
and Middle Eastern market for cleaning
andhygieneproducts.
TheneedsofHayat Kimya
The huge growth experienced by Hayat
had obliged them to distribute goods be
tween several warehouses located near di-
fferent production centres, which involv
ed high logistical costs that could increase
overtheyears.
Faced with this situation and seeking to re-
duce production costs, Hayat Kimya de-
cided to build a single warehouse with a
minimum storage capacity of 150,000 pal
lets and in which to undertake picking
functions.
In addition, and in order to save on trans-
port costs, they thought of putting it in
a space available in their largest facility,
equal distance from three of their most im-
portant plants and near a fourth high pro-
ductionsite.
In the two images on this page the ware-
house’s location in relation to the factories
and to the connecting overpasses can be
seen:
1. Logisticscentre
2. Tissuefactory1
3. Tissuefactory2
4. Hygienefactory1
5. Hygienefactory
6. Detergentfactory
7. Tissueinputoverpass2
8. Tissueinputoverpass1
9. Hygieneinputoverpass
The company has twelve
brands distributed
in three sectors:
household care, hygiene
products and tissues
Atpresent,HayatKimyaistheseventhlarg-
est manufacturer in Europe in its sector,
having more than 5,200 employees and
reaching all its consumers through an
export network which covers101countries.

15Best Practices
1
2
3
4
5
Thesolution
Taking into account the above premises
and the data provided by Hayat Kimya,
Mecaluxworkedfromtheoutsetinthede-
signandconstructionofawarehousewith
thefollowingfeatures:
- Automated clad-rack warehouse
withacapacityfor161,000pallets.
- Four raised overpasses above the la-
nes inside the installation that connect
the factories and the main conveyor cir-
cuit.
- Agroundfloordedicatedalmostexclu-
sively to dispatches, with the exception
of two multipurpose docks and a dock
fitted with an automated unloading sys-
temintendedforthereceiptofmerchan-
disefromotherfactories.
- First floor used exclusively for offices
andotherservices.
- Second floor reserved entirely for pick-
ing.
- On the third floor is where all inputs
take place in the warehouse from the
factoriesthatarelocatedinthecomplex,
as well as the outputs intended for pic-
kingareas.
- Wide manoeuvring area and loading/
unloadingoftrucks,with21docks.
9
8
7
For the design of the whole package that makes up
the logistics centre, operative details were meticulously
taken care of, trying to achieve not only the goals
in the initial specifications of required flows,
but that were also the best
6
Mapdata©2015Google

16 Best Practices
Thewarehouse
The size of the warehouse is 120 m long x
105 m wide and 46 m tall, with a total ca-
pacity that exceeds 161,000 pallets that
are 800 x 1200 mm in size and weigh a
maximum700kgeach.
The construction system is self-support
ing, that is to say the racks, in addition
to storing goods, have additional struc-
tures on which sheet clad panels are
attached to that make up the building.
This forms a complete unit that is the
warehouse.
The racks must support their own weight,
the pallets stored, the wind pressure, han-
dling equipment, the seismic activity on
the basis of the coefficient indicated at the
construction site and the weight of snow
thatconformstotheregulations.
The Hayat Kimya warehouse consists of
15 aisles with double-depth racks placed
on both sides and is 24 load levels high. In
each aisle a 45 m high stacker crane was
set up that is responsible for the move-
ments within the warehouse, from the re-
ceptionareatoproductlocations.
Each stacker crane is equipped with a
double cradle that allows two pallets
to be moved at a time and with single-
mast construction, something unusual
for a warehouse of this height. The main
tenance of the stacker cranes is carried out
on the side that coincides with the conve-
yorcircuit.
It is interesting to point out that in each
of the 24 load levels that integrate rack
bays, three pallets in the first position and
three other pallets in the second are stor
ed. This is very difficult to achieve in a tall
warehouse which is located, as explained
below, in an area with such a high rate of
seismicactivity.
In this image the loading
docks and the offices
located on the bottom
floor of the warehouse
can be seen.

17Best Practices
The final solution
was the construction
of a huge 12.500 m2
logistics centre, with
a 46 m tall, clad-rack
warehouse, readied
to house up to
161,000 pallets
The warehouse itself is an enclosed box
in which all passages between the inside
and the outside connection floor are done
through airlocks that help maintain the
atmosphererequired bythefireprotection
system.
This system (inerting) works by reducing
the oxygen in the interior’s air, to an
atmospheric level of 14%, at which point
combustion is no longer possible. A piece
of equipment controls the oxygen levels
in the air and adds nitrogen until reaching
the percentage that has been previously
programmed.

18 Best Practices
Major construction challenge:
its location
The city of Izmit is located at the beginning
of the Northern Anatolian fault line, which
runs along the upper zone of the peninsu-
la and which makes up the greater part of
Turkey’s territory. This stretch, parallel to
the Black Sea, also coincides with the fault
line that crosses the Sea of Marmara and
theBosphorusStrait.
To build a warehouse of these dimensions
in a place with such a high rate of earth
quakes, with a height of more than 45 m
and with stacker cranes prepared to move
twopalletsatatimeandoperateindouble-
depth racks, was a challenge never before
surpassed by Mecalux. Furthermore, the
warehouse was built in an area exposed
Izmit
Anatolia
AfricanPlate
ArabianPlate
EurasianPlate

19Best Practices
to the wind and where snowfall, although
not frequent, can be abundant when it
doesoccur.
With all these constraints, only one com-
pany with the experience and quality of
Mecalux was able to build a warehouse on
thisscale.
By its particularities, this logistics centre
could not be built with the traditional
cold-formed profiles. Nor was it possible
to do so with a structure of standard hot
rolled profiles, due to the accuracy of as-
sembly that this installation required was
extremelyhigh.
The solution provided by Mecalux’s tech-
nical team was to combine the two con
The main difficulty Mecalux faced was
the existence of a major earthquake zone right
where Hayat Kimya wanted to build its
upcoming central warehouse
structive options. The first to conform all
racks, and the second to complete the
construction of a vertical reticulate struc-
turecoupledtotheracks.
The objective was to absorb all the hori-
zontal dynamic forces, mainly those of a
longitudinal direction, which is the least
rigidpartoftheracks.
The weight of this additional structure was
more than 1,900 t (for the whole structure
10,000twasused).
Both the dimensions and mode of opera-
tion, as the building’s location, represent
ed a challenge for the Mecalux’s Structural
Engineering department that had to deal
withsomeextremedeterminants.

20 Best Practices
Upperfloor:inputs
All warehouse inputs from the factories
that are located on-premises take place
on the third floor of Hayat Kimya’s logistics
centre. The accumulative automatic roller
conveyors have been set up in the four
overpasses connecting the warehouse to
thefactories.
All the factories have a conveyor circuit
that is tasked with the input of the pal
lets into the system after checking both
its size and its weight. Only then will they
ensure that the pallets that arrive to the
warehousedosoingoodcondition.
Ineachoverpasstwoliftswereplaced,one
in each factory’s entry points and another
at the end of each overpass, allowing
goods to be lifted to transport height and
subsequentlytothethirdfloor.Atthesame
time, this floor has a triple electrified mo-
norailcircuitrunningboththeexternaland
internalmovementsofthewarehouse.
On the third floor, alongside inputs, out-
puts of goods that are lowered to the de-
signated picking floor are also done via the
elevators.
Every day an average
of 6,500 pallets come
into the warehouse,
peaking at 400 pallets
per hour
This image shows the
upper floor where inputs
into the warehouse are
performed.

21Best Practices

22 Best Practices
Plant intended for
the picking operations
The second floor of Hayat Kimya’s ware-
house has been reserved for picking func-
tions,dividingitintotwoareas:
Zone A: 118 live channels, each three pal
lets deep, are grouped into four blocks.
Each block is serviced by a shuttle that
automatically feeds the channels with the
goodsfromthelifts.
This area is intended for A type products
(highdemand).
This image displays the floor
set up for picking.

23Best Practices
Zone B: 174 pallet racking bays with 2 or
4 levels for pallets, including the ground
floor, grouped into four double and two
singlerackalignments.
It has a total capacity of 500 pallets for
picking placed directly on the floor and
1,050 reserve pallets on upper levels. This
second area is allocated for the picking of
B typeproducts(mediumdemand).
In addition, the same racks were set up for
levels of live box picking to give access to
C typeproducts(lowdemand).
The feeding of the pallet racks is perform
ed using front loading reach trucks that
take the pallets from the warehouse in a
specific exit, where one of the lifts has pre-
viously deposited the pallets destined for
thiszone.
Picking is done manually by the opera-
tors, aided by order fulfilment machines
and a computer terminal that works via
radiofrequency.
When the orders are
completed, they are taken
to the baling area and,
via two lifts, are sent to
the ground floor to be
dispatched

24 Best Practices
Lower floor: dispatches
All outputs designated for the dispatch
area are carried out on the ground floor
by electrified monorails. These automated
transport units take the pallets from the
conveyor output inside the warehouse,
and the lifts that descend from the picking
floor,andclassifythemintopreloads.
The preloads are composed of 17 triple-
channel groupings, which have a capacity
todeep-store11pallets.
Eachtriple-channelgrouphasatotalcapa-
city of 33 pallets each that correspond to
anorder,routeoranout-sourcedmeansof
transport (truck or sea container). This re-
quest is prepared before loading the truck
to avoid waiting time in goods being dis-
patchedfromthewarehouse.

25Best Practices
Every day an average
of 7,000 pallets
leave the warehouse,
in other words,
more than
200 truckloads
Depending on the means of transport
used, and the agreements with company’s
individual customers, the merchandise
is shipped on pallets (usually by truck) or
in single, stacked boxes (sea container).
For loading trucks generally light, front
loading forklifts are used, since they are
veryagileandthusthemostsuitable.
The dispatch area has 17 docks only for
loading, allowing the preparation of
17 transportvehiclesatatime.

26 Best Practices
Automaticunloading
Inaddition,onthelowerfloormerchandise
inputs from the detergent factory (located
2kmaway)isalsodone.
The inputs take place on the ground floor
via three reception docks, one of which is
readiedtoautomaticallyrununloading.
From here, the pallets pass, one by one,
through the checkpoint and continue via
the electrified monorails to the input
stations located inside the warehouse that
isfoundonthisfloor.
The automatic
unloads accumulation
device can receive
all the pallets of a full
truckload (trucks are
set up with similar
equipment)

27Best Practices
Easy WMS: the nerve centre
of the logistics centre
Alltheoperationsofthelogisticscentreare
governed by the warehouse management
system Mecalux Easy WMS and its Galileo
control software; tasked with controlling
the computers that run the transport and
thestorageofgoodstasks.
EasyWMSisalsoresponsiblefor:
- Management of goods input from its re-
ceptionatthedocks.
- Locate pallets in the warehouse using
rules previously parameterised, under
the criteriaofstreamliningandmaximum
productivity.
- Manages the stock and the warehouse
layout(whatandwherethegoodsare).
- Manages the warehouse outputs to the
pickingand/ordispatchareas.
- Manages and controls the picking opera-
tions through radio frequency terminals,
guiding the operator in the tasks to be
performed and the order to follow to op-
timiseroutes.
- Allowsthecheckingofthestatusofdiffe-
rent parts of the logistics centre, and the
various equipment that operate in it, via
queryandreportingtools.
The Easy WMS (Warehouse Management
Software) is in permanent and bi-direc-
tional connection with Hayat Kimya’s SAP
ERPsystem.
ERP
SAP
of Hayat
Mecalux Easy WMS
Electrified monorails and airlocks
All movements from the stations to the
inside of the warehouse, both on the third
floor and on the ground floor, are carried
out by autonomous shuttles hung from
electrified monorail that works at a speed
of100metersperminute.
There are more than 900 meters of elec-
trified monorail and 55 autonomous shut-
tlesintheentireinstallation that are able to
movemorethan850palletsperhour
The warehouse should be as airtight as
possible to avoid the entry of air currents
with a higher percentage of oxygen. This
means that all the merchandise that enters
and exits via the electrified monorails
passes through a sealed area with double
doors or airlocks that can never be opened
atthesametime.
These spots are often bottlenecks in an
unattended installation – consequently in
this case, which work via electrified mo-
norails and where there are also very high
flow rates – it was necessary to design se-
veral accesses with triple inner shuttle ca-
pacity. In other words, the shuttles of the
electrifiedmonorailspassthreeatatime.

28 Best Practices
AdvantagesforHayatKimya
- Highstoragecapacity:161,000 pallets, 800 x 1200 mm in size and each weighing a maximum of
700kgcanbewarehoused,inasurfaceareaof12,500m2
.
- Production cost savings: they have built four overpasses connecting the factories and the front
of the warehouse. Each day an average of 6,500 pallets come into the warehouse, peaking at
400palletsperhour.
- Total control of the automated warehouse: thanks to the Mecalux Easy WMS (Warehouse
Management Software), Hayat Kimya controls all the processes and operations that take place
insidethewarehouse,fromthemomenttheproductleavespackaginglinesuntilitisdelivered.
- Remote support, remote maintenance: Mecalux is available to give technical support to Hayat
Kimya24hoursaday,sevendaysaweek.
Technicaldata
Lengthofthewarehouse 120m
Widthofthewarehouse 105m
Heightofthewarehouse 46m
Storagecapacity 161,000pallets
No.ofstorageaisles 15
No.ofdocks 24
No.ofdoublecradlestackercranes 15
Extractionsystem double-depth
Totalelectrifiedmonorails >900linearmetres
No.ofshuttlesintheinstallation 55
Totalinoverpasses >420linearmetres
Totalnumberoflifts 12
Totalnumberofshuttles 4
Livechannelsforpicking 118
Livepreloads 17
Totallivepreloadchannels 51
Automaticunloadingplatform 1
Palletinputperday 6,500
Maximumpalletinputperhour 400
Palletoutputperday 7,000
Maximumpalletoutputperhour 450
Averagetruckloadsissuedperday >200
Weightofthewarehousestructure 10,000t
For further information about this and other success stories look at our web www.mecalux.com/success-stories

29Best Practices
Casestudy:Gioseppo
Two million pairs of shoes: Mecalux builds
Gioseppo a clad-rack solution for footwear
Location:Spain
The installation that Gioseppo has in Elche (Spain) is composed of an automated
clad-rack warehouse for pallets, with live racks and a specific area for picking.
The warehouse management system Mecalux Easy WMS was supplied, which is
responsible for managing all the centre’s processes.

30 Best Practices
Case Study I Gioseppo
WhoisGioseppo?
Founded in 1991, Gioseppo is a family
business from the Elx region, dedicated to
designing and marketing medium to high-
endshoesformen,womenandchild.
After almost 25 years, Gioseppo is cur-
rently a well-established brand whose
products are marketed in more than 60
countriesworldwide.
Its growth and track record has led
Gioseppo to be included in the prestigious
‘Forum for Renowned Spanish Brand’s’, an
alliancemadeupofcompaniesandleading
brandsfromtheirrespectivesectors.
Logistical needs
The objectives presented by Gioseppo to
Mecalux were very specific: build a ware-
housetoincreaseitsstoragecapacitytolo-
cate all products coming from production,
and automate the internal transport of
goods with the purpose of managing a
greater number of SKUs in the most effi-
cientwaypossible.
With this, the company would take a quali-
tative leap forward on a logistical level that
could reduce production costs, while im-
provingwarehouseproductivity
Basedontheserequirements,Mecaluxde-
signed an integrated solution in which au-
tomatedstorageprocessesweremorepro-
fitableforGioseppo.

31Best Practices
3
2
1
Constructionneeds
AnotherpremisethatMecaluxhadtokeep
in mind was to pay careful attention to the
public image of the company. It was of ut-
most importance to limit the impact con-
structing a clad-rack warehouse would
have on the landscape of the Gioseppo
“Love Work Place” logistics centre, an
environmentally friendly space near the
MediterraneanSea.
Accordingly,thedimensionsofthelogistics
centre could not exceed a certain height.
So, it was necessary to find a solution that
offered high storage capacity, while at the
sametimereducingtheinstallation’ssize.
It was paramount
to reduce the impact
constructing a clad-rack
warehouse had on the
landscape of Gioseppo’s
‘Love Work Place’
logistics centre
Mapdata©2015*Google

32 Best Practices
A clad-rack warehouse as a solution
This 18.5 m high, 79 m long and 21.5 m
wide clad-rack warehouse is composed
of three aisles with double-deep racks on
both sides, offering a storage capacity of
5,844pallets,weighing500kgeach.Tobe
clad-rack means that the structure of the
buildingisformedbytheracksthemselves,
and that the outer cladding is supported
andattached tothem.
For structural calculations of clad-rack
warehouses the following are taken into
account: its own weight; the weight of the
goodsstored;thewindpressurebothpush
andsuctiondependingwhereitisbuilt;the
weight of the snow as indicated by the re-
gulations; ramming by stacker cranes; and
finally, the seismicity corresponding to the
territoryinwhichitislocated.
Its purpose, as explained above, was two-
fold: to optimise height in order to achieve
the largest possible storage capacity, and
reduce landscape impact to preserve
Gioseppo’spublicimage.
In each aisle a stacker crane circulates,
handling the movements of the pallets
from the conveyors at the end of the aisle
toitsdesignatedlocation.
The use of stacker cranes helps increase
productivity, at the same time decreasing
the resources required to manipulate the
goods.
Gioseppo’s clad-rack
warehouse is distinctive
because they excavated
a 6 meter deep trench
where a large portion
of the warehouse was
installed
3
2
1

33Best Practices

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

35Best Practices

36 Best Practices
Picking functions
Thissametransfercaristaskedwithtransfer-
ring the pallets from the aisles to the P&D
stations.Thepickingareaisorganisedstart-
ing with six independent stations where
operators take the boxes they need from
the pallet and deposit them onto the box
conveyor with the order sorter located on
theback.
In addition, and in order to facilitate work,
each picking station has a lift table so that
the pallets are kept at the ideal height for
each operator, improving its ergonomic
position.

37Best Practices
The picking area
has six independent
stations that are
set up with a lift table
to improve ergonomic
design

38 Best Practices
Liveracksfor orders completed and
consumerproducts
A block of 36 live rack channels has been
installed both for storing orders prepared,
aswellasthestacksofidlepallets.
This 8 m high, 9.5 m long and 11 m deep
warehouse has a storage capacity of
324 pallets 800 x 1,200 x 1,900 mm in
size, each with a maximum weight of
400kg.Eachchannelreceivesninepallets.
The live racks are a compact storage sys-
temthatallowsmaximumuseofspaceand
that are composed of roller channels on a
slight incline. The pallets are inserted into
the highest part of the rack and move via
gravity to the lower end, being available to
theoperator.Thepallettravel speed is con-
trolledbyrollerbrakes.
Therefore, this storage system is ideal
for lowering handling times and exped
ites picking, increasing the installation’s
productivity.

39Best Practices
of the installation
In Gioseppo’s new warehouse the ware-
house management system Mecalux Easy
WMS was implemented to manage and
coordinate the different automated oper
ations that take place within the installa-
tion: the input and output of goods, stor
age,pickinganddispatches.
This powerful management software has
been customised to Gioseppo’s demands,
being able to: locate pallets in the racks
based on algorithms or parametrisable
rules, manage outputs on the basis of tra-
ceability and FIFO criteria, check the stock,
run standard and custom labelling of con-
tainers, group output orders in different
modalities,etc.
Easy WMS (warehouse management soft-
ware) provides a competitive advantage
to Gioseppo, since it involves cost sav
ings, an improvement in service quality
and consequently, maximising warehouse
profitability.
In addition, Easy WMS is in perman
ent communication with the SAP ERP,
Gioseppo’s main management system, ex-
changing orders and the information that
isessentialforitsoverallmanagement.

40 Best Practices
AdvantagesforGioseppo
- Increased storage capacity in a small space: Gioseppo’s clad-rack warehouse receives 5,844
palletsinasurfaceareaof1,700m2
,quadruplingthecapacityofthepreviouswarehouse.
- Limiting environmental impact: a 6 meter deep hole was excavated to obtain height and stor
agecapacity,whiletheimpactonthearea’slandscapewasminimised.
- Cost savings: the automation of the clad-rack warehouse allows Gioseppo to increase efficiency
andreducepersonnelandlogisticscosts.
- Complete control: the Mecalux Easy WMS controls all the processes and operations that take
placeinsidethewarehouse.
Technicaldata
AutomatedWarehouse
Maximumweightperpallet 500kg
Warehouse height 18.5m
No.ofstackercranes 3
Typeofstackercrane twin-mast
Forktype double-deep
Constructionsystem self-supporting
Liveracks
Storagecapacity 324pallets
Palletsize 800x1,200mm
Warehouseheight 8m

41Best Practices
Casestudy:Ypê
Wide prep area for orders: a key Mecalux
design feature for Ypê warehouse in São Paulo
Location:Brazil
Ypê, a company dedicated to the
development of cleaning products for
the household and personal hygiene,
has hired Mecalux to install a 29.5 m
high automated clad-rack warehouse
with a 24,168 pallet storage capacity
in its logistical support centre in
Amparo (São Paulo).

42 Best Practices
Case study I Ypê
Analysingtheneeds
The main production centre of Ypê is loca-
ted in Amparo, a town close to the city of
São Paulo. The growing needs of the com-
panyrequiredtheconstructionofalargelo-
gisticscentrenexttotheproductionplants,
fromwhichtheycouldoffercomprehensive
service,andatthesametimereducecosts.
Mecalux installed the racks and structu-
res of the warehouse, the automatic inter-
nal handling equipment, the construction
of a picking area and Mecalux Easy WMS
software deployment, the warehouse
management system which governs and
controls the operations of the logistics
centre.
The collaboration of
Mecalux with Ypê has
been very close from the
development phase of the
project to its execution

43Best Practices
Case study I Ypê

44 Best Practices
Case study I Ypê
Solution adopted:
clad-rack warehouse
The most striking part of the project de-
veloped by Mecalux is the installation
of a self-supporting construction ware-
house with a total capacity of 24,168 pal-
lets, 1000 x 1200 mm in size, each with a
weightof1,300kg.
Being clad-racked, the racks are a funda-
mental part of the structure of the building
and cladding is placed on them. In addition
to its own weight, it must withstand the
pallets stored, the force of the wind on the
basis of the site characteristics, the pres-
sure of the handling equipment and the
seismic risk that corresponds to the zone in
accordancewiththecountry’sregulations.
The traditionally constructed buildings are
adjacent to Ypê’s logistics centre, just be-
sides the automated warehouse, where
available space has been set aside for futu-
reexpansion.
At present, this 29.5 m high, 107.5 m long
and 49.5 m wide warehouse has a total
of eight storage aisles, with racks on both
sides, of which five are double-depth and
threesingle-depth.
Each aisle is set up with a twin-mast stac-
ker crane that automatically performs the
movements between locations and the
mainconveyorcircuit,placedattheheader
ofthewarehouse.
Warehousearea
reservedtoexpandthestorage
capacityofYpê

45Best Practices
Case study I Ypê
Thewarehouseisdistributedintothefollowing
areas,ascanbeseeninthelayout:
A. Warehouse
B. Inputstations
C. Mainconveyorcircuit
D. Directoutputsstation
E. Pickingchannels

46 Best Practices
Case study I Ypê
The input of the pallets that go into the
warehouse takes place via three stations
readied with a gauge control and input
checkpoint equipment. This space is locat-
ed in the reception dock area for incom-
ing goods, occupying one of the sides of
thewarehouse.
A conveyor with accumulation capacity
transports them to the header, where the
mainconveyorcircuitsareplaced.
Alargepercentageofthepalletsthatleave
the warehouse do so designated for the
pickingarea.
As of now, there are five groups of live
channels outfitted and one for pallets
placedonthefloorofthewarehouse.
Groupofpickingchannels

47Best Practices
Case study I Ypê
Each grouping contains 66 channels with
a three pallet capacity. The feeding is per-
formed via transfer cars that automatical-
ly move from specific positions of the hea-
der to the live channels. The slight tilt with
which channels are mounted allows the
pallet to move by gravity to the closest free
positioninworkaisles.
Among the five groups, there is a total of
330 channels with a capacity for 990 pal-
lets; each channel is intended for a single
SKU. Apart from that, there are 138 posi-
tions for pallets placed on the floor, which
aredirectlysuppliedbyforklifts.
The consolidation of orders, once the pal
lets have already passed by the balers, is
carried out in the area allocated to pre-
loadsclosetotheloadingdocks.
The logistics centre of Ypê also features live
racks to store consumer products that do
not enter into the automated warehouse.
Thisarea,nexttothedocks,worksascross-
docking,theliveracksactingasabuffer.
of the logistics centre
Easy WMS is a powerful warehouse ma-
nagement system developed by Mecalux
with which you can manage all the ware-
house needs, stepping in from when the
goods are received till the order has been
dispatched.
Among all the functions that Easy WMS is
capable of performing, the most impor-
tant are: the receipt and registration of
the pallets that enter into the warehouse,
the management of the locations on the
basis of rules or parametrable algorithms,
control of outputs in accordance with FIFO
criteria and traceability, order preparation,
consolidation, label issuing, documenta-
tionpriortodelivery,etc.
All of this with the major advantage of re-
ducing the errors arising from manual ma-
nagementtoaminimum.
Furthermore, the Mecalux Easy WMS
warehouse management software is con-
tinuously and directly connected to the
ERPofYpê,fromwhichitreceivestheback-
ground information and that reports the
outputsexecuted.
The installation
that Ypê has in São Paulo,
with a 24,168 pallet
capacity, is expected to
achieve a total flow of
200 pallets/hour in inputs
and outputs

48 Best Practices
Case study I Ypê
AdvantagesforYpê
- High storage capacity: the clad-rack warehouse of Ypê enables them to locate 24,168 pallets, 1,000 x
1,200mminsizeeachwithaweightof1,300kg,ina5,200m²area.
- Cost savings: automation of the different storage processes helps Ypê to boost efficiency while redu-
cingoperationalcosts.
- Flexibility for future growth: an area to the side of the automated warehouse has been prepared in
ordertoexpandstoragecapacitybasedonthefutureneedsofthecompany.
- Completecontrol:thankstotheMecaluxEasyWMS,Ypêcontrolsalltheprocessesandoperationsthat
takeplaceinsidethewarehouse.
Technicaldata
Dimensionsofthepallet 1,000x1,200mm
Maximumweightperpallet 1,300kg
Forktype singleanddouble-depth
Livepickingchannels 330
Palletsinpickingpositions 1,128pallets
No.oftransfercars 5
Preload onthefloor

49Best Practices
Casestudy:Takeda
Turnkey pharmaceutics: automated warehouse
by Mecalux for Japanese partner Takeda
Location:Poland

50 Best Practices
Case Study I Takeda
A clad-rack warehouse as a solution
When Takeda moved forward with the ex-
pansionofitsproductioncentre,itwasvery
clear that the warehouse should be auto-
mated. This would allow for perfect con-
trol of stored goods, in addition to being
able to achieve the maximum permissible
height, given that the space available for
warehouseconstructionwaslimited.
ThesolutionproposedbyMecaluxwasthe
construction of a 32.5 m high clad-rack
warehouse located next to the manufac
turing facilities and the bay assigned to
delivery preloading. In this type of cons-
Who is Takeda?
Takeda Pharmaceutical Company Limited,
with its headquarters in Osaka (Japan), is
a global company specialising in the inves
tigation of pharmaceutical products. In
the mid-twentieth century, it experienced
massive growth, making it a world leader
in the pharmaceutical industry and the
largestofitskindinJapan.
The company has a commercial presence
in more than 70 countries, most signifi-
cantly those in Asia, North America and
Europe and emerging markets such as
LatinAmerica,RussiaandChina.
truction, the racks themselves make up
thestructureofthewarehouse.
The installation consists of two aisles, in
which two automatic stacker cranes move
independently, handling the pallets stored
in double-deep racks (two pallets in depth
oneachlevel).Thankstotheoptimalspace
utilisation, the Takeda warehouse has a
storage capacity of more than 6,500 pal
letsinasurfaceareaofonly950m2
.
The warehouse was equipped with a
HVAC system (Heating Ventilation Air
Conditioning) which keeps the tempera
ture between 16 and 24 °C and prevents
the humidity level from exceeding 70%,
which is something that could affect
goodsstored.
3DcomputergraphicoftheTakedaclad-rackwarehouse
Takeda, one of the most important
pharmaceutical companies in the
world, has entrusted Mecalux to
build a turnkey warehouse in its
new Lyszkowice production plant,
near the Polish city of Lowicz.
The solution was to construct a
temperature controlled, 32.5 m
high clad-rack warehouse with
a capacity to store more than
6,500 pallets. It is equipped
with a cold storage system and
an ‘oxygen reduction system’
for fire prevention. They were
also supplied with a warehouse
management system, the Mecalux
Easy WMS, which is responsible
for managing all the centre’s
processes.

51Best Practices
Case Study I Takeda
Warehouseaisle

52 Best Practices
Case Study I Takeda
Outsideviewofthewarehouse
14,505mm
32,382mm
Aninnovativefireprotectionsystem(inert-
ing) has also been used, which reduces the
amount of oxygen in the atmosphere to
15%toavoidfires.
Thepipesoftheair’shumidityandtemper
ature control system have been installed
above, targeting the aisles and placed in
the free space between trusses in the fa-
cility.
For structural calculations of clad-rack
warehouses the following are taken into
account: its own weight; the weight of the
goodsstored;thewindpressurebothpush
and suction where it is built; the weight of
the snow as indicated by the regulations;
thrusts by stacker cranes; and finally, the
seismicity corresponding to the territory
whereitislocated.
Due to the slenderness of the building
(14.5 m wide and 32.4 m high), a highly re-
inforced structure was built. Also, many
large sized anchorages have been placed
with the aim of absorbing maximum wind
pressure.
This 32.5 meter high clad-rack warehouse has a storage
capacity of 6,584 pallets, 800 x 1200 mm in size,
with a maximum weight of 800 kg
Layout: elevation, floor and
profile of the Takeda warehouse
65657 mm
85,657mm

53Best Practices
Case Study I Takeda
Coolingtube Reinforcedracks
Twin-maststackercrane
19800
19,800mm

54 Best Practices
Case Study I Takeda
Inputs and outputs are practically unified
and are constructed very simply, they are
suitable for forklifts and stackers use. The
entry conveyor has a checkpoint, which
ensures top condition of all the pallets that
areputintotheautomatedwarehouse.
The connection with the inside of the
warehouse is done using a double convey-
or circuit (inputs and outputs) that pas-
ses through doors with double vertical
screens.
The space between the two screens
amounts to what is needed for a single pa-
llet, being that the system sends alterna-
ting open and close signals, limiting tem-
peraturechangesinside.
In order to avoid capacity loss, a superior
platformwassetupfordoingsecuremain-
tenancewithoneaccessperaisle.
Entryandexitofthewarehouse
Mainconveyorcircuit
The stacker cranes
are double-mast
and incorporate a
maintenance cabin,
which is located
on the lifting cradle
itself
Entryandexitofthewarehouse

55Best Practices
Case Study I Takeda
Easy WMS:
The management, synchronisation and
control of the entire warehouse, includ-
ing parts that interact with the mainte-
nance equipment, work thanks to the
Mecalux Easy WMS (Warehouse Manage-
mentSoftware).
ThemainfunctionsofEasyWMSare:
- Receiving and recording the pallets that
comeintothewarehouse.
- Palletlocationintheracksbasedonalgo-
rithmsorparametricalrules.
- ManagementofoutputsbasedonFIFO
criteriaandtraceability.
- ViatheGalileosoftware,allmovements
ofthemechanicalpartsrunandoptimi-
sedtheinternalroutes.
- Connectiontothewarehousedoor
controlprogramsothatitacts
automatically.
In addition, Easy WMS is in constant com-
munication with the SAP ERP, Takeda’s
main management system, exchanging
orders and information that is essential to
itsoverallmanagement.
Plant’smaintenanceaccess
Maintenanceaccess

56 Best Practices
Case Study I Takeda
Turnkeywarehouse
Takeda wanted all development and cons-
truction phases of the warehouse, inclu-
ding the supply of the software needed to
properly manage all internal operations,
carriedoutbyasinglecompany.
That is why Mecalux was commissioned to
run the turnkey project from beginning to
end.
Stagesofwarehouseimplementation:
- Land preparation via pilings: due to
the low bearing capacity of the soil, and
the large static demands, a deep founda-
tionwasmadeonpilings.
- Installation of a reinforced concrete
foundation slab: first a reinforced top
andbottomwasbuiltwithsteelrods,and
subsequently the ground was filled with
concrete.
- Finish: the foundation was finished and
hardenedwiththeobjectiveofobtaining
dustfreepaving.
- Rack assembly: regarding clad-rack
warehouse, the racks themselves make
uptheactualstructure.
- Assembly of warehouse cladding:
in clad-rack warehouses wall panelling
and ‘sandwich type’ roofs are fastened
directly to the rack structure. In Takeda’s
case,andhavingusedaninertingsystem,
it was necessary for the outside cladding
tobeaswatertightaspossible.
- Introduction of maintenance teams:
conveyors and stacker cranes were
assembledinsidethewarehouse.

57Best Practices
Case Study I Takeda
- Installation of the inerting system:
implementation of a fire protection sys-
tem that allows you to inject nitrogen in-
tothewarehousesothattheoxygencon-
centrationisreducedtolessthan15%.
- Installing the HVAC air conditioning
system: it controls the temperature that
should be maintained between 16 and
24 ºC.
- Assembly of the electrical and light-
ningprotectionsystems.
- Assemblyofthedrainagesystem.
- Airlock construction: the separation of
the portion of the warehouse equipped
with the inerting system to the adjoining
building that work under normal envi-
ronmentalconditions.

58 Best Practices
Case Study I Takeda
AdvantagesforTakeda
- High storage capacity in a small space: the clad-rack warehouse enables you to place 6,584, 800 x
1,200mmsizedpalletseachweighing800kginasurfaceareaof980m2
.
- Product security: pharmaceutical products stored by Takeda are protected and isolated thanks to the
automaticwarehouseinstallation.Onlyauthorisedpeoplecanaccessthewarehouse.
- Turnkey warehouse: Mecalux was responsible for the development phases, the construction of the
warehouse, the supply of storage, cooling, and fire safety systems, as well as the implementation of the
WMS(WarehouseManagementSoftware).
- Completecontrol: thanks to Mecalux Easy WMS, Takeda controls all the processes and operations that
takeplaceinsidethewarehouse,fromthetimetheproductleavesthepackaginglinestoitsdelivery.
Technicaldata
Warehousecapacity 6,584pallets
Forktype double-deep
Heightofthewarehouse 32m

59Best Practices
Casestudy: Nufri
Nufri has put its confidence in Mecalux yet
again by installing Movirack mobile pallet
racking in its headquarters in Catalonia
Location:Spain
Needs and the proposed solution
Nufri handles around 400 million tons of
fresh and processed materials, selling to
more than 40 countries worldwide. To
guarantee quality, personalized service,
Nufri needed a warehouse in which it
could access all its stored products in a
straightforward manner, all the while
maximizing surface area and the volume
oftheinstallations.
In response, Mecalux opted to install
Movirack mobile pallet racks of 12 m high,
converting it into one of the tallest solu-
tions of this kind and perfectly adapting it
totheneedspresentedbyNufri.
The warehouse is divided into two well-
marked areas: the first, which is small-
er in size, is set up to store products and
packaging at ambient temperature, while
the remainder of the area is cold storage
usedtostoreextracts,juicesandpurees.
Mecalux supplied and installed a Movirack mobile racking system in Nufri,
business leader in processing fresh fruits and vegetables with more than
40 years’ experience in the sector. This new warehouse in its logistics centre in
Mollerussa (Lleida) allows the storage of more than 6,100 pallets.

60 Best Practices
Case Study I Nufri
Ambienttemperaturearea
Itissetuptosupplyproductionareas,from
cylindrical containers of enormous dimen-
sions, including the products necessary to
completeitsrangeofprocessing.
This area, with a storage capacity of
1,200 pallets that are 1,200 x 1,200 mm
in size and have a maximum weight of
2,100 kg each, is available with seven mo-
bilebasesandtwonon-movingracks.
2
3
2
3
BLOCK 3
BLOCK 1
BLOCK 2
Being located beside the cold storage
allows combined supply, removal and sto-
rage of processed goods, significantly opt
imising the internal movements inside the
installation.
Providing for the future needs of the com-
pany, an area has been set up where five
more mobile pallet racks can be installed.
To that end, the floor has been fitted from
the beginning to facilitate possible pro-
gressivegrowth.
Block3:ambient
temperaturearea
The utilization of
Movirack mobile pallet
racking provides the
maximum installation
streamlining

61Best Practices
Case Study I Nufri
Coldstorage
There are a total of 31 double mobile ba-
ses and four non-moving racks which give
a storage capacity of 4,930 pallets 1,200 x
1,200 mm in size, and have a maximum
weight of 2,100 kg each, which conser-
ves processed materials at a controlled
temperature.
The racks are arranged in two large blocks
separated by a main gangway. Each block
has a wide work aisle that opens up be
tween racks. To automatically open it, the
operator must only push a button via the
remotecontrol.
For the purpose of ensuring the security of
its operators and the installation in gene-
ral, the Movirack system has the following
devices: external optical safety barriers,
longitudinal photocells placed on both
sides of the bases, proximity sensors, pre-
programmed activation protocols and
emergencystopandresetbuttons.
The forklifts that are used in the refrigerat
ed storage area are the retractable type
that makes it possible to work in an aisle
less than 3 m high. The last load level is
placed at 10.6 m high, and the maximum
loadheightwouldreach12mhigh.
The racks have mesh shelves in them for low strength
pallets or those that are not standard size
Blocks1and2:coldstorageunit

62 Best Practices
Case Study I Nufri
Technicaldata
Palletsize 1,200x1,200mm
Maximumweigthperpallet 2,100kg
No.ofmobilebases 38
Rackheight 10.6m
Totalheightwithload 12m
Workaislelength 23m
Warehousetemperature ambient/refrigerated
Advantagesforthecustomer
- StoragecapacityisincreasedusingaMovirackmobilepalletracksystem.
- Directaccesstoanypallet:theaisleopensupexactlywherethegoodsarelocated.
- Products are maintained in optimal condition facilitated by the parking function, which keeps
theracksslightlyapartmaintainingbetteraircirculation.
- Flexibilityforfutureexpansion.

63Best Practices
Case study: MGA
MGA has an efficient automated miniload
warehouse coupled with conventional
pallet racking
Location: France
For the new logistics center located in Saint-Quentin Fallavier, a town close
to the city of Lyon, MGA chose Mecalux as provider of all management and
storage systems, including an automated miniload warehouse with a capacity
of 15,872 boxes.
MGA is an important spare parts distribu
tor with regional warehouses in different
cities within France. The priority of the
company is to offer express delivery to its
customers, generally automobile replace
ment part wholesalers.
Inthislogisticscenter,Mecaluxhasinstalled
an automated miniload warehouse with a
specific picking area and a warehouse for
pallets placed on conventional type racks.
It has also included the implementation of
a Mecalux Easy WMS (warehouse mana
gement software), tasked with handling
all operations, from the entry of goods till
dispatch, previously passing through the
storage and picking phases.

64 Best Practices
Case Study I MGA
Warehouse interior
Connection between the warehouse and the picking area
Warehouse for pallets: ‘A’ and bulky type product picking
Conventional pallet racks
The conventional pallet rack warehouse
is intended for bulkier products and items
with greater turnover (A type) placed
upon pallets. Racks have two inferior le
vels to conduct direct picking from the pal
lets, while reserves are placed on superior
levels.
This storage system is characterised by
its simplicity and capacity to adapt itself
to the needs of the company. In addition,
conventional pallet racks make it possible
to directly access each pallet, storing the
maximum number of unit loads in a safe
and organised way.
The miniload warehouse
A miniload warehouse with four aisles,
and two doubledeep racks (one per side),
was installed, allowing storage of a total
of 15,872 plastic euroboxes, 600 x 400 x
320 mm in size. The height of the racks is
12.3 m and the total admissible weight per
box is 50 kg.
All medium and small sized products are
located in the miniload warehouse, gene
rally B and C type items. These products
are handled by four stacker cranes, three
picking stations and a replenishment
station.

65Best Practices
Case Study I MGA
Four stacker cranes
The construction of the miniload
warehouse was done in two phases, in
accordance with the needs of MGA. The
first included three storage aisles with
three stacker cranes and three picking
stations, while in the second they installed
four aisles, set up a new stacker crane and
completed the replenishment station.
If we analyse the parts that the instal
lation is composed of, represented by
the images on this page, you will see the
following:
A. An automated warehouse
B. Automated warehouse conveyors
C. Three picking stations
D. A replenishment station
The MGA
miniload warehouse
can store 15,872 plastic
euro-boxes

66 Best Practices
Case Study I MGA
Two box extractions
Miniload with conveyors inside the warehouse
Double-mast stacker cranes were install
ed; the extraction system placed in the
cradle is a double box and double-deep,
being capable of handling two boxes at a
time.
The extractor is formed by a fork and two
independently moving belts that allow
them to interchangeably pick boxes from
one or another side, first moving to the
contrary side where you are going to make
the second extraction.
The conveyor system has been sized to
move great quantities of boxes that may
coincide with times of higher demand,
whilethetravelspeed,andmainlythestac
ker crane’s lifting speed, were adjusted to
the characteristics of this warehouse.

67Best Practices
Case Study I MGA
Access doors to the stacker cranes
Interior of the stacker crane aisle
Cantilevered storage levels Rear area of the warehouse
In addition, a cantilevered structure has
been made above the loading and un
loading stations, managing to increase
capacity by 320 more boxes.
In the rear, equipped with a large main
tenance area, there are reference devices
for the position of the stacker crane. The
whole space is enclosed with mesh pa
nels and safety doors that will individually
disconnect the machines in case they are
opened.
Thanks to the four
stacker cranes
and the high number
of boxes that they
operate with, MGA
ensures the liquidity
of the flow of
movements

68 Best Practices
Case Study I MGA
Main picking area circuit
Control computers and picking stations
Picking stations
The enclosure where the main warehouse
is located is independent of other build
ings and, in particular, from the picking
station, which was installed on the side of
the warehouse.
The picking stations, in the shape of a “U”,
arelocatedterracedperpendicularlytothe
main conveyors.
These conveyors are comprised of a dou
ble circuit that allows both the recircula
tion of boxes, as well as the connection
to the warehouse and the replenishment
station. Moving boxes to either of the two
main conveyors is direct, thus avoiding un
necessary movements.
Each station, with capacity for three boxes
on hold plus the one which is being pro
cessed, is run by an operator, who in turn
is able to prepare waves of six orders at the
same time. To that end, there is a compu
ter connected to the Mecalux Easy WMS
(warehouse management software) and
different support devices for picking. For
example, put to light devices placed on top
of the containers of each order, indicating
to the operator which order each item
corresponds to.
On the pallets/containers of each order,
the item location in the pallet racks has
been previously introduced, that is to say,
this same zone serves as an order conso
lidation area. In this way, fast and agile
order preparation has been achieved.
Three picking stations,
a replenishment station
and the consolidation
area were set up
throughout the facility

69Best Practices
Case Study I MGA
Put to light device
Conveyors in the picking station
Easy WMS
The Mecalux Easy WMS is the nerve center
that manages all the necessary functions
for the general operations of any type of
warehouse, regardless of its complexity.
Easy WMS (Warehouse Management
System) controls: all the inbound proces
ses, the warehouse locations, stocks, lo
cation rules, storage and extraction, the
pallets that have to go to picking stations,
the picking itself, returns to the ware
house, etc. It is also able to analyze the
state of distinct parts or areas via query
and reporting tools, as well as the devices
that operate in it.
Easy WMS is in
bidirectional and
permanent connection
with the customer’s
SAP ERP

70 Best Practices
Case Study I MGA
Technical data
Storage capacity 15,872 boxes
Maximum weight per box 50 kg
No. of stacker cranes 4
Type of stacker crane double-mast
Extraction system double-deep,two boxes
Advantages for MGA
- Improved storage capacity: the MGA miniload warehouse offers a storage capacity of 15,872 boxes.
- Increased productivity: thanks to the high level of warehouse automatization, the speed of order pre
paration has increased.
- Perfect stock control: thanks to the Mecalux Easy WMS, the company MGA can manage all move
ments, processes and operations that take place within their warehouse.
Miniload warehouse height 12.3 m
Picking stations 3
Replenishment stations 1
Pallet capacity 1,480 pallets
Maximum weight per pallet 1,000 kg

71Best Practices
Case study: Luís Simões
Mecalux equips Luís Simões’ new
installations in Portugal with Pallet Shuttle
and conventional pallet racking
WhatisLuísSimões:
whatareitsneeds?
Luís Simões is a comprehensive transport
and logistics services operator that began
operating in 1948 in the portuguese city
of Loures.
The firm has operated in Spain for over
25years,andiscurrentlythemarketleader
in trade flows between the two countries,
with a fleet of 2,000 vehicles (owned and
outsourced) and over 1,500 employees.
According to its storage facilities expan
sion and modernisation plan, the com
pany commissioned Mecalux to equip
two large, newly built sites, with almost
10,000 m2
of surface area each.
Luís Simões needed to speed up the flow
of incoming and outgoing pallets in the
warehouse while, at the same time, in
creasing storage capacity. This was need
ed to efficiently meet the demands of both
existing and potential customers.
Location: Portugal
This warehouse, separated into
two distinct areas and built under
the “multi-client” concept, covers
a surface area of 17,500 square
metres and can supply more than
33,000 pallets.
Luís Simões performs all of its
business-related activities from
this installation, including storage
and picking, mass and capillary
distribution.

72 Best Practices
Case Study I Luís Simões
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Seven double and one single conventio
nal pallet racks were installed, along with
two compact racking units with the Pallet
Shuttle system. They feature six load levels
and the capacity to deepstore 15 pallets
per level.
The lower level of the conventional pallet
racking was prepared to perform picking
functions, because a high percentage of
Luís Simões’s orders require it. Moreover,
a spacious area was provided for subse
quently consolidating the orders.
Thedocks,locatedoneitherside,havetheir
own preloading channels on the ground;
these allow access to the pallets from both
sides, thus optimising truck loading.
The conventional pallet racking has the
capacity for 10,386 pallets, and with the
Pallet Shuttle system the capacity is 5,544.
Warehouse A
Mecalux’s proposed solution
After analysing all the operations, and Luís
Simões’s needs and flows, Mecalux pro
posed a separate solution for each build
ing, which are interconnected and share
the same management and control centre.
Moreover, the new logistics centre has
34 loading and unloading docks, as well
as three spacious order consolidation pre
loading areas.
Warehouse A
In Warehouse A, a semiautomatic com
pact Pallet Shuttle system combined with
conventional racks was installed, giving
rise to two distinct storage areas, each
served by reach trucks.

73Best Practices
Warehouse B
Warehouse B
Warehouse B consists of twenty rows of
singledeep conventional pallet racking
enabling direct access to the merchan
dise with maximum flexibility. The rows of
racking, which are 130 m long, are served
via 10 storage aisles along which the reach
truck runs.
The height layout can be seven, eight or
nine levels, depending on the product to
bestoredandtheunitloadmeasurements,
whichmaybeEuropallets(800x1,200mm)
or US pallets (1,000 x 1,200 mm).
Three transverse aisles cross the racking to
facilitate the movement of operators; they
can also be used as emergency escape
routes.
Because of their significant length, and in
ordertotraveltheshortestpossibledistan
ceduringmaintenancetasks,eightloading
docks with their own preloading area
were set up at both ends of the warehouse.
Warehouse B’s total storage capacity is
19,503 pallets.
The combination of capacity and flexibility enables
Luís Simões to offer its customers quality service
and short delivery times, strengthening the firm’s
position as a top provider of logistics services
in the Iberian Peninsula

74 Best Practices
Conventional pallet racking
This storage system, which was installed in
both warehouses, has two major advan
tages: direct access to any pallet, and the
ability to devote the lower level to picking
orders.
The machines used are high-lift reach
trucks that can operate in a 3-metre wide
aisle.
The last level of storage is 12 m high. To
facilitate handling, avoid impacts and
properly centre the pallets and/or forks,
observation cameras were fitted on the
upper part of the forklift.
Moreover, and as a safety precaution, pro
tectors were fitted on all the rack uprights
facing the aisles.
The WMS (warehouse
management system),
an essential element
in these types of
warehouses, enables
“chaotic” storage
to be used, achieving
high occupancy of all
locations

75Best Practices
Pallet Shuttle System
Mass market consumer products, which
have a greater number of pallets per item,
are stored with this highdensity storage
system. The movements inside the rack are
independent and follow the instructions
that the operator transmits using a WiFi
tablet; this significantly reduces the need
for loading and unloading goods.
Racking with the Pallet Shuttle system
Pallet Shuttle
In warehouse A, two blocks with six load
levels were installed. The channels are
13.2 m deep and have a unit capacity of
15 pallets. The installation has 378 chan
nels that are served by six Pallet Shuttles.

76 Best Practices
Pallet Shuttle Racking
The racks using Pallet Shuttle are operated
as follows:
1. Using the forklift, the operator intro
duces the Pallet Shuttle into the corres
ponding channel.
2.Withthepalletloaded,thePalletShuttle
moves horizontally until it reaches the
first free location, where it leaves the
pallet.
3.While the Pallet Shuttle moves and
places the pallet into its location, the
operator places another pallet in the ori
ginal position in the channel.
Thus, when the shuttle returns to the
beginning of the lane it can successively
repeat the same movement.
Whenloadinginthechanneliscompleted,
the Pallet Shuttle is moved on to the next
one. Extraction is done by reversing these
steps.

77Best Practices
The program to control the Pallet Shuttle is
installed on each tablet. Various functions
can be performed, including:
Selecting the Pallet Shuttle to be used.
Automated movements.
Manual movements for maintenance.
Compacting or relocating pallets, bring
ing them closer to the exit point.
Battery charging station
Interface for operating the shuttle
Inventory: counts the number of pallets
stored in each channel.
User management: this funcionality
manages shuttle user permissions for
authorised personnel.
Battery charge status.
The observation camera facilitates opera
tions conducted at heights.
A batterycharging station was installed
that can charge the batteries of six Pallet
Shuttle simultaneously. Batteries can also
be charged independently of the shuttles,
that is, the battery can be removed from
the shuttle and replaced with a previously
charged one. In this way, all the shuttles
will always be operational to fulfil the or
ders needed.
Observation camera

78 Best Practices
Technical data
Pallet capacity 1,000 x 1,000 mm 26,000
Pallet capacity 1,200 x 1,200 mm 1,600
Total storage capacity 27,600 pallets
Maximum height of last level 12.3 m
Type of reach truck retractable
Pallet Racking with Pallet Shuttle
Pallet capacity 800 x 1,000 mm 5,550
Number of channels 378
Channel depth 13.2 m
Channel pallet capacity 15
Maximum height of last level 12.5 m
Number of Pallet Shuttle 6
Type of control wifi
Number of tablets 4
Type of reach truck retractable
Advantages for Luís Simões
- Optimaluseofspace:theflexibilityofconventionalpalletrackingandthehigh-densitystorageprovided
by the Pallet Shuttle enables a total capacity of 33,150 pallets.
- Increased productivity: the Pallet Shuttle increases the flow of pallets per hour and allows for greater
diversification by enabling items to be grouped by channel.
- Strategic positioning: this new logistics platform has given an important competitive advantage to
Luís Simões, positioning the firm as a leading logistics centre on the Atlantic coast and bolstering its drive
towards internationalisation.
For further information about this and other success stories look at our web www.mecalux.com/success-stories

79Best Practices
Casestudy:DHL
Mecalux installs a new logistics centre
for DHL on the outskirts of Madrid
Location:Spain
The warehouse, with a capacity
for more than 90,000 pallets, has
two areas allocated for palletised
products. Another, formed by a
two level high mezzanine floor, is
earmarked for hanging garments.
Its strategic location allows DHL
to respond quickly to all its main
customers’ stores within the Iberian
Peninsula (Spain and Portugal).

80 Best Practices
Case Study I DHL
Storageofproductsonpallets
Due to the fact that the majority of orders
delivered by DHL to these stores are full
boxes and they move very few pallets with
a single item type, it was necessary to allo-
cate the bottom level of the conventional
pallet racks for picking activities. Reserve
palletised goods are stored on higher
levels.
Handling equipment used to place the
pallets on the racks are reach trucks.
However, during order preparation, spe-
cific machines are used that have the
capacity to transport up to two pallets at
atime.

81Best Practices
Case Study I DHL
Conventional pallet
racks are an ideal system
to quickly replenish
locations that have been
left without product
Operators maximise streamlining routes
inside the logistics centre thanks to
the WMS (Warehouse Management
Software), which divides the warehouse
so that each operator is responsible for a
single zone. This means that an order can
be prepared by several people at the same
time. Once their part of the order is finis-
hed, each operator will transfer it to one of
the consolidation areas according to the
assigneddock.
Full use of the racks was made to install fire
protectionsystempipelinesandsprinklers.
These coincide with the rack beams or gir-
derstowastetheminimumspacepossible.

82 Best Practices
Case Study I DHL
Assemblybyphases
Mecalux adapted to the company’s needs,
thus they decided to build the warehouse
in phases. So, DHL could make a tailored,
gradual investment as it ran each project
phase.
Aisle length forced them to build inter-
mediate passageways wide enough to
give two pieces of handling equipment
the ability to cross each other at the same
point.
Each sector of the warehouse has its own
loading docks in order to avoid large dis-
placements and significantly reduce ope-
rating costs. The warehouse is also com-
partmentalisedforsecurityreasons.
The breadth of consolidation areas, and
the laying of pre-loads on the floor just
in front of their assigned dock, allows for
speedyloadingoftransportvehicles.

83Best Practices
Case Study I DHL
The total storage capacity
of more than 90,000 pallets and more
than 30,000 metres of profiles used
to hang garments on the racks

84 Best Practices
Case Study I DHL
Thegarmenthangingarea
Racks specifically for hanging garments
are on the mezzanine floor and are two,
fully interconnected, levels high. On each
floor, a space has been left without racks
to allow for the circulation and classifica-
tionofgarments.
Thankstothemezzaninefloor,theproduc-
tive surface area was multiplied, adding
two extra floors that are perfectly suited to
thespaceavailable.
The connection of the operators with the
different warehouse floors is done via a
pedestrian access staircase. On the other
hand, conveyors have stairs and spaces
specifically for automatic access to over-
head carriage that transports hanging
garments.
The Sigma profiles
used for the mezzanine
floor construction system
join all the uprights in the
installation, as well as
attach the rails
of the overhead conveyor
system to the hanging
garments

85Best Practices
Case Study I DHL
The tubes used for hanging garments
on the racks are located at an optimum
height from an ergonomic point of view
and, although they have bearings every
2.2 m, the hangers slide and are grouped
by items without producing any kind of
interference.
Boththefiresafetysystemtubes,sprinklers
andthewarehouselightingareattachedto
the structure. The overhead shuttle trans-
portation rails that are situated in the cen-
tralareaoftheaisleshangthereupon.
Spaces between
pedestrian aisles
are protected
to avoid garments
falling from one floor
to another

86 Best Practices
Case Study I DHL
Technicaldata
Conventionalpalletracking
Palletsize 800x1,200mm
1,000x1,200mm
Maximumweight perpallet 1,000kg
Handlingequipment reachtruck
Orderpicker groundfloorwith
forksfor2pallets
Hunggarmentarea
Surfaceareaoccupied 3,000m2
Surfaceareaofthe3floors 9,000m2
Hangerprofiles >30,000linearmetres
AdvantagesforDHL
- Streamlining the space: the DHL warehouse is set up to store more than 90,000 pallets and more
than30,000mofhangerprofiles.
- Increased productivity: the compartmentalisation of items, the breadth of consolidation areas and
the location of pre-loading zones are some of the factors that help increase the volume and efficiency
ofthemovementofgoods.
- Cost savings: each sector has its own loading dock, thus avoiding large displacements and notably
reducingoperationcosts.
- Efficient service: thanks to this new logistics center, DHL has met the high level of service demanded
byitscustomersandiscapableofofferingfastdeliverywithouterrorsinthegoodssent.

87Best Practices
Casestudy:PAVI‑Groupauto
Conveyor belts as the axis of a picking
installation distributed over several floors
Location:France
PAVI‑Groupauto, a major
supplier of auto spare parts from
France, hired Mecalux
to install the necessary equipment
in its warehouse in Saint‑Priest,
a town near the city of Lyon.
The supply included two levels of mezza
nines, racking, conveyor belts and auto
matic sorters, as well as the Mecalux Easy
WMSwarehousemanagementsystem.

88 Best Practices
Case Study I PAVI‑Groupauto
Analysing the needs
The needs of PAVI-Groupauto required
the construction of a warehouse capa
ble of storing a large number of SKUs of
varying dimensions and characteristics, as
wellasbeinglowconsumption.
To do this, a storage system was needed
that offered optimal use of the surface
area, as well as being highly flexible and
allowingdirectaccesstoanyproduct.
The main objective of the company was
thusmet:rapidserviceforitscustomers.
Solution adopted: a conveyor circuit
The need to maximise the size of the ware
house and the fact that most of the orders
consist of very few units and different
SKUs led Mecalux to propose and install
thefollowingsolution:
- Construction of a structure capable
of integrating two raised floors on a
2,000 m2
area, which would allow the
floorspacetobetripled.
- Installation, on each of the floors, of
racking with different sizes and types of
distribution in order to suit the different
products.
- Implementation of a continuous and
automatic transport system connecting
all the floors. This means operators can
prepare orders by area, and transport
them to the specific sorting and consoli
dation area after completion. The circuit
is also used to send empty boxes from
the lower level to the order preparation
stations.
- Replenishment of the goods directly
from the receiving container to their lo
cations. On each floor, pallet unloading
docks have been installed on the other
sideofsafetyswingdoors.

89Best Practices
- Swivel modules have also been located
at strategic points along the transport
circuitforthepassageofoperators.
- Installation of access stairs between
floors, enabling access and rapid eva
cuationduringpossibleemergencies.
All of this is controlled using the Mecalux
Easy WMS warehouse management
system.

90 Best Practices
Groundfloor
The ground floor is dedicated to bulkier
products with direct picking and does not
requiretheuseofconveyors.
Also, the high consumption products are
stored here, for which picking stations
have been prepared adjacent to the con
veyorbelts.
On the ground floor
the conveyor belt
borders the installation
on two sides
and is connected
to the first floor
via a ramp located
on the third side

91Best Practices
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The second and third floors of the PAVI-
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arestoredonbothofthem.
In addition, the conveyor circuit on these
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92 Best Practices
Preparation and consolidation
of orders
Roller tables have been set up and attach
ed to both sides of the conveyors on differ
ent parts of each floor in order to collect
the boxes containing unfinished orders
and serving at the same time as picking
stations.
Throughout the three floors, ten picking
stationshavebeensetup,eachonecorres
ponding to a different area or sector in the
warehouse.
The boxes, once the part of the order as
signed to a zone has been put together or
completed, are placed on the main conve
yor circuit to be transferred to the stations
inotherareasortothesortingarea.
The circuit descends along conveyor belts
from the third floor to the bottom floor,
where the classification and consolidation
ofordersisperformed.
In this area, the operators check, pack and
draw up the packing list and the shipping
labels of the orders.To complete the oper
ation, there are packing boxes of different
sizes,preptables,computersandprinters.
Once the orders are
completed, they are
sent to the staging areas
located opposite the
loading docks to be sorted
into dispatch routes

93Best Practices
Easy WMS:
Warehouse Management System
The Mecalux Easy WMS (Warehouse
Management System) is responsible,
among other things, for managing all
the incoming processes, choosing the
location where the goods are received,
controlling the stock, designating the
picking functions to be performed by each
operator, executing the movement of the
boxesandsendingtheordersviacomputer
terminals.
The program for controlling the conveyors
is connected to the WMS itself in order to
ensure the efficient transport and alloca
tion of boxes, eliminating human error and
reducing PAVI-Groupauto’s personnel
costs.
The conveyor belts
allow height differences
to be overcome and
movements to be
carried out at different
levels, while the swing
conveyors allow
the passage of
the operators

Mecalux Best Practices Magazine 01 - English

Mecalux Best Practices Magazine 01 - English

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