Best Practices Magazine - issue nº1 - 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

95 

111 

79 

135 

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. 

Best Practices 

3

News I Mecalux 

Mecalux Shop: 

a new look, new 

clickable content 

Keeping with its commitment to innovation 

and new technologies, Mecalux has completely 

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 direct 

sale of metal shelving and related products 

to warehouses, workshops, offices, 

archives, change rooms, etc., building on 

the extensive knowledge and experience of 

Mecalux within the sector. 

Among the newly integrated 

enhancements 

are the following: 

• New categories and 

advanced search filters which allow 

you to easily find any product. 

• More information on each product: 

description of main product features, 

with more detailed technical information 

and more pictures. 

• Making a purchase is streamlined and 

speedy with a user friendly design. 

• Optimised design for smartphones and 

tablets. 

• More advantages for registered users: 

custom offers, easy personal data admin, 

order tracking, purchase history access, 

etc. 

Another of the key points of Mecalux Shop 

is its Customer Service, with professionals 

who know the product and its applica- 

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. 

Safe and sound: Mecalux introduces 

an innovative safety locking mechanism 

Safety in the warehouse is the foundation 

on which to develop an installation’s day-today 

work operations in an efficient and riskfree 

way. Therefore, Mecalux invests a significant 

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 integration 

of a safety locking mechanism in 

the actual connector, which results in two 

key advantages: on the one hand, it is impossible 

for the safety device not to work 

or to lose it accidentally; while on the other 

hand, once it is assembled it is not possible 

to remove it without the disassembly of the 

entire beam. This prevents accidental or 

deliberate manipulation of the connector – 

with a blow by a forklift, for example – thus 

avoiding the beam displacement and its 

possible consequences, such as the collapse 

of the load. 

After successfully introducing this new 

locking system into installations set up in 

the United States, where Mecalux is a leader 

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 incorporate 

this breakthrough device into their 

storage solutions. 

4 Best Practices


Maxi-innovation for Mecalux’s 

semi-automated compact storage 

As one of the leading companies in storage 

solutions for more than 50 years, Mecalux 

invests significant resources in the development 

of new products and the continuous 

improvement of those which are already 

part of their catalogue. It always aims to incorporate 

the latest in technological innovations 

to deliver better profitability. 

So, one of the solutions that has experienced 

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 manoeuvring 

times and helping to streamline storage 

processes for all kinds of companies. 

Among the new add-on innovations what 

stands out is the adoption of Wi-Fi techno- 

logy, which multiplies 

the system 

benefits: the forklift 

operator communicates 

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: continuous 

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 eliminates 

the need for cables. 

• Pallet type selector (the shuttle supports 

various sizes). 

• LIFO/FIFO setup to select the load management 

strategy. 

• Position camera that facilitates the operator 

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 technologies 

to enhance the warehouse performance 

and its profitability. It is an ideal solution 

for companies with a large volume of pallets 

per SKU and high loading and unloading 

activity. 


5


Success, innovation & automation: the Mecalux UPC classroom 

offers new courses in breakthrough logistics systems in 2016 

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 deepen 

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 logistics 

industry. To this end, Mecalux offers 

scholarships covering course fees for UPC 

master’s students, which fulfil the entry 

requirements, in addition to putting the 

Mecalux technological centres at their disposal 

and offering them the possibility of 

starting their career in the company. 

New courses are scheduled to start in 

March of 2016, with 30 lecture hours, at the 

Mecalux UPC classroom premises. 

Mecalux and the UPC 

As a company that bases its leadership on 

technological innovation, Mecalux has 

for years been committed to fostering this 

company-University relationship, collaborating 

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 Characterisations 

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 longterm 

collaboration in R&D&I activities and 

the transfer of research results and scientific 

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 

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 numerous 

Mexican companies to rely on the Easy 

WMS Mecalux software, as a means to manage 

and capitalise their storage processes. 

Among the rollout Easy WMS projects signed 

in Mexico in the past few months, the 

following stand out: 

• Grupo Acuícola Mexicano (GB- 

PO). With Easy WMS they can automate 

the management of one of 

its freezing chambers, controlling 

the entries from the production line, 

and correct load management 

using FIFO and expeditions. 

• Distribución Hugo’ss. Within 

its improved processes, they have 

chosen the Easy WMS, which 

communicates with their SAP 

ERP, to speed up and streamline 

their picking processes, eliminating 

customer service errors. 

• Polioles. ELeader in the petrochemical 

industry. Its main objectives are the reduction 

of costs and storage errors, to control 

warehouse operations, product traceability 

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 universities, 

the Autonomous University of 

Queretaro (UTEQ) and the Autonomous 

University of the State of 

Mexico (UAEM) have acquired the 

field license for Easy WMS Basic for 

academic use in the Logistics degree 

professorship. 

Visit the Mecalux Mexico 

stand in the upcoming industry 

fairs at: 

Logistic Summit & Expo, México DF, 

on April 6 th and 7 th , 2016. 

Expopack, México DF, from May 

17 th to 20 th , 2016. 


News I Our customers 

Logistics chain 

innovation in Argentina 

and Peru: clad-rack 

warehouses with Pallet 

Shuttle to be built 

In recent months, the markets of Argentina 

and Peru have opted for the compact 

storage system Pallet Shuttle by Mecalux. 

This solution incorporates numerous innovations 

to streamline the processes of the 

entry and exit of goods in the warehouse. It 

also provides great storage capacity, thanks 

to an electric shuttle that loads and unloads 

pallets in the interior of the racks, moving 

autonomously along rails. 

Among the projects recently carried out in 

these countries, two constructions, in particular, 

stand out that have combined the benefits 

of clad-rack warehouses with those 

containing Pallet Shuttle racks. 

In Argentina, Granja Tres Arroyos, one of 

the major producers and exporters of frozen 

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 recommended 

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 volumetric 

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 pharmaceutical 

laboratories in Peru. In this project, given 

the diversity of the products marketed, 

the versatility of the system proved essential, 

while also increasing the number of cycles 

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 constructed 

to the depth which was strictly ne- 

Close up of the Granja Tres Arroyos warehouse in Argentina 

cessary, calculated according to their required 

functionality. 

The goal is to put new technologies and 

approaches within reach all kinds of companies, 

to multiply the productivity and profitability 

of storage installations, achieving 

maximum performance within the logistics 

chain. 

Mecalux, in their effort to provide up close 

and personal service to its customers, are 

present in Argentina with two sales offices 

in Buenos Aires and a 21,000 m 2 production 

centre, while there is also a delegation in 

Lima, Peru. Overall, the strength of the customer 

support is second to none. 

Close up of the Mediafarma warehouse 


7


Mecalux will build 

Çaykur a clad-rack 

warehouse with 

a capacity for more 

than 29,000 pallets 

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 locations, 

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 warehouse 

management system Easy WMS and 

the Galileo control software. 

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 overpasses 

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 annually 

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. 

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 Colombia. 

The installation, with a capacity for 

7,416 pallets and 31.2 m high, is managed by 

three stacker cranes. 

A few years later, the company has again chosen 

Mecalux to execute the Cájica warehouse 

expansion. The objective: to reach 34.4 m in 

height, increase capacity to include another 

9,480 pallets, and install an additional three 

stacker cranes. Moreover, recirculation is set 

up that allows both the management of inputs 

from outside sources and internal production, 

and also direct dispatch from the warehouse. 

The warehouse management system, Easy 

WMS software, implemented by Mecalux will 

also be supplied. 

With this expansion, the Family Group warehouse 

will achieve greater inputs and outputs, 

bringing it to the forefront of logistics within 

the tissue and the personal hygiene sector. 

8 

Best Practices


Bem Brasil is keeping cool with clad-rack: 

Mecalux sets up automated storage in Brazil 

United Caps seals 

the deal: Mecalux 

to automate new 

warehouse 

This company, specialised in the manufacture 

and marketing of caps and closures, 

will incorporate an automated 

and asymmetrical, four tiered warehouse 

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 operations. 

For the first time in its history, 

Easy WMS will be permanently connected 

to Axapta (Microsoft Dynamics AX), the 

ERP system that the client uses. 

United Caps is a leader in the design and production 

of plastic caps and closures. With 

their headquarters in Luxembourg, this 

family business offers its innovative solutions 

throughout the world and has its 

own production plants in France, Belgium, 

Germany, Hungary, Ireland, Luxembourg 

and Spain. The company, which had an annual 

turnover of 122.000.000 € in 2015, 

employs more than 530 workers. 

The very popular Brazilian company, 

specialised in the production of precooked, 

frozen potato products, has 

entrusted Mecalux to design, install 

and launch a clad-rack automated 

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 

attained. The stacker cranes, when working 

in deep lanes, are supported by a 

Pallet Shuttle that is responsible for moving 

the pallet up to the location designated 

by the Mecalux Easy WMS software. 

Additionally, in order to ensure the perfect 

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 national 

leader within the sector, and one of 

the most consumed brands within Brazil. 


9


Agrarian giant Gregoire Besson announces new automated 

miniload warehouse in France by Mecalux 

The French company, dedicated to the 

technological agribusiness sector, will 

have an automated mainland warehouse 

for boxes – with a capacity of 

more than 10,000 boxes – built. 

The miniload warehouse is comprised of two 

double depth aisles where a stacker crane will 

circulate and be tasked with executing the input 

and output of 400 x 600 mm sized boxes, 

each weighing a maximum of 50 kg. In the 

header of the automated warehouse, three 

P&D stations are set up to prepare orders of 

smaller products. In addition, the installation 

will be equipped with six conventional pallet 

rack aisles with a capacity for 4,440 pallets 

and a cantilever rack for over-sized products. 

Thanks to the different storage solutions 

provided by Mecalux, Gregoire Besson 

will optimise space and, at the same time, 

streamline order preparation. 

Gregoire Besson, with almost 200 years’ experience, 

is a leading French company in the 

manufacture of agricultural machines and 

in the implementation of technological solutions 

designed to optimise land produced 

resources. 

With a large representation worldwide, their 

ploughing machines are innovative, efficient, 

robust and adaptable to the characteristics 

of any type of arable land. 

Home decor’s largest 

warehouse: Mecalux 

will equip Maisons 

du Monde with new 

installation 

The new conventional pallet rack warehouse, 

of the French company specialised 

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 distributing 

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 logistics 

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 m 2 

of storage in strategic locations in the south 

of France, extending its firm grip on the decoration 

market. 

Founded in 1990 by Xavier Marie, Maisons 

du Monde has 260 shops spread throughout 

France, Italy, Spain, Luxembourg, Switzerland, 

Germany and Belgium, and which employ 

more than 4,500 workers. The Group 

has more than 40,000 high-quality products, 

making it one of the leading companies 

in home decor in France. 

10 



Throughput conveyed and supersized: Quality Pascual and 

Mecalux collaborate on new conveyor system in Barcelona 

This renowned Spanish food and beverage 

company has entrusted Mecalux 

in the semi-automation of transport 

and delivery processes of Leche 

Pascual, one of its leading brands, in 

its packaging centre located in Gurb 

(Barcelona). 

After a thorough study, the technical team 

at Mecalux opted for the installation of two 

automatic conveyor circuits, one on each 

floor of the facility, and a lift which connects 

the two levels. Therefore, they get the streamlining 

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 dispatch 

area, or the storage-ready area on the 

first floor. 

On the other hand, the conveyor circuit designed 

for this upper floor will be reversible, 

so that it can be used for both inputs and 

outputs of pallets. The maximisation of this 

space will make it possible for the Catalan 

Pascual plant to dispense with external warehouses, 

with subsequent cost and time savings 

in the transport of goods between distant 

warehouses. 

In addition to the lift which connects the two 

levels of the warehouse, they complement 

the equipment with a pallet stacker and a pallet 

unstacker. 

All movements of the equipment will be 

monitored by the Mecalux Galileo control 

software, which is in communication 

with the warehouse management software 

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 offering 

excellent quality service, and the continuous 

improvement of both its products 

and processes. 

Kronopol goes automated: Mecalux constructs custom 

warehouse for timber products 

The new automated warehouse, to be 

built in the Polish town of Zary can store 

more than 20,000 pallets, or 2.9 million 

square meters of finished product. 

Kronopol, one of the world’s leading producers 

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 deposited. 

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 stacker 

crane will circulate 

that is able to move 840 x 

1,410 x 1,200 mm pallets, 

with a maximum weight 

of 1,075 kg each. 

This installation, which 

is scheduled for completion 

in the third quarter 

of 2016, was the Kronopol organisation’s 

most substantial investment in 2015. Its 

construction, apart from increasing storage 

capacity by maximising available space, will 

give the company a series of advantages. 

Among these are complete automation, 

an increase in the loading and unloading 

speeds of vehicles, and the preclusion of 

damaged goods caused by forklift usage. In 

addition, the warehouse is also distinguished 

by being environmentally friendly because 

the solutions used will work via electricity, 

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 variety 

of their timber products earmarked for 

the manufacture of interior finishings and 

furniture. 


11


Design and efficiency go 

hand in hand: a new automated 

clad-rack warehouse designed 

by Mecalux for STUA 

Founded in 1983 by Jesus Gasca, STUA 

in one of the most internationally recognized 

Spanish contemporary furniture 

design companies. Recently, its operations 

moved to a new facility in Astigarraga 

(Guipúzcoa) in order to boost continuous 

growth. 

After assessing various options for the implementation 

of a storage system that best resolved 

their needs, STUA finally chose the 

project submitted by Mecalux, due to the 

confidence that being made in Spain and 

their extensive experience conveys. 

STUA’s objectives are to gain perfect control 

of both their products and deliveries to 

any part of the world, in addition to maximise 

storage capacity. To fulfil these requirements, 

Mecalux has planned out a solution 

consisting of an automated clad-rack warehouse 

annex to the production building that 

stands out for its slenderness, since it has had 

to adapt to some unusual measurements: 

80 m long, 25 m high and only 9 m wide. 

The automatic warehouse is made up of 

an aisle where a single-mast stacker crane 

circulates, which serves the double depth 

racks located on both sides. The racking has 

10 levels of different heights in order to locate 

various sized load units – some larger 

than usual – given the characteristics of the 

product. The inputs and outputs of the automated 

warehouse have been dealt with a 

circuit of conveyors. 

Last but not least, to manage all warehouse 

processes, Mecalux will implement its Easy 

WMS warehouse management software, 

which will allow the full control STUA stock 

and real-time inventory, while also optimising 

and coordinating product throughput, 

from its entry into the warehouse to its dispatch 

to the end customer. 

The new automated clad-rack warehouse will 

provide STUA with better efficiency and profitability 

in their logistics operations. This will, 

in turn, give them a competitive advantage in 

their job of innovating and promoting Spanish 

design, which was recognized in 2008 with 

the National Prize for Innovation and Design. 

12 


Case study: Hayat Kimya 

Tallest warehouse in Europe constructed: 

earthquake prone area in Turkey not an issue 

for Mecalux and its partner Hayat Kimya 

Location: Turkey 

Hayat Kimya is the leading chemical company in the Turkish and Eurasian 

market in the manufacture of cleaning and hygiene products. They entrusted 

Mecalux in the construction of a spectacular 12,500 m 2 , 46 m tall automated 

logistics centre in the city of Izmit (Turkey). 

They were supplied with a plan that included 

the warehouse management system 

Mecalux Easy WMS, responsible for managing 

all the centre’s activities. 

The solution implemented for Hayat Kimya 

has become a global benchmark for automated 

clad-rack warehouses, showcasing 

Mecalux’s professional fortitude and skill. 


13

Case Study I Hayat Kimya 

Who is Hayat Kimya? 

Founded in 1937, Hayat Kimya is the leading 

chemical company in the Turkish, Asian 

and Middle Eastern market for cleaning 

and hygiene products. 

The company has twelve 

brands distributed 

in three sectors: 

household care, hygiene 

products and tissues 

At present, Hayat Kimya is the seventh largest 

manufacturer in Europe in its sector, 

having more than 5,200 employees and 

reaching all its consumers through an 

export network which covers 101 countries. 

The needs of Hayat Kimya 

The huge growth experienced by Hayat 

had obliged them to distribute goods between 

several warehouses located near different 

production centres, which involved 

high logistical costs that could increase 

over the years. 

Faced with this situation and seeking to reduce 

production costs, Hayat Kimya decided 

to build a single warehouse with a 

minimum storage capacity of 150,000 pallets 

and in which to undertake picking 

functions. 

In addition, and in order to save on transport 

costs, they thought of putting it in 

a space available in their largest facility, 

equal distance from three of their most important 

plants and near a fourth high production 

site. 

In the two images on this page the warehouse’s 

location in relation to the factories 

and to the connecting overpasses can be 

seen: 

1. Logistics centre 

2. Tissue factory 1 

3. Tissue factory 2 

4. Hygiene factory 1 

5. Hygiene factory 

6. Detergent factory 

7. Tissue input overpass 2 

8. Tissue input overpass 1 

9. Hygiene input overpass 



The solution 

Taking into account the above premises 

and the data provided by Hayat Kimya, 

Mecalux worked from the outset in the design 

and construction of a warehouse with 

the following features: 

- Automated clad-rack warehouse 

with a capacity for 161,000 pallets. 

- Four raised overpasses above the lanes 

inside the installation that connect 

the factories and the main conveyor circuit. 

- A ground floor dedicated almost exclusively 

to dispatches, with the exception 

of two multipurpose docks and a dock 

fitted with an automated unloading system 

intended for the receipt of merchandise 

from other factories. 

- First floor used exclusively for offices 

and other services. 

- Second floor reserved entirely for picking. 

- On the third floor is where all inputs 

take place in the warehouse from the 

factories that are located in the complex, 

as well as the outputs intended for picking 

areas. 

- Wide manoeuvring area and loading/ 

unloading of trucks, with 21 docks. 

3 

Map data ©2015 Google 

1 

5 

2 

4 

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 

7 

9 

8 


15


The warehouse 

The size of the warehouse is 120 m long x 

105 m wide and 46 m tall, with a total capacity 

that exceeds 161,000 pallets that 

are 800 x 1200 mm in size and weigh a 

maximum 700 kg each. 

The construction system is self-supporting, 

that is to say the racks, in addition 

to storing goods, have additional structures 

on which sheet clad panels are 

attached to that make up the building. 

This forms a complete unit that is the 

warehouse. 

The racks must support their own weight, 

the pallets stored, the wind pressure, handling 

equipment, the seismic activity on 

the basis of the coefficient indicated at the 

construction site and the weight of snow 

that conforms to the regulations. 

The Hayat Kimya warehouse consists of 

15 aisles with double-depth racks placed 

on both sides and is 24 load levels high. In 

each aisle a 45 m high stacker crane was 

set up that is responsible for the movements 

within the warehouse, from the reception 

area to product locations. 

Each stacker crane is equipped with a 

double cradle that allows two pallets 

to be moved at a time and with singlemast 

construction, something unusual 

for a warehouse of this height. The maintenance 

of the stacker cranes is carried out 

on the side that coincides with the conveyor 

circuit. 

It is interesting to point out that in each 

of the 24 load levels that integrate rack 

bays, three pallets in the first position and 

three other pallets in the second are stored. 

This is very difficult to achieve in a tall 

warehouse which is located, as explained 

below, in an area with such a high rate of 

seismic activity. 

In this image the loading 

docks and the offices 

located on the bottom 

floor of the warehouse 

can be seen. 



The warehouse itself is an enclosed box 

in which all passages between the inside 

and the outside connection floor are done 

through airlocks that help maintain the 

atmosphere required by the fire protection 

system. 

This system (inerting) works by reducing 

the oxygen in the interior’s air, to an 

atmospheric level of 14%, at which point 

combustion is no longer possible. A piece 

of equipment controls the oxygen levels 

in the air and adds nitrogen until reaching 

the percentage that has been previously 

programmed. 

The final solution 

was the construction 

of a huge 12.500 m 2 

logistics centre, with 

a 46 m tall, clad-rack 

warehouse, readied 

to house up to 

161,000 pallets 


17


Eurasian Plate 

Izmit 

Anatolia 

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 peninsula 

and which makes up the greater part of 

Turkey’s territory. This stretch, parallel to 

the Black Sea, also coincides with the fault 

line that crosses the Sea of Marmara and 

the Bosphorus Strait. 

African Plate 

Arabian Plate 

To build a warehouse of these dimensions 

in a place with such a high rate of earthquakes, 

with a height of more than 45 m 

and with stacker cranes prepared to move 

two pallets at a time and operate in doubledepth 

racks, was a challenge never before 

surpassed by Mecalux. Furthermore, the 

warehouse was built in an area exposed 



to the wind and where snowfall, although 

not frequent, can be abundant when it 

does occur. 

With all these constraints, only one company 

with the experience and quality of 

Mecalux was able to build a warehouse on 

this scale. 

The main difficulty Mecalux faced was 

the existence of a major earthquake zone right 

where Hayat Kimya wanted to build its 

upcoming central warehouse 

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 assembly 

that this installation required was 

extremely high. 

The solution provided by Mecalux’s technical 

team was to combine the two con- 

structive options. The first to conform all 

racks, and the second to complete the 

construction of a vertical reticulate structure 

coupled to the racks. 

The objective was to absorb all the horizontal 

dynamic forces, mainly those of a 

longitudinal direction, which is the least 

rigid part of the racks. 

The weight of this additional structure was 

more than 1,900 t (for the whole structure 

10,000 t was used). 

Both the dimensions and mode of operation, 

as the building’s location, represented 

a challenge for the Mecalux’s Structural 

Engineering department that had to deal 

with some extreme determinants. 


19


Upper floor: 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 

the factories. 

All the factories have a conveyor circuit 

that is tasked with the input of the pallets 

into the system after checking both 

its size and its weight. Only then will they 

ensure that the pallets that arrive to the 

warehouse do so in good condition. 

In each overpass two lifts were placed, one 

in each factory’s entry points and an other 

at the end of each overpass, allowing 

goods to be lifted to transport height and 

subsequently to the third floor. At the same 

time, this floor has a triple electrified monorail 

circuit running both the external and 

internal movements of the warehouse. 

On the third floor, alongside inputs, outputs 

of goods that are lowered to the designated 

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. 




21


Plant intended for 

the picking operations 

The second floor of Hayat Kimya’s warehouse 

has been reserved for picking functions, 

dividing it into two areas: 

Zone A: 118 live channels, each three pallets 

deep, are grouped into four blocks. 

Each block is serviced by a shuttle that 

automatically feeds the channels with the 

goods from the lifts. 

This area is intended for A type products 

(high demand). 

This image displays the floor 

set up for picking. 



Zone B: 174 pallet racking bays with 2 or 

4 levels for pallets, including the ground 

floor, grouped into four double and two 

single rack alignments. 

It has a total capacity of 500 pallets for 

picking placed directly on the floor and 

1,050 reserve pallets on upper levels. This 

second area is allocated for the picking of 

B type products (medium demand). 

In addition, the same racks were set up for 

levels of live box picking to give access to 

C type products (low demand). 

The feeding of the pallet racks is performed 

using front loading reach trucks that 

take the pallets from the warehouse in a 

specific exit, where one of the lifts has previously 

deposited the pallets destined for 

this zone. 

Picking is done manually by the operators, 

aided by order fulfilment machines 

and a computer terminal that works via 

radio frequency. 

When the orders are 

completed, they are taken 

to the baling area and, 

via two lifts, are sent to 

the ground floor to be 

dispatched 


23


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, and classify them into preloads. 

The preloads are composed of 17 triplechannel 

groupings, which have a capacity 

to deep-store 11 pallets. 

Each triple-channel group has a total capacity 

of 33 pallets each that correspond to 

an order, route or an out-sourced means of 

transport (truck or sea container). This request 

is prepared before loading the truck 

to avoid waiting time in goods being dispatched 

from the warehouse. 



Every day an average 

of 7,000 pallets 

leave the warehouse, 

in other words, 

more than 

200 truckloads 

Depending on the means of transport 

used, and the agreements with company’s 

individual customers, the merchandise 

is shipped on pallets (usually by truck) or 

in single, stacked boxes (sea container). 

For loading trucks generally light, front 

loading forklifts are used, since they are 

very agile and thus the most suitable. 

The dispatch area has 17 docks only for 

loading, allowing the preparation of 

17 transport vehicles at a time. 


25


Automatic unloading 

In addition, on the lower floor merchandise 

inputs from the detergent factory (located 

2 km away) is also done. 

The inputs take place on the ground floor 

via three reception docks, one of which is 

readied to automatically run unloading. 

The automatic 

unloads accumulation 

device can receive 

all the pallets of a full 

truckload (trucks are 

set up with similar 

equipment) 

From here, the pallets pass, one by one, 

through the checkpoint and continue via 

the electrified monorails to the input 

stations located inside the warehouse that 

is found on this floor. 



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 

of 100 meters per minute. 

There are more than 900 meters of electrified 

monorail and 55 autonomous shuttles 

in the entire installation that are able to 

move more than 850 pallets per hour 

The warehouse should be as airtight as 

possible to avoid the entry of air currents 

with a higher percentage of oxygen. This 

means that all the merchandise that enters 

and exits via the electrified monorails 

passes through a sealed area with double 

doors or airlocks that can never be opened 

at the same time. 

These spots are often bottlenecks in an 

unattended installation – consequently in 

this case, which work via electrified monorails 

and where there are also very high 

flow rates – it was necessary to design several 

accesses with triple inner shuttle capacity. 

In other words, the shuttles of the 

electrified monorails pass three at a time. 

ERP 

SAP 

of Hayat 

Mecalux Easy WMS 

Easy WMS: the nerve centre 

of the logistics centre 

All the operations of the logistics centre are 

governed by the warehouse management 

system Mecalux Easy WMS and its Galileo 

control software; tasked with controlling 

the computers that run the transport and 

the storage of goods tasks. 

Easy WMS is also responsible for: 

- Management of goods input from its reception 

at the docks. 

- Locate pallets in the warehouse using 

rules previously parameterised, under 

the criteria of streamlining and maximum 

productivity. 

- Manages the stock and the warehouse 

layout (what and where the goods are). 

- Manages the warehouse outputs to the 

picking and/or dispatch areas. 

- Manages and controls the picking operations 

through radio frequency terminals, 

guiding the operator in the tasks to be 

performed and the order to follow to optimise 

routes. 

- Allows the checking of the status of different 

parts of the logistics centre, and the 

various equipment that operate in it, via 

query and reporting tools. 

The Easy WMS (Warehouse Management 

Software) is in permanent and bi-directional 

connection with Hayat Kimya’s SAP 

ERP system. 


27


Advantages for Hayat Kimya 

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

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

- Production cost savings: they have built four overpasses connecting the factories and the front 

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

400 pallets per hour. 

- Total control of the automated warehouse: thanks to the Mecalux Easy WMS (Warehouse 

Management Software), Hayat Kimya controls all the processes and operations that take place 

inside the warehouse, from the moment the product leaves packaging lines until it is delivered. 

- Remote support, remote maintenance: Mecalux is available to give technical support to Hayat 

Kimya 24 hours a day, seven days a week. 

Technical data 

Length of the warehouse 

120 m 

Width of the warehouse 

105 m 

Height of the warehouse 

46 m 

Storage capacity 


No. of storage aisles 15 

No. of docks 24 

No. of double cradle stacker cranes 15 

Extraction system 

double-depth 

Total electrified monorails 

> 900 linear metres 

No. of shuttles in the installation 55 

Total in overpasses 

> 420 linear metres 

Total number of lifts 12 

Total number of shuttles 4 

Live channels for picking 118 

Live preloads 17 

Total live preload channels 51 

Automatic unloading platform 1 

Pallet input per day 6,500 

Maximum pallet input per hour 400 

Pallet output per day 7,000 

Maximum pallet output per hour 450 

Average truckloads issued per day > 200 

Weight of the warehouse structure 10,000 t 

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


Case study: Gioseppo 

Two million pairs of shoes: Mecalux builds 

Gioseppo a clad-rack solution for footwear 

Location: Spain 

The installation that Gioseppo has in Elche (Spain) is composed of an automated 

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

The warehouse management system Mecalux Easy WMS was supplied, which is 

responsible for managing all the centre’s processes. 


29

Case Study I Gioseppo 

Who is Gioseppo? 

Founded in 1991, Gioseppo is a family 

busi ness from the Elx region, dedicated to 

designing and marketing medium to highend 

shoes for men, women and child. 

After almost 25 years, Gioseppo is currently 

a well-established brand whose 

products are marketed in more than 60 

countries worldwide. 

Its growth and track record has led 

Gioseppo to be included in the prestigious 

‘Forum for Renowned Spanish Brand’s’, an 

alliance made up of companies and leading 

brands from their respective sectors. 

Logistical needs 

The objectives presented by Gioseppo to 

Mecalux were very specific: build a warehouse 

to increase its storage capacity to locate 

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 efficient 

way possible. 

With this, the company would take a qualitative 

leap forward on a logistical level that 

could reduce production costs, while improving 

warehouse productivity 

Based on these requirements, Mecalux designed 

an integrated solution in which automated 

storage processes were more profitable 

for Gioseppo. 



Construction needs 

Another premise that Mecalux had to keep 

in mind was to pay careful attention to the 

public image of the company. It was of utmost 

importance to limit the impact constructing 

a clad-rack warehouse would 

have on the landscape of the Gioseppo 

“Love Work Place” logistics centre, an 

environmentally friendly space near the 

Mediterranean Sea. 

Accordingly, the dimensions of the logistics 

centre could not exceed a certain height. 

So, it was necessary to find a solution that 

offered high storage capacity, while at the 

same time reducing the installation’s size. 

3 

It was paramount 

to reduce the impact 

constructing a clad-rack 

warehouse had on the 

landscape of Gioseppo’s 

‘Love Work Place’ 

logistics centre 

2 

1 

Map data ©2015* Google 


31


A clad-rack warehouse as a solution 

This 18.5 m high, 79 m long and 21.5 m 

wide clad-rack warehouse is composed 

of three aisles with double-deep racks on 

both sides, offering a storage capacity of 

5,844 pallets, weighing 500 kg each. To be 

clad-rack means that the structure of the 

building is formed by the racks themselves, 

and that the outer cladding is supported 

and attached to them. 

For structural calculations of clad-rack 

warehouses the following are taken into 

account: its own weight; the weight of the 

goods stored; the wind pressure both push 

and suction depending where it is built; the 

weight of the snow as indicated by the regulations; 

ramming by stacker cranes; and 

finally, the seismicity corresponding to the 

territory in which it is located. 

Its purpose, as explained above, was twofold: 

to optimise height in order to a chieve 

the largest possible storage capacity, and 

reduce landscape impact to preserve 

Gioseppo’s public image. 

In each aisle a stacker crane circulates, 

hand ling the movements of the pallets 

from the conveyors at the end of the aisle 

to its designated location. 

The use of stacker cranes helps increase 

productivity, at the same time decreasing 

the resources required to manipulate the 

goods. 

Gioseppo’s clad-rack 

warehouse is distinctive 

because they excavated 

a 6 meter deep trench 

where a large portion 

of the warehouse was 

installed 

3 

2 

1 




33


Inputs and outputs 

The inputs and outputs of palletised goods 

are done via a double shuttle that connects 

the main circuit of conveyors with 

the stor age aisles. The goods input area 

has an entry checkpoint, which is responsible 

for verifying that the size, weight, and 

condition of the pallets comply with the 

installation’s specifications. 




35


Picking functions 

This same transfer car is tasked with transferring 

the pallets from the aisles to the P&D 

stations. The picking area is organised star t- 

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 

the back. 

In addition, and in order to facilitate work, 

each picking station has a lift table so that 

the pallets are kept at the ideal height for 

each operator, improving its ergonomic 

position. 



The picking area 

has six independent 

stations that are 

set up with a lift table 

to improve ergonomic 

design 


37


Live racks for orders completed and 

consumer products 

A block of 36 live rack channels has been 

installed both for storing orders prepared, 

as well as the stacks of idle pallets. 

This 8 m high, 9.5 m long and 11 m deep 

warehouse has a storage capacity of 

324 pallets 800 x 1,200 x 1,900 mm in 

size, each with a maximum weight of 

400 kg. Each channel receives nine pallets. 

The live racks are a compact storage system 

that allows maximum use of space and 

that are composed of roller channels on a 

slight incline. The pallets are inserted into 

the highest part of the rack and move via 

gravity to the lower end, being available to 

the operator. The pallet travel speed is controlled 

by roller brakes. 

Therefore, this storage system is ideal 

for lowering handling times and expedites 

picking, increasing the installation’s 

productivity. 




of the installation 

In Gioseppo’s new warehouse the warehouse 

management system Mecalux Easy 

WMS was implemented to manage and 

coordinate the different automated operations 

that take place within the installation: 

the input and output of goods, storage, 

picking and dispatches. 

This powerful management software has 

been customised to Gioseppo’s demands, 

being able to: locate pallets in the racks 

based on algorithms or parametrisable 

rules, manage outputs on the basis of traceability 

and FIFO criteria, check the stock, 

run standard and custom labelling of containers, 

group output orders in different 

modalities, etc. 

Easy WMS (warehouse management software) 

provides a competitive advant age 

to Gioseppo, since it involves cost savings, 

an improvement in service quality 

and consequently, maximising warehouse 

profitability. 

In addition, Easy WMS is in permanent 

communication with the SAP ERP, 

Gioseppo’s main management system, exchanging 

orders and the information that 

is essential for its overall management. 


39


Advantages for Gioseppo 

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

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

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

capacity, while the impact on the area’s landscape was minimised. 

- Cost savings: the automation of the clad-rack warehouse allows Gioseppo to increase efficiency 

and reduce personnel and logistics costs. 

- Complete control: the Mecalux Easy WMS controls all the processes and operations that take 

place inside the warehouse. 


Automated Warehouse 


5,844 pallets 

Maximum weight per pallet 500 kg 

Warehouse height 

18.5 m 

No. of stacker cranes 3 

Type of stacker crane 

twin-mast 

Fork type double-deep 

Construction system 

self-supporting 

Live racks 


Pallet size 

Maximum weight per pallet 


324 pallets 

800 x 1,200 mm 

400 kg 

8 m 


Case study: Ypê 

Wide prep area for orders: a key Mecalux 

design feature for Ypê warehouse in São Paulo 

Location: Brazil 

Ypê, a company dedicated to the 

development of cleaning products for 

the household and personal hygiene, 

has hired Mecalux to install a 29.5 m 

high automated clad-rack warehouse 

with a 24,168 pallet storage capacity 

in its logistical support centre in 

Amparo (São Paulo). 


41

Case study I Ypê 

Analysing the needs 

The main production centre of Ypê is located 

in Amparo, a town close to the city of 

São Paulo. The growing needs of the company 

required the construction of a large logistics 

centre next to the production plants, 

from which they could offer comprehensive 

service, and at the same time reduce costs. 

Mecalux installed the racks and structures 

of the warehouse, the automatic internal 

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 




43


Warehouse area 

reserved to expand the storage 

capacity of Ypê 

Solution adopted: 

clad-rack warehouse 

The most striking part of the project developed 

by Mecalux is the installation 

of a self-supporting construction warehouse 

with a total capacity of 24,168 pallets, 

1000 x 1200 mm in size, each with a 

weight of 1,300 kg. 

Being clad-racked, the racks are a fundamental 

part of the structure of the building 

and cladding is placed on them. In addition 

to its own weight, it must withstand the 

pallets stored, the force of the wind on the 

basis of the site characteristics, the pressure 

of the handling equipment and the 

seismic risk that corresponds to the zone in 

accordance with the country’s regulations. 

of eight storage aisles, with racks on both 

sides, of which five are double-depth and 

three single-depth. 

Each aisle is set up with a twin-mast stacker 

crane that automatically performs the 

movements between locations and the 

main conveyor circuit, placed at the header 

of the warehouse. 

The traditionally constructed buildings are 

adjacent to Ypê’s logistics centre, just besides 

the automated warehouse, where 

available space has been set aside for future 

expansion. 

At present, this 29.5 m high, 107.5 m long 

and 49.5 m wide warehouse has a total 



The warehouse is distributed into the following 

areas, as can be seen in the layout: 

A. Warehouse 

B. Input stations 

C. Main conveyor circuit 

D. Direct outputs station 

E. Picking channels 


45


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 located 

in the reception dock area for incoming 

goods, occupying one of the sides of 

the warehouse. 

A conveyor with accumulation capacity 

transports them to the header, where the 

main conveyor circuits are placed. 

A large percentage of the pallets that leave 

the warehouse do so designated for the 

picking area. 

As of now, there are five groups of live 

channels outfitted and one for pallets 

placed on the floor of the warehouse. 

Group of picking channels 



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 

Each grouping contains 66 channels with 

a three pallet capacity. The feeding is performed 

via transfer cars that automatically 

move from specific positions of the header 

to the live channels. The slight tilt with 

which channels are mounted allows the 

pallet to move by gravity to the closest free 

position in work aisles. 

Among the five groups, there is a total of 

330 channels with a capacity for 990 pallets; 

each channel is intended for a single 

SKU. Apart from that, there are 138 positions 

for pallets placed on the floor, which 

are directly supplied by forklifts. 

The consolidation of orders, once the pallets 

have already passed by the balers, is 

carried out in the area allocated to preloads 

close to the loading docks. 

The logistics centre of Ypê also features live 

racks to store consumer products that do 

not enter into the automated warehouse. 

This area, next to the docks, works as crossdocking, 

the live racks acting as a buffer. 


of the logistics centre 

Easy WMS is a powerful warehouse management 

system developed by Mecalux 

with which you can manage all the warehouse 

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 important 

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, documentation 

prior to delivery, etc. 

All of this with the major advantage of reducing 

the errors arising from manual management 

to a minimum. 

Furthermore, the Mecalux Easy WMS 

warehouse management software is continuously 

and directly connected to the 

ERP of Ypê, from which it receives the background 

information and that reports the 

outputs executed. 


47


Advantages for Ypê 

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

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

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

operational costs. 

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

order to expand storage capacity based on the future needs of the company. 

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

take place inside the warehouse. 




Dimensions of the pallet 

1,000 x 1,200 mm 

Maximum weight per pallet 1,300 kg 



twin-mast 

Fork type 

single and double-depth 

Live picking channels 330 

Pallets in picking positions 1,128 pallets 

No. of transfer cars 5 

Preload 

on the floor 


Case study: Takeda 

Turnkey pharmaceutics: automated warehouse 

by Mecalux for Japanese partner Takeda 

Location: Poland 


49

Case Study I Takeda 

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. 

Who is Takeda? 

Takeda Pharmaceutical Company Limited, 

with its headquarters in Osaka (Japan), is 

a global company specialising in the invest 

igation of pharmaceutical products. In 

the mid-twentieth century, it experienced 

massive growth, making it a world leader 

in the pharmaceutical industry and the 

larg est of its kind in Japan. 

A clad-rack warehouse as a solution 

When Takeda moved forward with the expansion 

of its production centre, it was very 

clear that the warehouse should be automated. 

This would allow for perfect control 

of stored goods, in addition to being 

able to achieve the maximum permissible 

height, given that the space available for 

warehouse construction was limited. 

The solution proposed by Mecalux was the 

construction of a 32.5 m high clad-rack 

warehouse located next to the manufact 

uring facilities and the bay assigned to 

delivery preloading. In this type of cons- 

The company has a commercial pre sence 

in more than 70 countries, most significantly 

those in Asia, North America and 

Europe and emerging markets such as 

Latin America, Russia and China. 

truction, the racks themselves make up 

the structure of the warehouse. 

The installation consists of two aisles, in 

which two automatic stacker cranes move 

independently, handling the pallets stored 

in double-deep racks (two pallets in depth 

on each level). Thanks to the optimal space 

utilisation, the Takeda warehouse has a 

storage capacity of more than 6,500 pallets 

in a surface area of only 950 m 2 . 

The warehouse was equipped with a 

HVAC system (Heating Ventilation Air 

Conditioning) which keeps the temperature 

between 16 and 24 °C and prevents 

the humidity level from exceeding 70%, 

which is something that could affect 

goods stored. 

3D computer graphic of the Takeda clad-rack warehouse 



Warehouse aisle 


51


32,382 mm 

14,505 mm 

Layout: elevation, floor and 

profile of the Takeda warehouse 

85,657 mm 

65657 mm 

An innovative fire protection system (inerting) 

has also been used, which reduces the 

amount of oxygen in the atmosphere to 

15% to avoid fires. 

The pipes of the air’s humidity and temperature 

control system have been installed 

above, targeting the aisles and placed in 

the free space between trusses in the facility. 

For structural calculations of clad-rack 

warehouses the following are taken into 

account: its own weight; the weight of the 

goods stored; the wind pressure both push 

and suction where it is built; the weight of 

the snow as indicated by the regulations; 

thrusts by stacker cranes; and finally, the 

seismicity corresponding to the territory 

where it is located. 

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 

Due to the slenderness of the building 

(14.5 m wide and 32.4 m high), a highly reinforced 

structure was built. Also, many 

large sized anchorages have been placed 

with the aim of absorbing maximum wind 

pressure. 

Outside view of the warehouse 



Twin-mast stacker crane 

19800 

19,800 mm 

Cooling tube 

Reinforced racks 


53


Inputs and outputs are practically unified 

and are constructed very simply, they are 

suitable for forklifts and stackers use. The 

entry conveyor has a checkpoint, which 

ensures top condition of all the pallets that 

are put into the automated warehouse. 

The connection with the inside of the 

warehouse is done using a double conveyor 

circuit (inputs and outputs) that passes 

through doors with double vertical 

screens. 

Entry and exit of the warehouse 

The space between the two screens 

amounts to what is needed for a single pallet, 

being that the system sends alternating 

open and close signals, limiting temperature 

changes inside. 

In order to avoid capacity loss, a superior 

platform was set up for doing secure maintenance 

with one access per aisle. 

Entry and exit of the warehouse 

The stacker cranes 

are double-mast 

and incorporate a 

maintenance cabin, 

which is located 

on the lifting cradle 

itself 

Main conveyor circuit 



Plant’s maintenance access 

Easy WMS: 

The management, synchronisation and 

control of the entire warehouse, including 

parts that interact with the maintenance 

equipment, work thanks to the 

Mecalux Easy WMS (Warehouse Management 

Software). 

The main functions of Easy WMS are: 

- Receiving and recording the pallets that 

come into the warehouse. 

- Pallet location in the racks based on algorithms 

or parametrical rules. 

- Management of outputs based on FIFO 

criteria and traceability. 

- Via the Galileo software, all movements 

of the mechanical parts run and optimised 

the internal routes. 

- Connection to the warehouse door 

control program so that it acts 

automatically. 

In addition, Easy WMS is in constant communication 

with the SAP ERP, Takeda’s 

main management system, exchanging 

orders and information that is essential to 

its overall management. 

Maintenance access 


55


Turnkey warehouse 

Takeda wanted all development and construction 

phases of the warehouse, including 

the supply of the software needed to 

properly manage all internal operations, 

carried out by a single company. 

That is why Mecalux was commissioned to 

run the turnkey project from beginning to 

end. 

Stages of warehouse implementation: 

- Land preparation via pilings: due to 

the low bearing capacity of the soil, and 

the large static demands, a deep foundation 

was made on pilings. 

- Installation of a reinforced concrete 

foundation slab: first a reinforced top 

and bottom was built with steel rods, and 

subsequently the ground was filled with 

concrete. 

- Finish: the foundation was finished and 

hardened with the objective of obtaining 

dust free paving. 

- Rack assembly: regarding clad-rack 

warehouse, the racks themselves make 

up the actual structure. 

- Assembly of warehouse cladding: 

in clad-rack warehouses wall panelling 

and ‘sandwich type’ roofs are fastened 

directly to the rack structure. In Takeda’s 

case, and having used an inerting system, 

it was necessary for the outside cladding 

to be as watertight as possible. 

- Introduction of maintenance teams: 

conveyors and stacker cranes were 

assembled inside the warehouse. 



- Installation of the inerting system: 

implementation of a fire protection system 

that allows you to inject nitrogen into 

the warehouse so that the oxygen concentration 

is reduced to less than 15%. 

- Installing the HVAC air conditioning 

system: it controls the temperature that 

should be maintained between 16 and 

24 ºC. 

- Assembly of the electrical and lightning 

protection systems. 

- Assembly of the drainage system. 

- Airlock construction: the separation of 

the portion of the warehouse equipped 

with the inerting system to the adjoining 

building that work under normal environmental 

conditions. 


57


Advantages for Takeda 

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

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

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

automatic warehouse installation. Only authorised people can access the warehouse. 

- Turnkey warehouse: Mecalux was responsible for the development phases, the construction of the 

warehouse, the supply of storage, cooling, and fire safety systems, as well as the implementation of the 

WMS (Warehouse Management Software). 

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

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


Warehouse capacity 

6,584 pallets 




twin-mast 

Fork type 

double-deep 

Height of the warehouse 32 m 


Case study: Nufri 

Nufri has put its confidence in Mecalux yet 

again by installing Movirack mobile pallet 

racking in its headquarters in Catalonia 


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. 

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 

of the installations. 

In response, Mecalux opted to install 

Movirack mobile pallet racks of 12 m high, 

converting it into one of the tallest solutions 

of this kind and perfectly adapting it 

to the needs presented by Nufri. 

The warehouse is divided into two wellmarked 

areas: the first, which is smaller 

in size, is set up to store products and 

packag ing at ambient temperature, while 

the remainder of the area is cold storage 

used to store extracts, juices and purees. 


59

Case Study I Nufri 

Block 3: ambient 

temperature area 

Ambient temperature area 

It is set up to supply production areas, from 

cylindrical containers of enormous dimensions, 

including the products necessary to 

complete its range of processing. 

This area, with a storage capacity of 

1,200 pallets that are 1,200 x 1,200 mm 

in size and have a maximum weight of 

2,100 kg each, is available with seven mobile 

bases and two non-moving racks. 

Being located beside the cold storage 

allows combined supply, removal and storage 

of processed goods, significantly optimising 

the internal movements inside the 

installation. 

Providing for the future needs of the company, 

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 progressive 

growth. 

The utilization of 

Movirack mobile pallet 

racking provides the 

maximum installation 

streamlining 

BLOCK 3 

BLOCK 1 

2 

3 

BLOCK 2 



Blocks 1 and 2: cold storage unit 

The racks have mesh shelves in them for low strength 

pallets or those that are not standard size 

Cold storage 

There are a total of 31 double mobile bases 

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 conserves 

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 between 

racks. To automatically open it, the 

operator must only push a button via the 

remote control. 

For the purpose of ensuring the security of 

its operators and the installation in general, 

the Movirack system has the following 

devices: external optical safety barriers, 

longitudinal photocells placed on both 

sides of the bases, proximity sensors, preprogrammed 

activation protocols and 

emergency stop and reset buttons. 

The forklifts that are used in the refrigerated 

storage area are the retractable type 

that makes it possible to work in an aisle 

less than 3 m high. The last load level is 

plac ed at 10.6 m high, and the maximum 

load height would reach 12 m high. 


61


Advantages for the customer 

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

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

- Products are maintained in optimal condition facilitated by the parking function, which keeps 

the racks slightly apart maintaining better air circulation. 

- Flexibility for future expansion. 



6,130 pallets 

Pallet size 

1,200 x 1,200 mm 

Maximum weigth per pallet 2,100 kg 

No. of mobile bases 38 

Rack height 

10.6 m 

Total height with load 

12 m 

Work aisle length 

23 m 

Warehouse temperature ambient / refrigerated 


Case study: MGA 

MGA has an efficient automated miniload 

warehouse coupled with conventional 

pallet racking 

Location: France 

For the new logistics center located in Saint-Quentin Fallavier, a town close 

to the city of Lyon, MGA chose Mecalux as provider of all management and 

storage systems, including an automated miniload warehouse with a capacity 

of 15,872 boxes. 

MGA is an important spare parts distributor 

with regional warehouses in different 

cities within France. The priority of the 

company is to offer express delivery to its 

customers, generally automobile replacement 

part wholesalers. 

In this logistics center, Mecalux has in stalled 

an automated miniload warehouse with a 

specific picking area and a warehouse for 

pallets placed on conventional type racks. 

It has also included the implementation of 

a Mecalux Easy WMS (warehouse management 

software), tasked with handling 

all operations, from the entry of goods till 

dispatch, previously passing through the 

storage and picking phases. 


63

Case Study I MGA 

Warehouse interior 

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 levels 

to conduct direct picking from the pallets, 

while reserves are placed on superior 

levels. 

This storage system is characterised by 

its simplicity and capacity to adapt itself 

to the needs of the company. In addition, 

conventional pallet racks make it possible 

to directly access each pallet, storing the 

maximum number of unit loads in a safe 

and organised way. 

The miniload 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, generally 

B and C type items. These products 

are handled by four stacker cranes, three 

picking stations and a replenishment 

station. 

Connection between the warehouse and the picking area 

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


The MGA 

miniload warehouse 

can store 15,872 plastic 

euro-boxes 

The construction of the miniload 

warehouse was done in two phases, in 

accordance with the needs of MGA. The 

first included three storage aisles with 

three stacker cranes and three picking 

stations, while in the second they installed 

four aisles, set up a new stacker crane and 

completed the replenishment station. 


If we analyse the parts that the installation 

is composed of, represented by 

the images on this page, you will see the 

following: 

A. An automated warehouse 

B. Automated warehouse conveyors 

C. Three picking stations 

D. A replenishment station 

Four stacker cranes 


65


Two box extractions 

Double-mast stacker cranes were installed; 

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, 

while the travel speed, and mainly the stacker 

crane’s lifting speed, were adjusted to 

the characteristics of this warehouse. 

Miniload with conveyors inside the warehouse 



Interior of the stacker crane aisle 

Access doors to the stacker cranes 

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 

In addition, a cantilevered structure has 

been made above the loading and unloading 

stations, managing to increase 

capacity by 320 more boxes. 

In the rear, equipped with a large maintenance 

area, there are reference devices 

for the position of the stacker crane. The 

whole space is enclosed with mesh panels 

and safety doors that will individually 

disconnect the machines in case they are 

opened. 

Cantilevered storage levels 

Rear area of the warehouse 


67


Main picking area circuit 

Picking stations 

The enclosure where the main warehouse 

is located is independent of other buildings 

and, in particular, from the picking 

station, which was installed on the side of 


The picking stations, in the shape of a “U”, 

are located terraced perpendicularly to the 

main conveyors. 

These conveyors are comprised of a double 

circuit that allows both the recirculation 

of boxes, as well as the connection 

to the warehouse and the replenishment 

station. Moving boxes to either of the two 

main conveyors is direct, thus avoiding unnecessary 

movements. 

Each station, with capacity for three boxes 

on hold plus the one which is being processed, 

is run by an operator, who in turn 

is able to prepare waves of six orders at the 

same time. To that end, there is a computer 

connected to the Mecalux Easy WMS 

(warehouse management software) and 

different support devices for picking. For 

example, put to light devices placed on top 

of the containers of each order, indicating 

to the operator which order each item 

corresponds to. 

On the pallets/containers of each order, 

the item location in the pallet racks has 

been previously introduced, that is to say, 

this same zone serves as an order consolidation 

area. In this way, fast and agile 

order preparation has been achieved. 

Control computers and picking stations 

Three picking stations, 

a replenishment station 

and the consolidation 

area were set up 

throughout the facility 



Conveyors in the picking station 

Put to light device 

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 processes, 

the warehouse locations, stocks, location 

rules, storage and extraction, the 

pallets that have to go to picking stations, 

the picking itself, returns to the warehouse, 

etc. It is also able to analyze the 

state of distinct parts or areas via query 

and reporting tools, as well as the devices 

that operate in it. 

Easy WMS is in 

bidirectional and 

permanent connection 

with the customer’s 

SAP ERP 


69


Advantages for MGA 

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

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

has increased. 

- Perfect stock control: thanks to the Mecalux Easy WMS, the company MGA can manage all movements, 

processes and operations that take place within their warehouse. 



15,872 boxes 

Maximum weight per box 50 kg 



double-mast 

Extraction system 

double-deep,two boxes 

Miniload warehouse height 12.3 m 

Picking stations 3 

Replenishment stations 1 

Pallet capacity 

1,480 pallets 



Case study: Luís Simões 

Mecalux equips Luís Simões’ new 

installations in Portugal with Pallet Shuttle 

and conventional pallet racking 

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. 

What is Luís Simões: 

what are its needs? 

Luís Simões is a comprehensive transport 

and logistics services operator that began 

operating in 1948 in the portuguese city 

of Loures. 

The firm has operated in Spain for over 

25 years, and is currently the market leader 

in trade flows between the two countries, 

with a fleet of 2,000 vehicles (owned and 

outsourced) and over 1,500 employees. 

According to its storage facilities expansion 

and modernisation plan, the company 

commissioned Mecalux to equip 

two large, newly built sites, with almost 

10,000 m 2 of surface area each. 

Luís Simões needed to speed up the flow 

of incoming and outgoing pallets in the 

warehouse while, at the same time, increasing 

storage capacity. This was needed 

to efficiently meet the demands of both 

existing and potential customers. 


71

E 

E 

E 

E 

1 

E 

E 

38 

F 

F 

F 

F 

A 

A 

A 

A 

G 

G 

G 

G 

C 

C 

C 

C 

A 

A 

A 

A 

C 

C 

C 

C 

C 

C 

C 

C 

C 

C 

C 

C 

1 

45 

C 

C 

Case Study I Luís Simões 

Mecalux’s proposed solution 

After analysing all the operations, and Luís 

Simões’s needs and flows, Mecalux proposed 

a separate solution for each building, 

which are interconnected and share 

the same management and control centre. 

Moreover, the new logistics centre has 

34 loading and unloading docks, as well 

as three spacious order consolidation preloading 

areas. 

Warehouse A 

In Warehouse A, a semiautomatic compact 

Pallet Shuttle system combined with 

conventional racks was installed, giving 

rise to two distinct storage areas, each 

serv ed by reach trucks. 

Seven double and one single conventional 

pallet racks were installed, along with 

two compact racking units with the Pallet 

Shuttle system. They feature six load levels 

and the capacity to deepstore 15 pallets 

per level. 

The lower level of the conventional pallet 

racking was prepared to perform picking 

functions, because a high percentage of 

Luís Simões’s orders require it. Moreover, 

a spacious area was provided for subsequently 

consolidating the orders. 

The docks, located on either side, have their 

own preloading channels on the ground; 

these allow access to the pallets from both 

sides, thus optimising truck loading. 

Warehouse A 

1 

2 

The conventional pallet racking has the 

3 

capacity for 10,386 pallets, and with the 

Pallet Shuttle system the capacity is 5,544. 

4 

5 

P R OT E C Ç ÃO L AT E R AL DE B AS T IDOR 



P R OT E C Ç ÃO LAT E R AL DE B AS T IDOR 

MUR O MS M1 

1 

2 

3 

4 

5 



Warehouse B 

Warehouse B consists of twenty rows of 

singledeep conventional pallet racking 

enabling direct access to the merchandise 

with maximum flexibility. The rows of 

rack ing, which are 130 m long, are served 

via 10 storage aisles along which the reach 

truck runs. 

The height layout can be seven, eight or 

nine levels, depending on the product to 

be stored and the unit load measurements, 

which may be Europallets (800 x 1,200 mm) 

or US pallets (1,000 x 1,200 mm). 

Three transverse aisles cross the racking to 

facilitate the movement of operators; they 

can also be used as emergency es cape 

routes. 

Because of their significant length, and in 

order to travel the shortest possible distance 

during maintenance tasks, eight loading 

docks with their own preloading area 

were set up at both ends of the warehouse. 

Warehouse B’s total storage capacity is 

19,503 pallets. 

Warehouse B 

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 


73


Conventional pallet racking 

This storage system, which was installed in 

both warehouses, has two major advantages: 

direct access to any pallet, and the 

ability to devote the lower level to picking 

orders. 

The machines used are high-lift reach 

trucks that can operate in a 3-metre wide 

aisle. 

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 

The last level of storage is 12 m high. To 

facilitate handling, avoid impacts and 

properly centre the pallets and/or forks, 

observation cameras were fitted on the 

upper part of the forklift. 

Moreover, and as a safety precaution, protectors 

were fitt ed on all the rack uprights 

facing the aisles. 



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 in structions 

that the operator transmits using a WiFi 

tablet; this significantly reduc es the need 

for loading and unloading goods. 

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 channels 

that are served by six Pallet Shuttles. 

Pallet Shuttle 


Racking with the Pallet Shuttle system 


75


The racks using Pallet Shuttle are operated 

as follows: 

1. Using the forklift, the operator introduces 

the Pallet Shuttle into the corresponding 

channel. 

2. With the pallet loaded, the Pallet Shuttle 

moves horizontally until it reaches the 

first free location, where it leaves the 

pallet. 

3. While the Pallet Shuttle moves and 

places the pallet into its location, the 

opera tor places another pallet in the original 

position in the channel. 

Thus, when the shuttle returns to the 

beginning of the lane it can successively 

repeat the same movement. 

When loading in the channel is completed, 

the Pallet Shuttle is moved on to the next 

one. Extraction is done by reversing these 

steps. 

Pallet Shuttle Racking 



Observation camera 

Interface for operating the shuttle 

Battery charging station 

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, bringing 

them closer to the exit point. 

Inventory: counts the number of pallets 

stored in each channel. 

User management: this funcionality 

manages shuttle user permissions for 

autho rised personnel. 

Battery charge status. 

The observation camera facilitates operations 

conducted at heights. 

A batterycharging station was installed 

that can charge the batteries of six Pallet 

Shuttle simultaneously. Batteries can also 

be charged independently of the shuttles, 

that is, the battery can be removed from 

the shuttle and replaced with a previously 

charged one. In this way, all the shuttles 

will always be operational to fulfil the orders 

needed. 


77


Advantages for Luís Simões 

- Optimal use of space: the flexibility of conventional pallet racking and the high-density storage provided 

by the Pallet Shuttle enables a total capacity of 33,150 pallets. 

- Increased productivity: the Pallet Shuttle increases the flow of pallets per hour and allows for greater 

diversification by enabling items to be grouped by channel. 

- Strategic positioning: this new logistics platform has given an important competitive advantage to 

Luís Simões, positioning the firm as a leading logistics centre on the Atlantic coast and bolstering its drive 

towards internationalisation. 



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

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

Total storage capacity 



1,000 kg 

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 


1,000 kg 

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 



Case study: DHL 

Mecalux installs a new logistics centre 

for DHL on the outskirts of Madrid 


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). 


79

Case Study I DHL 

Storage of products on pallets 

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 allocate 

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, specific 

machines are used that have the 

ca pacity to transport up to two pallets at 

a time. 



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 finished, 

each operator will transfer it to one of 

the consolidation areas according to the 

assigned dock. 

Full use of the racks was made to install fire 

protection system pipelines and sprinklers. 

These coincide with the rack beams or girders 

to waste the minimum space possible. 

Conventional pallet 

racks are an ideal system 

to quickly replenish 

locations that have been 

left without product 


81


Assembly by phases 

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 intermediate 

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 displacements 

and significantly reduce operating 

costs. The warehouse is also compartmentalised 

for security reasons. 

The breadth of consolidation areas, and 

the laying of pre-loads on the floor just 

in front of their assigned dock, allows for 

speedy loading of transport vehicles. 



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 


83


The garment hanging area 

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 classification 

of garments. 

Thanks to the mezzanine floor, the productive 

surface area was multiplied, adding 

two extra floors that are perfectly suited to 

the space available. 

The connection of the operators with the 

different warehouse floors is done via a 

pedestrian access staircase. On the other 

hand, conveyors have stairs and spaces 

specifically for automatic access to overhead 

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 



The tubes used for hanging garments 

on the racks are located at an optimum 

height from an ergonomic point of view 

and, although they have bearings every 

2.2 m, the hangers slide and are grouped 

by items without producing any kind of 

interference. 

Both the fire safety system tubes, sprinklers 

and the warehouse lighting are attached to 

the structure. The overhead shuttle transportation 

rails that are situated in the central 

area of the aisles hang there upon. 

Spaces between 

pedestrian aisles 

are protected 

to avoid garments 

falling from one floor 

to another 


85


Advantages for DHL 

- Streamlining the space: the DHL warehouse is set up to store more than 90,000 pallets and more 

than 30,000 m of hanger profiles. 

- Increased productivity: the compartmentalisation of items, the breadth of consolidation areas and 

the location of pre-loading zones are some of the factors that help increase the volume and efficiency 

of the movement of goods. 

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

reducing operation costs. 

- Efficient service: thanks to this new logistics center, DHL has met the high level of service demanded 

by its customers and is capable of offering fast delivery without errors in the goods sent. 




Pallet size 


Handling equipment 

Order picker 


800 x 1,200 mm 

1,000 x 1,200 mm 

1,000 kg 

reach truck 

ground floor with 

forks for 2 pallets 

Hung garment area 

Surface area occupied 3,000 m 2 

Surface area of the 3 floors 9,000 m 2 

Hanger profiles 

> 30,000 linear metres 


Case study: PAVI‐Groupauto 

Conveyor belts as the axis of a picking 

installation distributed over several floors 

Location: France 

PAVI‐Groupauto, a major 

supplier of auto spare parts from 

France, hired Mecalux 

to install the necessary equipment 

in its warehouse in Saint‐Priest, 

a town near the city of Lyon. 

The supply included two levels of mezzanines, 

racking, conveyor belts and automatic 

sorters, as well as the Mecalux Easy 

WMS warehouse management system. 


87

Case Study I PAVI‐Groupauto 

Analysing the needs 

The needs of PAVI-Groupauto required 

the construction of a warehouse capable 

of storing a large number of SKUs of 

varying dimensions and characteristics, as 

well as being low consumption. 

To do this, a storage system was needed 

that offered optimal use of the surface 

area, as well as being highly flexible and 

allowing direct access to any product. 

The main objective of the company was 

thus met: rapid service for its customers. 

Solution adopted: a conveyor circuit 

The need to maximise the size of the warehouse 

and the fact that most of the orders 

consist of very few units and different 

SKUs led Mecalux to propose and install 

the following solution: 

- Construction of a structure capable 

of integrating two raised floors on a 

2,000 m 2 area, which would allow the 

floor space to be tripled. 

- Installation, on each of the floors, of 

racking with different sizes and types of 

distribution in order to suit the different 

products. 

- Implementation of a continuous and 

automatic transport system connecting 

all the floors. This means operators can 

prepare orders by area, and transport 

them to the specific sorting and consolidation 

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 locations. 

On each floor, pallet unloading 

docks have been installed on the other 

side of safety swing doors. 



- Swivel modules have also been located 

at strategic points along the transport 

circuit for the passage of operators. 

- Installation of access stairs between 

floors, enabling access and rapid evacuation 

during possible emergencies. 

All of this is controlled using the Mecalux 

Easy WMS warehouse management 

system. 


89


Ground floor 

The ground floor is dedicated to bulkier 

products with direct picking and does not 

require the use of conveyors. 

Also, the high consumption products are 

stored here, for which picking stations 

have been prepared adjacent to the conveyor 

belts. 

On the ground floor 

the conveyor belt 

borders the installation 

on two sides 

and is connected 

to the first floor 

via a ramp located 

on the third side 



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The second and third floors of the PAVI- 

Groupauto warehouse have a very similar 

distribution and products of identical size 

are stored on both of them. 

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In addition, the conveyor circuit on these 

two floors runs along the main aisle, with 

the order picking finishing on the top floor. 


91


Preparation and consolidation 

of orders 

Roller tables have been set up and attached 

to both sides of the conveyors on different 

parts of each floor in order to collect 

the boxes containing unfinished orders 

and serving at the same time as picking 

stations. 

Throughout the three floors, ten picking 

stations have been set up, each one corresponding 

to a different area or sector in the 

warehouse. 

The boxes, once the part of the order assigned 

to a zone has been put together or 

completed, are placed on the main conveyor 

circuit to be transferred to the stations 

in other areas or to the sorting area. 

The circuit descends along conveyor belts 

from the third floor to the bottom floor, 

where the classification and consolidation 

of orders is performed. 

In this area, the operators check, pack and 

draw up the packing list and the shipping 

labels of the orders.To complete the operation, 

there are packing boxes of different 

sizes, prep tables, computers and printers. 

Once the orders are 

completed, they are 

sent to the staging areas 

located opposite the 

loading docks to be sorted 

into dispatch routes 



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 

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 

boxes and sending the orders via computer 

terminals. 

The program for controlling the conveyors 

is connected to the WMS itself in order to 

ensure the efficient transport and allocation 

of boxes, eliminating human error and 

reducing PAVI-Groupauto’s personnel 

costs. 


93


Advantages for PAVI‐Groupauto 

‐ Excellent use of space: it was possible to increase storage capacity and triple the floor space through 

the construction of two raised floors. 

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

‐ Adjustable storage needs: the distribution of the racking can be changed if the turnover rate of a product 

varies or if the future needs of PAVIGroupauto so require. 

‐ Elimination of internal movement: as a result of the installed conveyor circuit and the optimal placement 

of the racking, it has been possible to eliminate part of the internal movement made by the operators. 

In this way productivity is increased and human errors are minimised. 

‐ Fast order picking: the storage system installed is highly flexible and allows the operator to have direct 

access to any product. 

‐ Efficient picking: operators can prepare orders by area using the continuous and automatic conveyor 

belt circuit that connects all the floors. 

‐ Perfect control of the stock: using the Mecalux Easy WMS, PAVIGroupauto can manage all the flows, 

processes and operations that take place within its warehouse. 


No. of floors 3 

Surface area per floor 2,000 m 2 

Total surface area occupied 6,000 m 2 

Access stairs 6 

Conveyor length 

800 m 

Picking stations 10 

Automatic order sorters 4 

Total No. of SKUs stored 50,000 


Case study: Hemosa 

Multi-system Mecalux solution: 

Hemosa’s preparation centre beefs 

up automation 


Hemosa, a company specialised in the supply of fresh meats and pork-based 

products, has entrusted Mecalux to fit out its new warehouse with the latest 

automation technologies and computerisation of its manufacturing processes. 

For this reason, and with the objective of offering maximum quality products, 

they have installed various storage systems ranging from an automated 

warehouse with Pallet Shuttle and stacker cranes to drive-in 

and live pallet rackings. 


95

Case Study I Hemosa 

Automated warehouse with Pallet 

Shuttle: finished products 

The Pallet Shuttle system is a version of 

compact solutions that offers maximum 

storage capacity, with the added advantage 

of having load channels with variable 

depths. Pallets are transported internally 

through the channels using autonomous 

shuttles, hence the system name. 

A totally automated version of Pallet Shuttle 

has been installed which uses a stacker crane as its 

transport equipment that lends to great speed 

and efficient stock control 

The version installed in the Hemosa warehouse 

is totally automatic and uses stacker 

cranes as its primary transport equipment 

between warehouse entry/exits and channel 

locations, lending to great speed and 

efficient control of both stock and operations 

done. The total capacity of this warehouse 

is 1,050 pallets, 1,200 x 1,200 mm 

in size with a maximum weight of 700 kg. 

The Mecalux Easy WMS is a system which 

manages all operational basis in a warehouse; 

starting with entry, next placement 

based on parametrizable criteria and ending 

with subsequent dispatch. 

Pallet Shuttle 

Stacker crane 


The Pallet Shuttle is housed on the cradle 

of the stacker crane in a position, slightly 

inferior to the pallet support level; said 

level is made up of two motorized chains 

which pick up and drop off the pallet in 

the entry/exit positions. When the stacker 

crane is positioned in front of the assigned 

location, the shuttle raises with the pallet 

on it and introduces it into the channel. 

It is placed on top of the support rail in 

the available location furthest from the 

aisle. The profile is also prepared to make 

movements guided by the Pallet Shuttle. 

Extractions are done in inverted order. 

The Pallet Shuttle is autonomous and 

charg es its battery in the cradle of 

the stacker crane in an automatic and 

straightforward manner. Each shuttle has 

eight wheels which provide the correct 

distribution of the weight upon the profile 

and which help it move smoothly from the 

stacker crane into the channels. On each 

side of the aisle, rails allow centering elements 

to facilitate the movement of the 

shuttle. 


In the warehouse the following elements 

have been installed: 

- Racks 

- Stacker cranes 

- Pallet Shuttles 

- Entry conveyors 

- Exit conveyors 

This image represents 

a solution similar to the 

one used in the Hemosa 

installation. 


97


Pallet entry and exit 

Two entry and one exit doors have been 

enabled. In each of these, a conveyor is 

entrusted to pick up and drop off pallets in 

the position which coincides with the aisle 

where the stacker crane circulates. 

Moreover, the doors are protected by 

rapid action vertical curtains that only 

open via a signal sent by the Easy WMS 

when the pallet passes through, avoiding 

changes in the internal temperature of the 

cold-storage. 

When the stacker crane is positioned in 

front of the conveyor, it sends a signal both 

to the corresponding conveyor, as well as 

to the one it carries in the cradle, in order 

to act in unison and move the pallet from 

one to another. It also emits a signal to the 

same Pallet Shuttle when it is positioned 

in front of the channel where it must perform, 

ordering its displacement and the 

operation to be done. 

The two located profiles on both sides of 

the channel are shaped to allow for double 

supporting functions both to the pallets 

and the guide rail, ensuring that the 

shut tle moves along safely. 

From the moment the operator drops off 

the pallet in one of the entry points and 

the system is indicated which reference it 

contains, Easy WMS takes over control of 

it and its internal management. 

The warehouse is a cold storage unit with 

temperatures kept slightly above 0 ºC, which conserves 

products deposited there in optimal condition 




99


Live Pallet Racking: 

semi-prepared fresh products 

This type of racking, as well as the Pallet 

Shuttle, is incorporated within the compact 

storage systems and also maximises 

space. The peculiarity of this warehouse 

is that it is composed of storage channels 

with a slight incline. Each channel has rollers 

on which the pallet, introduced into 

the more inclined side, moves along via 

gravity until the first position on the con 

trary side. The velocity of pallet movements 

of is controlled via roller brakes. 

Choosing said storage solution has to do 

with the type of products stored. Racks 

used for pallets with semi-prepared fresh 

products that need a perfect product 

turn over (FIFO). In order to achieve efficient 

turnover, live pallet racking is ideal 

be cause the first pallet to enter the channel 

is the first to leave. 

Live pallet racking, 

which is 5.5 m in height, 

has the capacity to store 

188 pallets, 800 x 

1,200 mm in size and 

weighing a maximum 

of 600 kg 



Drive-in system: semi-prepared 

frozen products 

Racks are put together having internal 

lanes of variable depth, in which forklifts 

enter with pallets raised to the corresponding 

height. At each level and on both 

sides, profiles are ready to support the 

pallets. 

Moreover, conventional pallet racking has 

been supplied to store other small volume 

products for internal consumption. 

The system installed in Hemosa is meant 

to store pallets of semi-prepared frozen products 

and large volume consumables, like packaging 

Easy WMS 

This is a powerful, tried and true warehouse 

management system developed 

by Mecalux. It controls all internal operational 

basis in any warehouse, from reception 

to verification and location assigned 

within the warehouse, picking functions 

and final dispatch based on rules and parametrizable 

criteria. 

In the case of Hemosa and in regards to the 

automated warehouse, the execution of 

movements is ordered via the Galileo control 

module. This software takes charge of 

controlling all actions which must be done 

by each moving device. 

The connection with ERP SAP or the general 

management system of Hemosa is permanent 

and bi-directional, exchanging information 

and instructions that permit the 

total control of all operations done. 

Best Practices 101


Advantages for Hemosa 

- High-density storage: the storage capacity demanded by Hemosa has been achieved thanks to a 

combination of distinct systems installed. 

- A place for each product: a storage solution has been enabled which best adapts to the characteristics 

and needs of each product that Hemosa works with, attaining perfect turnover and increased 

productivity. 

- Total control of the automated warehouse: Easy WMS from Mecalux controls all processes and 

operations that take place within a warehouse, from the moment the product leaves the packaging 

line, up until dispatch. 


Automated warehouse 


1,050 pallets 



10 m 



single mast + Pallet Shuttle 

Constructive system 

Pallet Shuttle – traditional 

construction 

Live pallet racking 


Maximum pallet weight 

Channel depth 

Maximum height 

Drivein pallet racking 


Maximum pallet weight 

Maximum lane depth 

Maximum height 

188 pallets 

600 kg 

6.2 m 

5.5 m 

426 pallets 

1,000 kg 

5 m 

6.8 m 


Case study: Zbyszko Company 

A high profit automated warehouse: 

200 pallets/hour and 18,000 pallets stored 

Location: Poland 

Aiming to keep pace with its growing 

business, the company Zbyszko 

wanted to expand the capacity and 

agility of their warehouse in addition 

to integrating their production and 

storage processes. In order to meet 

this demand, Mecalux built them an 

automated warehouse connected to 

the production plant via a 100 m long 

overpass equipped with conveyors. 

All this is coordinated and controlled 

by the warehouse management 

system Mecalux Easy WMS software. 


Case Study I Zbyszko 

Zbyszko Company 

and their needs 

Zbyszko Company, a company specialised 

in the production of carbonated drinks, 

soft drinks and flavoured waters, was 

creat ed by Zbigniew Bojanowicz in 1993 in 

the Polish city of Białobrzegi. 

In just 10 years, the Zbyszko Company has 

experienced spectacular growth that has 

made it one of the most successful Polish 

manufacturers within the natural beverages 

market. 

In the face of its incessant headway, 

Zbyszko Company has relied on Mecalux 

to provide it with a new storage centre to 

centralise all the company’s logistical activities 

and which is equipped with the 

newest, most innovative technologies in 

order to deal with high production rates 

and save on logistics costs. Present and future 

growth demand it. 

Speeding up internal transport was also a 

crucial prerequisite of the project, creating 

a direct connection between the warehouse 

and the production area. This was 

done via maximum automation of the storage 

processes in order to increase Zbyszko 

Company’s market competitiveness. 

The Zbyszko Company hired 

Mecalux to construct its newest warehouse 

located in the Polish city of Radom 


Connecting the production area 

and the warehouse 

Mecalux has set up an automated warehouse 

that connects the production area 

via a 100 m long overpass through which 

already palletised goods circulate on a circuit 

of roller conveyors. 

The checkpoint, located at the beginning 

of the circuit and within the same production 

area, verifies that the dimensions and 

the quality of each pallet are appropriate. 

The conveyors have two lines – one in each 

direction – working independently despite 

being placed in parallel. 

Inside the warehouse two levels of conveyors 

are arranged. The upper level is allocated 

to the input of goods, while the lower 

level has been reserved for outputs. 

There is also the possibility that outside 

goods, destined for the warehouse or the 

production area, can enter at this level. Not 

to mix operations, they have set up a conveyor 

just above the docks for inputs into 

the warehouse, with a lift placed at the end 

that raises the pallets to the upper level. 

On the ground floor, so that throughput is 

as high as possible, a circuit of electrified 

monorails capable of transporting SKUs 

at more than 100 m/min – and which links 

the warehouse with the preload area – was 

installed. 

This system is ideal for connecting distant 

points of the installation at a steady pace, 

eliminating unnecessary movements between 

rack areas. 


The Zbyszko Company 

warehouse is connected 

with the production 

area via a 100 m long 

overpass fitted with 

roller conveyors 



Inside the warehouse 

The warehouse occupies a 7,000 m 2 surface 

area and is built in a facility only 11 m 

high. 

The installation of stacker cranes makes it 

possible to warehouse up to 18,000 pallets 

despite this limited height. 

Having few SKUs, they chose to place 

doubledepth racks, a very common method 

in automated logistics centres that 

require a large storage capacity. 

The racks are served by eleven, fully automated 

stacker cranes, which move quickly 

along their respective aisles handling 

pallets weighing up to 1,000 kg each. 

Level 5 metres high 

Overpass 



The seven stacker 

cranes that are located 

in the middle zone 

are 11 m high, 

while the remaining 

four left at either 

end of the warehouse 

have been retrofitted 

to the shape of the 

building, with a height 

of 9 m 

Ground floor 



Dispatches 

The stacker cranes are responsible for automatically 

extracting stored goods from 

the production area and bringing them to 

the corresponding output conveyor. Once 

on the conveyor, the electrified monorails 

directed each pallet to their assigned preload 

area. 

1 

There are numerous options for creating 

an electrified monorail circuit. In Zbyszko 

Company’s case it was decided that a simple 

loop circuit, operated by 21 individually 

controlled shuttles, was the most costeffective, 

seamless solution. 

The software that controls the machines 

is connected with the WMS (Warehouse 

Management Software) throughout the 

warehouse, and to the customer’s ERP. 

The image on the right is differentiated into 

the following areas: 

Warehouse 

Inputs into the upper level 

Electrified monorails 

Preloads area 

Input conveyors from the docks 

3 

The pallets are loaded 

onto the shuttles 

on one side of the circuit 

and are unloaded 

in the consolidation 

area located 

on the opposite side 

Input conveyor on upper floor 

Shuttle depositing goods in preloads 



2 

5 

4 

Warehouse Management System: 

Mecalux EASY WMS 

Zbyszko Company uses the warehouse 

management system Mecalux Easy WMS 

to check each and every one of the movements 

that takes place in the logistics centre, 

and thus efficiently manage their storage 

space. 

Easy WMS communicates with the 

customer’s ERP SAP in order to be able to 

carry out the dispatch, reception, distribution, 

transfer processes, and other tasks 

related to the logistics centre. 

This powerful system ensures the proper 

operation of the machines that are used in 

the automation of the warehouses, which 

simplifies transportation, eliminates human 

errors and reduces staffing costs. 

Overpass between production and the warehouse 



Advantages for Zbyszko Company 

- Maximum space utilisation: the warehouse, only 11 m high, has an 18,000 pallet storage capacity in 

a 7,000 m 2 surface area. 

- Cost savings: the overpass that connects the warehouse to the production area allows Zbyszko to 

save in logistical costs. 

- Increased productivity: order preparation is fast and efficient thanks to the speed of the stacker cranes, 

the conveyor circuits and the electrified monorails installed, which can issue up to 200 pallets/hour. 





1,000 kg 


11 m 

Warehouse surface area 7,000 m 2 


Fork type 

double-depth 

No. of shuttles on the electrified monorails 21 

Length of the overpass 

100 m 


Case study: DAFSA 

A single warehouse in choice surroundings 


Mecalux builds DAFSA an automated 

clad-rack warehouse, in the scenic 

countryside near Valencia, whose 

outer finish was carefully made 

to be environmentally friendly. The 

new warehouse, with a capacity for 

more than 23,000 pallets, is integrated 

with production outputs via a two 

level overpass. Mecalux Easy WMS 

(Warehouse Management System) 

was supplied, which is responsible for 

managing all the warehouse processes. 


Case Study I DAFSA 

Who is DAFSA? 

DAFSA, manufacturer of juices, vegetable 

purees and horchata, was established 

in 2006 as an exclusive provider to 

Mercadona, Spain’s top supermarket. 

Strong growth experienced in recent years 

has made DAFSA one of the most active 

companies within its sector. They turn on 

more than 250 million litres a year. 

In 2014, with the startup of the new production 

plant in Segorbe (Castellón), that 

has a 66,000 m 2 total surface area, it became 

their sector’s most advanced and 

sustainable production, processing and 

packaging factory in Europe. Within the 

premises, is the most noteworthy automated 

warehouse built by Mecalux. 

The collaboration between the two companies 

dates back to DAFSA’s beginnings. 

Since then, Mecalux has built different 

warehouse solutions adapted to the 

company’s ever changing needs. 

Current warehouse 

of DAFSA and the area 

reseved for future 

expansion. 



DAFSA has a reserved 

space with which they 

can double current 

storage capacity 

A clad-rack warehouse: 

today and beyond 

The attached picture shows the design 

of the warehouse installed and the space 

reserved for future growth, which is intended 

to multiply storage capacity up to 

40,000 pallets if needed. 

In a clad-rack warehouse like this, the racks 

are the building’s structure and the wall 

and roof cladding is placed on them. In 

addition to the building’s own weight, the 

racks must bear the pallets stored and the 

external forces indicated by regulations, including 

wind. 



The warehouse is 39 m high, 31 m wide 

and 102 m long and has four storage aisles. 

One of these aisles was isolated from the 

rest in order to store refrigerated products. 

To achieve this, a specific type of construction 

was required aimed at integrating the 

aisle into the same facility, but without having 

to install components that act as coldbridging. 

The equipment supplied by Mecalux and 

the warehouse management system Easy 

WMS is responsible for palletised product 

movement at the end of production lines, 

achieving total integration between the 

factory and the warehouse. This minimises 

the human intervention needed to move 

the goods between different areas. 

Thanks to 

the warehouse design, 

the second phase 

could be built without 

interrupting DAFSA’s 

production or installation 

operations 





Entrance into the warehouse: 

upper level 

The warehouse, located on one side of the 

plant, is linked to production output via a 

two level overpass, leaving the middle area 

for future growth. 

So pallets could enter the warehouse, elevators 

were enabled at the overpass’ end 

that raise the load to the top level. Then 

a circuit of automatic conveyors is responsible 

for transferring pallets up to the 

stor age aisle allocated by the Easy WMS 

(Warehouse Management Software). 

Various checkpoints and set ups ensure 

the size and excellent condition of the pallets 

coming into the warehouse. Quality 

control is essential, since 1,200 x 800 mm 

sized euro-pallets and medium sized 600 x 

800 mm pallets are deposited in the same 

warehouse. 

An entry point was provided, which is served by forklifts 

for products from other plants 





Inside the warehouse 

High platforms were installed that coincide 

with the overpass’ top level, on top of 

which the aisle input conveyors are placed. 

The warehouse is composed of four aisles 

where stacker cranes circulate. These are 

responsible for making movements between 

locations and the conveyors for the 

input and output of pallets. As mentioned 

previously, one of the aisles was isolated 

from the rest in order to store refrigerated 

products. 

Racks, double in depth, were readied on 

both sides of the aisles, with 16 storage 

levels adapted to store the two pallet formats 

which DAFSA uses. 

The refrigeration equipment, fire protection 

systems, the stacker cranes’ upper 

guides and the rest of internal equipment 

are supported and attached to the 

racks themselves forming an integral part 

thereof. 



The stacker cranes are twinmast in nature 

and incorporate a mounted booth to facilitate 

maintenance work, as shown in the 

photo below and to the right. 

The installation is distributed in the following 

areas identified in the layout: 

1. Ambient temperature warehouse 

2. Cold storage aisle 

3. Connection overpass 

4. Entries from production 

5. Preloads deliveries 

6. Future expansion of the warehouse 

The warehouse’s capacity 

is for more than 

23,000 pallets, 

1,200 x 800 mm in size, 

1,700 mm high and 

weighing 1,050 kg each. 

If all the pallets were 

600 x 800 mm sized, the 

storage capacity would 

increase to more than 




Pallet output: lower level 

Even though the overpass’ top level was intended 

for inputs only, on the lower level 

outputs coexist with inputs, allowing for 

duplicate flow of inputs. 

The main circuit, located on the overpass’ 

lower floor, has dual conveyor strands to 

perform pallet input and output tasks. 

In bottom photo, of the overpass, you can 

see the access point to an ambient temperature 

aisle, followed by vertical access 

doors to the cold storage aisle. 

The main circuit of conveyors on the lower 

floor is connected via three doors with the 

conveyor circuit in the dispatch area, located 

in an adjoining building. 

Once there, two shuttles are tasked with 

depositing the pallets in one of the pallet 

flow channels available on the ground 

level. 

On the overpasses’ lower level is the consolidation area of the warehouse, 

where outputs and inputs exist side by side 





Deliveries 

Deliveries are also segmented depending 

on the product. Thereby, the part reserved 

for refrigerated products is built in a closed 

area that has a double preload capacity 

and vertical roll-up doors that automatically 

open for pallets to be deposited into the 

live channels. 

In all, seven preload groups and a quick exit 

have been provided. Each group consists 

of three live channels with a pallet capacity 

of 11 each. Between them the three full 

loads, 33 pallets in all, fill a lorry. 

The channels are prepared for the pallets, 

whose extraction is handled via electric 

pallet trucks. 

Preload outputs coincide with the lorry 

loading docks, as illustrated by the photographs 

on this two-page spread. 

A shuttle is 

responsible for 

connecting the output 

stations with different 

order consolidation 

channels 





Different pallets, different solutions 

The installation is outfitted to receive 800 x 

1,200 mm sized euro-pallets and medium 

800 x 600 mm sized pallets. 

The use of medium sized pallets is very frequent 

in the distribution sector, especially 

for high consumption products, because 

they go directly from production to linear 

supermarket shelves, avoiding interim 

handling. 

The facility was 

set up to handle and 

store medium sized 

pallets since the 

percentage, compared 

to euro-pallets, is 

higher 

800 x 600 mm medium pallet 

800 x 1,200 mm Euro-pallet 

To store 800 x 1,200 mm sized pallets of 

indiscriminate depth with the utmost security, 

cross-ties were put in the racks, as 

shown in the picture below on the right. 

The conveyors were also adapted for medium 

sized pallets. In the rollers, the separation 

between them is less than usual, 

while in the chain conveyors four strands 

are available. Furthermore, and in order 

to avoid confusion, checkpoints help to 

differ entiate the two pallet types. 



Easy WMS 

Easy WMS is the nerve centre that governs 

all operations from production outputs 

to their dispatch. This powerful warehouse 

management system developed by 

Mecalux performs, among others, these 

roles: 

- Management of the input of goods 

from production lines. 

- Pallet location in the warehouse using 

previously parameterised rules, according 

to the following criteria: product 

type, space optimisation and maximum 

productivity. 

- Stock management and the warehouse’s 

layout (what and where the goods 

are). Outputs to deliveries by batch 

and via FIFO criteria. 

- Preload fulfilment according to the order 

requested and subsequently loading 

the trucks. 

- Query the status of various parts of the 

warehouse and the machines that operate 

in them. 

Thanks to the Galileo control module, all 

movements of the different equipment 

that the installation is comprised of, as 

well as its safety measures, are managed. 

The communication between Easy WMS 

(Warehouse Management System) and 

the customer’s ERP is permanent and bidirectional, 

transferring the data both systems 

need to operate and to effectively 

manage the warehouse. 



Advantages for DAFSA 

- Enhanced storage capacity: the DAFSA warehouse has a capacity of more than 23,000 pallets, 

800 x 1200 mm in size. The facility has a space purposed for future expansion, which allows storage 

capacity to be multiplied up to 40,000 pallets. 

- Overall appearance: construction of a modern, high technology logistics centre, but at the same 

time integrated into the countryside in which it is located. 

- Increased logistical efficiency: DAFSA has improved its logistical efficiency thanks to the 

automation of inhouse movements and the connection with production outputs. 

- Complete control: the Mecalux Easy MWS software manages all movements, processes and 

operations that take place inside the warehouse. 






Type of stacker cranes 

Double-deep, twin-mast 


No. of shuttles 2 

Preload channels 21 

Capacity per channel 11 

Construction system 

Self-supporting 


Case study: Havi Logistics 

Mobile racks for continued growth 

at Havi Logistics 

Location: Italy 

Since its creation in Germany in 

1981 as a small family business, Havi 

Logistics has expanded its market to 

become one of the leading suppliers 

of integrated logistics services, with 

48 distribution centres in Europe 

and more than 5,000 employees. Its 

customers range from restaurant 

chains like McDonald’s to BP service 

station kiosks. The company is 

growing so fast that it has had to 

expand its facility in Lodi, Italy, and it 

has entrusted this project to Mecalux. 

Minding the essentials 

Havi’s logistics centre in Lodi, Italy, was 

opened in 2009 with a capacity for 4,566 

pallets. Given the company’s continuous 

growth and expanding customer base – 

and therefore the number of products to 

be stored and distributed – it quickly outgrew 

the facility. There was thus a clear 

need: to multiply the useful storage space 

by expanding the 4,870 m 2 available in the 

original warehouse. 

Furthermore, the characteristics of Havi 

Logistics’s activity had to be considered. 

Havi manages the supply chain for perishable 

and non-perishable products for a 

wide range of customers: frozen goods, 

fruits and vegetables, meat, dairy produce 

and cleaning products, amongst others. 

This made it necessary to conserve storage 

and handling areas with four different 

temperature ranges, with a particular focus 

on preserving the cold chain throughout 

the entire process to ensure optimal 

safety and conservation of the food that 

Havi stores and distributes daily. 

This project began with a very clear need: 

to reduce storage costs, especially in 

order to accommodate new customers. 

The result has been the combination of 

conventional pallet racks with mobile racking. 

By combining these two kinds of 

racks the size of the building needed to 

work with a given volume of pallets can be 

reduced. 


Case study I Havi Logistics 

The answer 

Mecalux’s technical team calculated the 

facility’s expansion and remodelling down 

to the tiniest detail. Since the customer’s 

priority was to multiply its storage capacity 

the Movirack mobile racks stole the 

show. These racks boast optimal performance 

at all temperatures. The immediate 

result was to expand from the original storage 

capacity of 4,566 pallets to the current 

capacity of 12,500 pallets, enlarging 

4,870 m 2 of surface area to 10,000 m 2 . 

As required by the customer, the four distinct 

zones with different temperatures at 

the Havi Logistics centre in Lodi were conserved, 

but the layout of each one was 

changed by implementing various storage 

solutions tailored to the specifications of 

the different products: 

- Dry or ambient temperature zone: 

370 linear metres of Movirack mobile 

racks were installed in this zone to a 

height of 9 metres. This system eliminates 

unnecessary storage aisles, as 

the operator selects the aisle that he or 

she needs to use, whether manually or 

by remote control, and the mobile racks 

move laterally on rails embedded in the 

floor. This leaves the space required for 

loading, unloading or picking access on 

the selected racks. Push-back racks for 

accumulative storage and conventional 

pallet racking were also installed. In this 

way, high occupancy was achieved and 

goods handling time was reduced. 

- Refrigerated zone: Movirack mobile 

racks combined with Push-back racks 

were installed here as well. This system 

allows four pallets per level to be placed 

in deep storage and uses the LIFO load 

management method (the last pallet 

in is the first out). The combination of 

both systems saves a significant amount 

of space and achieves high storage density 

while speeding the picking and replenishment 

of goods, which is essential 

in fresh food supply. 

- Freezing zone: in the cold storage area 

the Movirack mobile racks make it possible 

to reduce the volume that must 

be stored at low temperatures, thereby 

saving energy. Roller and trolley pushback 

racks and drive-in pallet racks were 

installed to round off this area. 

- Cool dock zone: this is a lengthwise 

loading and unloading zone linking 

the three storage areas described. Its 

function is to allow the goods to be handled 

without breaking the cold chain, 

which is kept at a temperature between 

1 and 4 degrees. This mode ensures that 

all products reach their destination in 

perfect condition. 

- Picking area without capacity loss: 

in this area there is a mix of conventional 

pallet racks, located on the sides, 

with Moviracks placed inside. The mobility 

and accessibility that the Movirack 

system offers frees up a wide aisle so that 

a forklift working with pallets can enter. 

It also opens all aisles so that operators 

carry out picking. Thereby, the area is set 

up to function both with pallets or smaller 

products that require picking. 

Mecalux has 

implemented a 

made-to-measure project 

that has allowed the 

Havi Logistics group 

to double the useful 

storage space and reap 

the benefits of a Movirack 

system on mobile bases 



Push-back system with shuttles 

Push-back system with rollers 


Movirack Mobile pallet racking 

Drive-in pallet racks 


129


A 

B 

The first diagram (A) shows the solution where 

only one aisle is freed up to operate with a forklift. 

In the second (B), this option displays when 

two aisles are opened up to do picking. 

Advantages for Havi Logistics 

- Increased storage capacity: the Havi Logistics warehouse has almost tripled the storage capacity, 

from 4,566 pallets to 12,500 pallets, doubling the surface area from 4,870 m 2 to 10,000 m 2 

- Profitable model: the distribution centre Havi Logistics has in Lodi has become a model of profitability 

and efficiency that will allow the company to manage future growth in a flexible manner. 

- Cost savings: with the remodelling and expansion of this installation, logistics costs have been 

reduced without affecting the service quality of the company and maintaining a high level of 

productivity. 




Length of the warehouse 152 m 

Width of the warehouse 62,5 m 


No. of racks 60 

No. of aisles 33 

No. of load levels 3, 4 and 5 

No. of Movirack mobile racks 12 double 

No. of push-back racks 9 

No. of drive-in racks 3 

No. of fixed conventional racks 20 

Pallet size 

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


1,000 kg 



Case study: Hepco Motion 

Mecalux installs a special mobile cantilever 

rack solution for metallic profiles 

Location: United Kingdom 

Hepco Motion, a world leader in 

the field of linear motion systems, 

has expanded its storage facility in 

Tiverton (Devon), with the aim of 

expanding their production growth 

and cutting down order fulfillment 

and delivery times. To optimize 

their warehouse capacity they put 

their trust in Mecalux, who installed 

cantilever racks on Movirack mobile 

bases for them. 


Case Study I Hepco Motion 

The needs of the customer 

Hepco Motion, a British company that is 

part of the Hepco business group, has branches 

and accredited distributors throughout 

the world and more than 40 years of 

experience. The company offers a wide 

range of products that are constantly being 

updated to meet the demands of their 

customers within the automation and 

other industrial sectors, offering all kinds 

of innovative linear move ment solutions. 

Due to their continued growth rate, Hepco 

has recently launched an expansion of 

its production and storage facility headquarters 

in Tiverton, UK. 

Given that the old warehouse was used 

to expand production area, storage processes 

were moved to a new premises adjacent 

to the factory. In other words, the 

main goal put forward by Hepco Motion 

has been to optimise this new space, which 

is 53 m x 13.5 m x 6.5 m in size. 

Given product 

characteristics and 

the need to maximise 

storage capacity, 

the solution proposed 

by the Mecalux 

delegation in the UK 

(located in Birmingham) 

was to install cantilever 

racks on Movirack 

mobile bases 

The company entrusted Mecalux with the 

development and implementation of this 

storage project, so in addition to sorting 

out space requirements, it also took into 

consideration the specific nature of the 

product: profiles of various lengths. 

Another project requirement has been the 

reuse of stationary cantilever racks from 

the old warehouse, so that they could be 

integrated into the new facility. 



The solution proposed by Mecalux 

In all, nine Moviracks were installed, 

grouped in 3 blocks of 3 racks each. Each 

Movirack cantilever is 11 m long, which 

allows you to make full use of the 13.5 m 

wide warehouse. 

The three blocks of mobile rack were interspersed 

with the stationary cantilever 

racks for heavy loads that came from the 

old warehouse: two single, one on each 

end of the warehouse, and 5 double, with 

access on both sides. 

A cantilever system is the best option for 

the storage of different length profiles, 

because the cantilever arms that support 

load units allow for easy, safe handling. In 

addition, it is possible to adapt them to the 

size, stiffness, tolerance, weight, etc. of 

the goods. 

In respect to the Movirack mobile base system, 

its main feature is the automatic sideways 

movement along rails embedded into 

the floor. This takes up less space by eliminating 

unnecessary aisles, but without losing 

direct access to the products stored in 


Consequently, each of the 3 blocks of 

3 Moviracks installed only needs a single 

work aisle, instead of the 4 that would be 

needed in a conventional system. 

Taking into account that rack length is 11 m 

and aisle width is 2.6 m, this amounts to an 

overall space saving of more than 250 m 2 , 

which has resulted in significant cost savings 

in the construction of the new building. 

The dimensions 

of the warehouse 

have been adjusted 

to the storage system, 

lining up the entry 

doors with the work aisles 

of the Movirack units 


133


Advantages for Hepco Motion 

- Higher productivity: the installation of mobile bases allows faster processing of inbound and 

outbound goods, optimising product placement and workflow. 

- Cost savings: the high-density nature of the mobile bases has made it possible to reduce the size 

of the new industrial building, requiring less surface area to achieve the desired storage capacity. 

The opportunity of combining mobile and stationary cantilever systems, by reusing old racks, has 

also resulted in cost savings. 

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

warehouse processes. 


Length of the warehouse 

Width of the warehouse 


Rack length 

Rack width 

Rack height 

53 m 

13.5 m 

6.5 m 

11 m 

2.4 m for each mobile base 

5.3 m 

No. of Movirack racks 9 

No. of rack units 3 

No. of possible aisles 

4 per rack unit 

Aisle width 

2.6 m 

No. of load levels 7 

Height of the load levels 

variable 


Case study: Iron Mountain 

Earthquake-proof racking: an installation 

with conventional racking on the Pacific Rim 

Location: Chile 

The Mecalux racks installed in Warehouse 11 of Iron Mountain, a leading 

records management and archiving company, were the only ones which were 

able to withstand the 8.8 magnitude earthquake in 2010 that devastated the 

Chilean regions of Maule and Bio Bio. After the earthquake, Iron Mountain 

commissioned Mecalux to rebuild its many damaged buildings and to build two 

new warehouses with similar characteristics. 


Case Study I Iron Mountain 

The collaboration between the two companies 

began five months before the earthquake, 

when Iron Mountain hired Mecalux 

to build Warehouse 11, which holds more 

than 1.4 million boxes. 

As soon as Mecalux took over the project for 

Warehouse 11, the design went through a 

structural review that took a variety of considerations 

into account, such as local seismic 

regulations and fire protection, electrical 

protection and safety systems. The conventional 

pallet racking is designed with a focus 

on the seismic resistance of the shelves. 

Before starting the installation of the warehouse, 

the racks also went through a preliminary 

design phase, so they would be 

capable of absorbing the force generated 

by any potential earthquakes. The warehouse, 

divided into four floors in order 

to allow manual handling of the goods, 

is made up of tall, high-resistance racks 

with shelves at different levels on which the 

boxes containing the files are deposited. 

Access to the various floors of the warehouse 

is performed by means of stairs, lifts 

and walkways. 



The Iron Mountain 

warehouse in Chile is 

located in the Ring 

of Fire on the Pacific Rim, 

one of the regions with 

the most seismic activity 

in the world. Therefore, 

Mecalux prioritised the 

safety of the installation 

and built a reinforced 

system that would be 

capable of withstanding 

potential earthquakes 

The conventional pallet racks put in 

place were designed from the inside 

out – first the shelves and then the building 

envelope. 

Longitudinal rigid frames to reinforce the 

beams and columns on the four floors of 

the warehouse were also installed, along 

with the creation of a 4 m wide central 

aisle that enables comfortable handling 

of the load at the different locations. The 

central frames were fixed on a base plate 

calculated with sufficient thickness to provide 

maximum absorption of the shocks, 

since according to the calculations made, 

the seismic waves would travel longitudinally 

through the frames. 

The land on which Warehouse 11 was built 

was classified as Type 3, of the lowest possible 

quality, so extraordinary measures 

were taken to reinforce the entire building. 

The earthquake and the 

reconstruction 

On 27 February 2010, an earthquake measuring 

8.8 on the Richter scale struck the 

Chilean regions of Maule and Biobío with 

devastating consequences. The company 

lost seven of its facilities, but there was one 

that was indeed able to pass the test: the 

warehouse built by Mecalux, which was 

still only half-finished. 

Given this natural disaster, many businesses 

were looking to store their documents 

and files in more secure facilities such as 

those Iron Mountain had been proven to 

have. 

Even so, the company needed to relocate 

the many thousands of boxes that 

were scattered on the floor, so the second 

phase of construction was begun quickly 

with the aim of storing part of those 

loads. However, Iron Mountain not only 

needed to rebuild all its facilities, it also 

had to progress and keep growing. For 

this reason, the company commissioned 

Mecalux to build two warehouses similar 

to Warehouse 11, with a total capacity of 

more than 3 million boxes. 

With so little time to lose, Mecalux made a supreme 

effort to meet the deadlines and erect 

the new facilities at a dizzying speed, so that 

the company would be able to resume its 

activities as quickly as possible and relocate 

its personnel to their regular workstations. 

An efficient and safe project 

With this earthquake-resistant project, 

Mecalux demonstrated its high standards 

of quality, safety and commitment. The 

challenge of building a warehouse of this 

kind in such a powerful earthquake zone 

was overcome while complying with local 

seismic regulations and supplying an installation 

which was fully reinforced and prepared 

to protect the workers and stored 

goods against earthquake tremors. 

Mecalux also pledged to assist in the difficult 

tasks of reconstruction through the 

construction of two new warehouses 

which were equally resistant. 



Advantages for Iron Mountain 

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

- Higher capacity: the three warehouses built by Mecalux have a total capacity of more than 

3 million boxes, which far exceeds the needs of Iron Mountain. 


Warehouse No. 11 – Iron Mountain 

1st stage 

2nd stage 

Total capacity 

720,000 boxes 


480,000 boxes 

Number of staircases 

4 levels 


4 levels 

Frame height 

12,600 mm 

Frame height 

12,600 mm 

Central aisles 

4 metres 

Central aisles 

4 metres 

Warehouse No. 12 – Iron Mountain 

Warehouse No. 77 – SA Storbox 


980,000 boxes 


823,000 boxes 


4 levels 


4 levels 

Frame height 

13,000 mm 

Frame height 

13,000 mm 


Case study: Benco Dental 

Uprooting Benco Dental: a customized 

warehouse to speed up picking 

Location: USA 

In January 2010, dental equipment supplier Benco Dental teamed up with 

Interlake Mecalux (IKMX) to create the nucleus of its rapidly swelling 

business: a new home office doubling as a distribution centre and lavish 

product showroom. After a decade that saw the Pennsylvania company open 

distribution centres throughout the USA, Benco Dental’s next step was to bring 

the corporation back home. 

The founder Ben Cohen put down roots 

in Pennsylvania in the 1930s and formally 

started Benco Dental in a modestly sized 

Wilkes-Barre Township office. Benco grew 

the business there for the next 30 years. In 

Wilkes-Barre, the enterprise was hampered 

by, among other things, limited and 

undersized pick locations, pockets of 

scattered secondary stock, and bins with 

inefficient replenishment. 

“The most bang-for-your-buck happens 

when companies receive product, stick it 

in its primary location and pick it,” said a 

Benco spokesperson. “That’s the philosophy 

we took when we designed the new 

facility.” 

In its latest move, Benco swapped a 

6,400 m² installation for over 14,900 m² 

just 11 km away in Pittston. 


Case Study I Benco Dental 

The fastest growing 

private dental distributor 

in the U.S. implemented 

a pick module as part 

of its expansion 

and legacy 

Mecalux steps in 

Bob Novak, Interlake Mecalux’s North East 

Market Manager, explained, explained 

that he first got involved with Benco Dental 

after one of its lift truck distributors came 

to him for help designing Benco’s pick module 

in Fort Wayne. 

He noted that after IKMX’s involvement 

with the Indiana installation, Benco Dental 

commissioned the well-known Spanish 

warehouse solutions provider to install 

racks in its future installations. 

As it often does, the evolution of this process 

started with Benco Dental’s conceptual 

drawings. After the sides volleyed 

their ideas back and forth, the concept was 

whittled down to a final design. 

“We went in as the experts on pick modules 

and have worked with Benco ever 

since,” said Novak. “It worked out pretty 

well,” top Benco managers replied, reflecting 

on both Benco’s reenlistment 

of Interlake Mecalux and the six-week 

installation. 

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



Today, more than 400 employees work 

out of the Pittston facility – not just in the 

distribution warehouse, but in the offices, 

classrooms and showrooms built into the 

structure’s design. “We have the biggest 

single place in the U.S., where dentists can 

come see all kinds of working operatories,” 

a spokesperson continued. Twentysix 

office sets display the products and 

tech nologies Benco distributes. 

Challenge and success 

Relocating a company is a tough business, 

even if it only means moving 11 km 

away. The Pittston installation rests in a 

never-occu pied building within a storage 

park that was adapted by Interlake 

Mecalux (IKMX) according to Benco’s 

specifications. 

Benco Dental’s team realized how tricky 

the several months preceding the 

move were going to be. It meant having 

to manually move 34,000 items oneby-one 

from old pick slots to new ones. 

“Maintaining customer satisfaction during 

the move was the biggest challenge,” 

Benco management explained, “We didn’t 

shut down for one day.” 



Benco Dental reinvented 

The design and size of Benco Dental’s installation 

ensures that it isn’t strained by 

constant restocking demands. Warehouse 

dimensions aside, the dental product distributor 

uses its space wisely by also building 

up and canvassing each square meter 

with efficient operations. 

Benco’s floor plan certainly fulfils all of its 

basic requirements, but it is the system’s 

bells and whistles that add a unique efficiency 

exclusive to that Pittston facility. 

In addition to the improvements the racks 

inherently create on the premises, the expert 

innovations and specialized flourishes 

of the Pittston location optimize 

production. 

Mobilizing Mecalux’s knowledge into innovative 

solutions is what helped solidify 

Pallets arrive on 

the outer decks of the 

module to be loaded 

on to the flow rails 

Benco. “I approached Interlake Mecalux 

with a basic design in mind, they tweaked 

it, and we both added some great features,” 

said a key Benco manager. 

Here are Pittston’s biggest customisations 

– and why they are necessary: 

Adjustable decks: make it easier for anyone 

to stock top shelves. The solution was 

to incline the deck on the higher end of the 

carton flow module by several inches and 

install multiple catwalks connecting the 

two. The end result is a seamlessly equal 

reach for personnel on both sides. 

An overpass: in addition to the catwalks, 

Novak and the IKMX design crew 

were able to create an overpass connecting 

the second floor of the pick module 

with a structural mezzanine for greater 

throughput. 

Extra shelf picking area: the design also 

called for shelf pick areas allowing for 

maximised order fulfilment or just-in-time 

shipping. Shuffling the product out 

the door or back into the system is easier 

to do the more shelf picking areas one has. 

Once a pallet is unloaded onto the dock, 

lift trucks transport the pallets to their locations 

throughout the module. 

Steel-encased flow rail: the ground level 

pallet flow rails were last-minute additions 

designed to maintain a productive picking 

speed of oversized products. It keeps product 

both stored and out of the way, and 

protects against possible damage done by 

lift trucks. 

V-shaped shelves: Benco Dental wanted 

their smaller, slower-moving products 

to be accessible to the pick area without 

going to great lengths to retrieve them – a 

common wish among facilities with similar 

products. For this, the group designed 

V-shaped shelves. The 20-inch deep units 

hang above the conveyor – accessible, but 

out of the way. 

Bonus storage: adding more storage space 

to each level meant that Benco would 

have extra floor space where pallet storage 

would have been. 

The extra floor space can be used by forklifts 

to unload additional goods faster. 

The stocking area rises 10 inches between 

the picking side and the charge side. 



Pick module safety 

How Interlake Mecalux worked with 

Benco Dental to ensure safety. 

1 

1 Safety straps. The operator is hooked 

into a harness, as well as a safety strap. 

The strap rides along a trolley line that 

runs the length of each module level 

(other than the ground floor). 

2 Galvanized safety deck. Once a pallet 

is fully picked, personnel relocate the 

pallet. The galvanizing ensures an easy, 

undamaged course of the pallet to a return 

lane, and the safety of personnel 

below from wood shards. 

2 

3 Safety netting. The netting extends 

past the safety deck in order to deter 

personnel from approaching the edge 

of the pick module, and to protect them 

if they do. 

The safety of the 

picking installation was 

fundamental throughout 

the design process 

3 

The extra shelf picking areas ensure 

constant quick turnaround. 

Added height for pallets and steel-encased 

flow rail keep product safely housed. 



CYCLING THROUGH A RESPONSIVE REPLENISHMENT METHOD 

Benco Dental has made it a company practice to saturate its distribution centers with efficient production strategies 

including its just-in-time replenishment method. JIT is a means to reduce stored inventory by optimizing system 

performance. Here is how Interlake Mecalux helped ensure Benco Dental’s efficiency: 

1. Product is 

received within 

24 hours 

Reduce store inventory by 

optimizing the time it sits in the 

factory, eliminating “change 

overtime” that would normally 

cause delays at the beginning of 

the process. 

2. Expedited 

product is sent 

straight to order 

fulfillment 

Schedules are synchronized with 

demand. If there is not product 

demand, personnel is placed 

else where, making multi-skilled 

employees more useful. 

6. Product is 

unloaded to dock 

Fewer pieces mean fewer delays. 

3. Remaining stock 

is stored 

With less inventory, there is 

decreased risk of product damage 

or expiration. 

5. Employee effort, 

emphasis is spent elsewhere 

Supplier relationships are enhanced as a company 

with limited inventory will do whatever it takes to 

avoid part shortages. 

4. Fulfilled orders loaded 

and shipped 

When production demand and supply is 

synchronized and goods move directly from 

receiving to order fulfillment, less space is necessary 

for storage. 



Advantages for Benco Dental 

- Design and dimensions: special design features and the large-scale installation ensure that they 

are able to supply the continuous demands of restocking products. 

- Space optimization: Dental Benco uses the available space intelligently, taking advantage of 

every square meter for efficient operations that contribute to the strong performance of the 

installation. 

- Development of made-to-measure products: the customization of the system, in accordance 

with the needs and requirements of the client, gives the installation unique efficiency. The application 

of Mecalux’s technical knowledge, in regards to innovative solutions, has helped Benco to 

stand out among their competitors. 

- Enhanced productivity: as a result of the incorporation of massive picking modules from 

Interlake Mecalux and other systems in the Pittston installation, Benco estimates that has increased 

its productivity by 12% in comparison to what it earned in its previous facilities. 


Our experts I Software 

Logistics software: the cloud is the future 

Due to the continuous evolution of technology, our business 

landscape is changing at a high speed. One of the most important 

paradigm changes that has taken place in recent years has been 

caused by the software industry, with the creation of cloud-based 

applications. The logistics operations of companies have quickly 

adapted to this change, demanding that software applications be 

implemented which are increasingly compatible with the cloud. 

This paradigm shift has been led principally 

by the needs of the clients themselves, 

who in light of periods of crisis have opted 

for the type of solutions that only the cloud 

can offer: controlled expenditure, versatility 

and portability. 

However, it is also important to take into 

account the fundamental influence that the 

evolution of technology has brought upon 

us, which has made it possible to increase 

the connection capacity both within locally 

or mobile based communications. The 

social changes caused by globalisation, the 

sharing of information and the need for 

continuous access to information can also 

not be ignored. 

What do we mean when we talk 

about “the cloud”? 

There are many definitions for such a broad 

term and that, in the here and now, is part of 

almost any solution. Perhaps the one that comes 

closest says that it is a “consumer technology 

model” (applications, computing 

and storage) as a service through a network 

(usually the Internet), without the need for 

investments, securely and accessible from 

anywhere. This virtual set up makes data 

control and management more obtainable. 

Key advantages 

The main features that have led to this 

growth in cloud based solutions are: 

• Savings in the initial investment of 

any project of software deployment. 

The hardware infrastructure to house the 

solution is eliminated, and only the equipment 

in use is required. Nor is the initial cost 

of licensing necessary, since a payment by 

use and monthly service (SaaS) is applied. 

• Automatic and secure application 

updates. There is no need to spend several 

weeks to update a company’s applications, 

with problems that can result in loss of data, 

downtimes, etc. Updates are completely 

transparent and without any form of 

intervention. 

• Savings in maintenance costs. By 

adopting a SaaS model, the maintenance of 

the application and the housing of the solution 

lies with the provider. Who is the one 

responsible for hardware upkeep. 


Our experts I Software 

CLOUD 

HOST 

LAN 

WAN 

LAN 

ON-PREMISE 

• Flexibility. This model is ideal for businesses 

with fluctuating growth over time, 

so that it is always possible to increase or 

decrease the service you are receiving. 

• Access to information from any location. 

Only an Internet connection is required 

to be able to work remotely. 

• Reduction of the implementation 

times when performing a solution rollout 

because it is unnecessary for clients to install 

software to access the computer program 

from an Internet browser. 

• Security. The cloud does not depend on 

computer equipment, so that data is not 

lost in the event of portable devices being 

misplaced, or because of any type of breakdown 

in a client’s computer. That is to say, 

because the data is stored in the cloud, you 

can access the information in the company, 

regardless of anything that happens to your 

computer. 

Some “cons” 

All these features are advantages that currently 

lead more than 60% of medium-sized 

companies to use cloud-based services. 

But there are also drawbacks to working in 

the cloud: 

• Dependence of network connections. 

For this reason, before deciding to step into 

the cloud, you should verify that your network 

infrastructure, that will support these 

services, is adequate enough and even be 

sure to have a contingency plan for network 

breakdowns. This way, you will get a solid 

system. 

• Loss of data control. This is the biggest 

drawback that many companies face when 

making the leap into the cloud. To upload 

information into a server hosted in the cloud 

that can be replicated in any other secure 

backup in the recovery of a system, relocation 

of the information is clear and this 

makes many businesses fearful. This distrust 

is based, in part, on the perception that data 

is more secure in their own facility, when the 

truth is that it is easier for data leaks to occur 

at a domestic level. The possibility of an incident 

within their own systems is much more 

likely than with any cloud hosted service. 

An example of evolution: Easy WMS 

Fundamentally, when analysing the pros 

and cons of using the cloud, it is obvious 

that the future of software and services 

lies within this new platform. In the coming 

years, companies will increasingly rely on 

adopting this technology. 

Responding to the changing needs of its 

customers and to this new paradigm, Mecalux 

Software Solutions – Mecalux’s software 

development division – has created a 

new version of its Easy WMS Warehouse 

Management Software, so that clients can 

operate as per the architecture that they 

desire to use: 

• Either in the cloud, offering a cloud service 

model, namely SaaS (Software as a 

Service). 

• Or the traditional client/server “on-premise” 

model, hosted in their facilities. 

This way it is the client who decides which 

option they feel more comfortable working 

with. And even if you prefer to start with the 

traditional model, you can then jump into 

the cloud or vice versa. Flexibility, is first and 

foremost. u 


147

Our experts I Clack-racks 

Clad-rack warehouses 

When racks also support the building 

This type of constructions are integrated buildings formed by the racks themselves, whose structure is 

coupled to both the roof and wall cladding. Clad-rack warehouses have achieved great importance in 

the last 30 years, mainly because of the need for space optimisation, and resulting in the construction of 

buildings that are taller than 45 m. 

In order to better understand the advantages 

offered by building a clad-rack 

warehouse, we should first consider some 

features of the traditionally built warehouses: 

• The building of a traditional warehouse 

is formed by a supporting structure, with 

its pillars, trusses, roof girders, side walls 

and roofing, on which external forces 

such as the wind, snow or earthquakes 

act against, depending on its geographic 

location. 

All the forces are transmitted to the 

ground through the pillars, which require 

the construction of load-redistribution 

footings. 

It is also essential to build a slab or floor 

with sufficient load capacity to be able to 

support the weight of the goods and handling 

equipment. 

• The warehouse, or one of its parts, is 

composed of racks that occupy the total 

height of the building’s interior. 

• There are usually heavy pallets stored on 

the racks, so calculations must be done to 

withstand all the stored goods. 

• The racks are metal structures that have 

a large number of pillars (frames/uprights) 

that distribute the weight evenly on the 

floor of the warehouse. 

• The forces that the racking units transmit 

to the ground are much higher than 

those that the pillars of the building transmit, 

although individually. Each upright 

transmits a much lighter load and which, 

above all, is distributed. 

• If the external forces that support the 

building were transmitted to the ground 

via the racks, it would add a relatively small 

percentage to each upright in comparison 

with the loads derived from the goods. 

Advantages of a clad-rack 

warehouse 

• Full use of the surface area: the warehouse 

is designed at the same time as the 

racks and only occupies the space required, 

without intermediate pillars that influence 

their distribution. 

• Optimisation of height: as with the 

surface area, the height will be only that 

which is required. At the same time, the 

upper trusses or girders require less height 

and incline being directly supported on 

the racking. 

• Maximum height of the construction: 

you can build to any height, it only 

depends on local regulations or the scope 

of the handling means which are used, being 

able to exceed 45 m high (which would 



be complex and expensive in traditional 

construction). 

• Simpler construction: the entire structure 

is assembled on a concrete slab of suitable 

thickness to achieve uniform distribution 

of the forces on the foundation; there isn’t a 

high concentration of loads 

• Less time for completion: once the 

slab is built, the entire structure and cladding 

are progressively and concurrently 

installed. 

• Cost savings: As a general rule, the 

cost of a clad-rack warehouse is less than 

the more traditional racks. The greater the 

construction height, the more profitable 

the clad-rack system. 

• Easily removable: being a structure 

formed by standard rack elements that come 

pre-assembled or bolted, they can be 

dismounted with ease and a high percentage 

of components recovered. 

When installing a clad-rack 

warehouse 

The variety of applications of this type of 

warehouses are very broad, although it 

is particularly suitable solution in the following 

cases: 

• When the warehouse exceeds 12 m high. 

• When the construction is of a lower, but 

its use is temporary or pro-visional. 

• When the maximum optimisation of space 

and volume is required, regardless of 

the height of construction that is built. 

In the case of clad-rack warehouses which 

are less than 12 m high, the storage system 

which is often used is non-automated 

• Minimal civil works: it only requires 

the construction of the slab on the ground 

and, in some cases, a waterproof wall between 

one and two metres high. In which 

case the operations area needs to be expanded 

for receipt and dispatch, a traditional 

building can be built, but of sufficient 

height without reaching the total height of 



149


9 8 

6 4 

2 

1. Frame 

2. Beam 

3. Footplates and 

anchor bolts 

4. Roof trusses 

5. Guide rails 

6. Roof joist 

7. Wall joist 

8. Roof 

9. Cladded walls 

7 

3 

5 

1 

the structure be respected (wind actions, 

roof overloads, seismic action, etc.), but 

also the specific regulations for the metal 

racking. 

compact (drive-in palletising, push-back, 

Pallet Shuttle and live by gravity). 

racks must also bear the forces that they 

transmit. 

On a European level, the following regulations 

are in force for all metal structures: 

The use of conventional pallet racking, either 

single or double-depth, is more common 

starting at this height. On the other 

hand, when above 15 m high handling 

machines should be automatic. 

As a general rule, in the case of automated 

warehouses, the best practice is to take advantage 

of the maximum height allowed 

by local regulations. This is provided that 

the amount of machines designed for the 

installation makes it possible to achieve 

the desired number of movements. To get 

same storage capacity, you can opt for a 

reduced height installation, but with more 

work aisles –which involves installing more 

machines–or opt for a warehouse with 

more height and less aisles, and therefore 

less machines. 

Basic components 

of a clad-rack warehouse 

The constructive system is very simple: the 

structure is composed by the racks themselves 

on which the upper trusses, roof 

girders and the side profiles are placed, 

which are used for attaching the panels 

that make up the walls and roofing. 

When the handling equipment are automatic 

stacker cranes, the upper guides 

are attached to the trusses, so that the 

How a warehouse clad-rack 

is calculated 

Apart from having to bear loads generated 

by the goods stored and the forces from the 

handling machines, clad-rack warehouses 

must also be designed to withstand the actions 

of a building, for example, the action 

of the wind, overburdened roofing (maintenance, 

snow, etc.), the weight itself and 

of the wall cladding – both covering and the 

facades – besides considering the seismic 

coefficient that corresponds to the zone 

where it is installed. 

As with any civil engineering structure, 

the clad-rack warehouse forms part of the 

building structure. However, this involves 

very specific constructions, because in 

addition to the peculiarities of a building 

used, the specifications of the racks must 

be taken into account. 

Thus, when calculating and designing the 

structure of a clad-rack warehouse, not 

only must each country’s rules of construction 

and the actions that can affect 

• EN 1990 / Basis of structural design. 

• EN 1991 / Eurocode 1: Actions on 

structures. 

• EN 1993 / Eurocode 3: Design of steel 

structures 

• EN 1998 / Eurocode 8: Design of structures 

for earthquake resistance. 

Logically, in each territory there are different 

climatic actions that involve deviations from 

the general rule. Moreover, certain countries 

require different calculation conditions 

(for example: more stringent security coefficients 

than those specified in European 

regulations). 

In regard to the European regulations specific 

to metal racking, the following are 

underscored: 

• EN 15512 / Steel static storage systems. 

Adjustable pallet racking systems. Principles 

for structural design. 

At the height of 12 m the inflection point between 

the costs of constructing a traditional warehouse and 

a clad-rack warehouse is usually found 



Modelling for the calculation of 

the structure in 3D 

Modelling for the calculation of a cross section 

of the structure in 2D 


Adjustable pallet racking. Tolerances, deformations 

and clearances. 


Application and maintenance of storage 

equipment. 

The structure of a clad-rack warehouse is 

composed of thousands of junctions and 

rods, so you need powerful calculation 

programs to model and calculate this type 

of installation in three dimensions. 3D modelling 

is indispensable if we want to predict 

the torsional effects that a simplified 

analysis in two dimensions cannot reveal. 

Calculation programs allow. 

by regulation EN 15620 must also be substantiated 

in two dimensions. 

It is important to point out that the calculation 

of a clad-rack warehouse is an 

iterative process. Which means that the 

person calculating uses some profiles and, 

subsequently, checks and verifies their 

appropriateness. This process is repeated 

until getting the most finely-honed solution 

possible, that meets all safety requirements 

and that delivers maximum profitability. 

The iterative process will be longer 

or shorter depending on the experience of 

the person calculating. 

Civil works and assembly 

The basic civil work is minimal: only the 

slab on which the structure sits and the pipes 

for the drains are required. Likewise, 

depending on its use, a water-proof perimeter 

wall and an additional operations 

• To consider the actions on the structure. 

For example, the stored load is modelled 

as a load evenly distributed on the beams. 

It also takes into account the action of the 

wind, roof overloads... 

• To obtain the forces that the racks bear: 

bending, shearing and axil moments on 

each rod and each junction. 

• To obtain the deformations and displacements 

of all the structure’s components. 

• Check the suitability of the sections or 

profiles hypothesised in the calculation, 

applying the verification formulas outlined 

in the EN 1993 and 15512 regulations. 

EIn very tall facilities (25 m and upwards), 

it is not enough to ensure that the profiles 

are sufficiently resistant to the forces 

which they must absorb, but warehouse 

displacement within the range specified 


151


area of appropriate height can be erected, 

as has already been mentioned. 

In the process of the structure’s assembly, 

the first job that is performed on site is the 

verification of the correct levelling of the 

slab, after which part of the anchor plates 

are placed in their final position (before 

putting up the structure). Once you have 

verified the correct levelling of the racks, 

you can fill the space between the plate and 

the ground with a non-shrink concrete. 

The next step is to assemble the structure. 

You can install any type of pallet storage 

system, both single and double-depth, with 

live racks, with or without Pallet Shuttle and 

in combination with stacker cranes or transfer 

cars. It is also possible to install clad-rack 

warehouses for boxes, particularly suited in 

combination with the miniload automated 

system (stacker cranes for boxes). 

The assembly usually starts at the head of 

the warehouse and, after putting up the 

first racks and part of the cladding (the 

coverings and facades), the handling machines 

are introduced. Then, the structure 

is finished being assembled and the rest of 

the cladding is placed. 

The requirements of clad-rack warehouse 

can vary depending on several factors. For 

example, when used as cold storage, two 

The slab must have suitable strength and thickness 

for bearing the weight of the structure plus the goods 

stored, as well as to withstand the forces produced by 

external factors 

slabs are built – one on top of the other – 

and you install insulation between them. 

At the same time, the bottom slab incorporates 

a ventilation system, or a circuit 

of pipes, to prevent the foundation from 

freezing. 

Another determining factor is height. 

When more height is required than is 

allowed by applicable regulations, there 

is the possibility of building part of the 

warehouse in a trench. In these cases, 

provisions for a hatch or door must be 

made for maintenance workers and the 

installation of access ladders, drains and 

over-flow water pumps. 

On other occasions, height will be determined 

by factors such as the wind or 

the seismicity that affects the zone. The 

repercussions of this factor will be greater 

the higher the warehouse, the vertical 

bracing has to transmit forces produced 

in the structure along to the concrete slab 

that makes up the floor. 



Integration 

of the warehouse 

In general, warehouses are built next to 

other production processes. When the 

constructive system is self-supporting, 

even more so if the handling machines 

are automatic, the height is usually much 

higher than the rest of the buildings 

and the site it is located at has been well 

analysed. 

It is essential to install the warehouse in a 

strategic zone, to simplify the flows between 

the different areas that have been 

connected as much as is possible. This will 

be easier when it is a part of a totally new 

plant, and according to the experience 

and know-how of the designer. 

Although the majority of the warehouses 

are joined to the production buildings, there 

are situations in which the warehouse 

will be more distant: for logistical needs, 

or future expansion, or to not eliminate inner 

lanes. To connect the warehouse with 

other buildings, you may resort to any of 

these options: 

1. Have shuttle trucks that connect the production 

centres with the warehouse. The 

logical thing to do in this case is that the 

vehicles and the warehouse are ready to 

perform unloading automatically. 

2. Build an underground tunnel to connect 

the two areas via conveyors. 

3. Build an overpass on a raised structure. 

Conclusion 

The possibility of configuring the warehouse 

with different types of storage systems 

for pallets and for boxes, both manual 

and automatic, allows you to respond 

to all types of loading units, operations 

and necessities. 

In any case, only companies Mecalux’s 

experience and service quality can undertake 

this type of construction and offer 

the best solution based on the demands, 

the intended utility, the location and the 

height of the construction while acting as 

the sole interlocutor throughout the process. 

Furthermore, Mecalux is committed 

to the development of the engineering of 

projects with its own team of technicians, 

whether it be in the mechanical, electrical, 

electronics or software specialist. This 

helps to ensure the fulfilment of all the 

technical and legal rules applicable to the 

installations. 

Clad-rack warehouses implemented by 

Mecalux have demonstrated their effectiveness 

in diverse sectors such as food, 

automotive, pharmaceutical, spare parts, 

petroleum, ceramics, metallurgy, chemical 

and cosmetics products, plastic products, 

logistics operators, etc. This solution is also 

recommended for cold or frozen storage, 

in particular when combined with automated 

handling systems. Thus, transforming 

know-how and cold-storage into profitability 

u 


153

Our experts I Structural Calculation 

How to calculate the structure 

of a conventional pallet rack 

What forces must be pondered when designing metal pallet racks? How do we verify that the structure 

will be suitable to withstand all loads? These and other issues are those which should be taken into 

account in the design of this type of rack, with the goal of ensuring its stability and resistance, and 

therefore the overall security of the installations. 

The European EN 15512 norm, according 

to its definition, specifies the requirements 

for structural design applicable to conventional 

pallet racking (selective racks) 

manufactured from steel components, 

designed to store palletised unit loads and 

subject to essentially stationary loads. It 

has become the main benchmark on this 

matter, and provides additional technical 

information required for the implementation 

of the Eurocodes. 

In addition, designers must also provide 

for the EN 15620, EN 15629 and EN 15635 

standards as guides for the specifications 

of the storage system, the required tolerances 

during assembly and the safe operation 

of the installation. 

Likewise, conventional racks for palletised 

loads are metal structures, generally 

formed by components made out of thin, 

cold-formed, steel sheet metal. They are 

able to withstand heavy loads, while the 

installation is designed to be as lightweight 

as possible; consequently the rack’s own 

weight rarely exceeds 5% of the load stored 

in the facility’s interior. 

On the other hand, it is imperative that this 

type of installations for palletised loads be 

versatile, to be able to adapt to different 

load types. For this reason, the connections 

between the main parts of the structure 

must be adjustable, and quick and 

easy to assemble. 

The uprights of these structures usually 

have perforations along the entire profile, 

while the beams include connectors provided 

with hooks that fit into the perforations 

of these uprights. 

Basic structural 

components 

• Frames: are vertical pieces composed 

of two uprights joined together by beams 

and cross-ties forming a lattice. 

Close up of the 

joining of an upright 

and a beam 

• Uprights: these tend to be cold-profiled 

components of thin sheet metal, with 

open sections and are always perforated, 

which makes them prone to distortion and 

torsional type sagging. 

• Beams: are horizontal pieces that bear 

the burden of the pallets. These tend to 

be cold-profiled and have connectors on 

their ends for attaching them to frame 

uprights. 

• Connectors: are parts welded onto 

the ends of beams to attach them to the 

uprights. They are equipped with hooks 

that fit into the perforations of the 

uprights. 



Calculation types: general and 

individual 

The calculation is carried out in two 

stages: 

1. General analysis of the structure 

Normally filiform, two-dimensional (2D) 

models with second order calculations 

applying the finite element method are 

used. In some types of installations, calculations 

are also frequently done via 3D models 

in accordance with the EN 1993-1-1. 

This analysis must incorporate the modelling 

of the actual behaviour of the connection 

between the upright-beams and 

the frame-ground. 

Example of down‐aisle analysis 

2. Individual verification of pieces 

Once the overall analysis is performed, it is 

vital to check the correctness of the design 

by verifying the buckling and the tensions of 

the pieces that make up the racking. 

Basically, the following items are verified: 

- General stability of the installation. 

- Stress state of frames: uprights and 

diagonals. 

- Base plates: pressure on the slab and 

anchorage. 

- Beams: buckling and stress state. 

- Connectors. 

General analysis: structural model 

For general analysis, it is usual to consider 

two, two-dimensional (2D) structures in 

concurrent vertical and perpendicular layouts 

with respect to the storage aisles. 

In the model calculation, the following requirements 

are observed: 

General analysis 

• Filiform model. 

• System lines through the CG (centre of 

gravit y) of the gross sec tion, or also through 

the CG of the actual cross section. 

Overall analysis of a 2D structure 

Example of cross‐aisle analysis 

• Terms of section corresponding to the 

gross section of the pieces (or also of the 

actual cross section). 

In this analysis the aim is to obtain: 

- The internal forces on the different pieces 

for their subsequent verification, 

combining the down-aisle and crossaisle 

calculations. 

- Checking the overall stability of the 

installation. 

It includes two types of analysis: 

- Down-aisle analysis: analysis in 2D on a 

vertical layout parallel to the load aisles. 

This analysis also includes the semi-rigid 

connections of the upright-beam and 

upright-floor, obtained by testing. 

- Cross-aisle analysis: analysis in 2D on a 

vertical layout perpendicular to the load 

aisles. Usually involves the articulated 

upright-floor joint. 

In both cases, the global imperfection can 

be modelled as: 

- The tilt of the agreed uprights to the 

imperfection. 

- Horizontal forces at the height of 

the load levels corresponding to the 

imperfection. 

Type of analysis according to the 

classification of the structure 

This classification is based on the relationship 

of the expected load design in regards 

to the critical load of the structure. According 

to the coefficient obtained by this re- 


155


lationship, the need to perform a second 

order calculation will be determined. 

Individual analysis: verifying 

elements 

In the verification of the different elements 

that make up the structure the following 

concepts, among others, must be taken 

into account: 

Uprights - Frames - Anchorage plates 

- Upright mainly function by compression 

and flexion. 

- The use of the reduction factor for buckling, 

obtained by laboratory testing or 

by using theoretical formulas. 

- The internal forces obtained from the 

down-aisle and cross-aisle calculations 

will be jointly perpended. 

- Axil force on the diagonals of the 

frame. 

- Axil force and momentum on uprights’ 

footplates. 

- Axil and shear force on fastening anchorage 

to the slab. 

Beams - Connectors 

- Working primarily with bending and 

shearing forces. 

- Buckling (deflection) is limited to a maximum 

of L/200. Occasionally, for certain 

installations smaller value deflections 

are required. 

So that the conventional 

pallet racking function 

safely, it is fundamental 

to know the structure 

you are working with, 

the preventive actions 

that exist and the safety 

measures to keep in mind. 

- Consideration of the cross-aisle forces 

of location. 

- Verifying the shear force and deflection 

in the endplate. 

Blocks of bracing - Vertical and horizontal 

bracing - Spacers 

- The brace diagonals work exclusively on 

axil force. 

- Verification of the deflection and shear 

forces on the elements that connect the 

diagonals of the vertical bracing to the 

frames (bracing spacers). 

- The actions of the bracing increases the 

forces on the uprights and beams that 

form part of the block of bracing or that 

are adjacent to it. 

- The eccentricity of the actions of the 

vertical bracing in respect to the racks 

requires a study of the torsion behaviour 

of the elements that form part 

of the block of bracing, as well as the 

racks. 

Actions 

There are different types of actions that 

may affect the strength and stability of 

the racks, so that it is also imperative to 

contemplate them when setting up an 

installation of this kind. The actions on the 

racking are classified into several groups: 

Permanent actions 

- Weight of the racks. 

- Permanent loads and various equipment 

supported by the racking. 

Variables actions 

- Weight of the pallets. 

- Weight and actions due to mobile loads 

on platforms and walkways. 

- Actions due to the location of the pallets 

(vertical + horizontal). 

- Actions on the positioning profiles. 

- Actions due to storage equipment 

guides. 

- Actions due to the imperfection in the 

elements and assembly. 

- Other actions arising from national regulations 

(wind, snow, etc.). 

- The weight of the pallets together with 

the general imperfection deemed as a 



structure’s parts subject to the corresponding 

unweighted actions (nominal loads) is 

studied: 

• Verifying the overall stability of the 

struc-ture. 

• Verifying beam deflection 

Ultimate Limit State (ULS) 

In each of the load cases the tensional 

state of components subjected to the corresponding 

weighted actions (affected 

by factors of security) is studied. In the 

verification formulas of the elements the 

combination of forces (down-aisle + crossaisle) 

must be considered. 

Variable actions like weight and actions due to moving loads on 

platforms and walkways. 

single action, which in turn is the most 

relevant (unfavourable). 

Accidental actions 

- Forklift blows. 

- Actions on security profiles. 

- Seismic actions. 

Load states and the combination 

of actions 

It is viewed as appropriate and sufficient 

to study the two load states listed below, 

considering the following actions or load 

cases: 

• Permanent actions + the most unfavourable 

variable action. 

• Permanent actions + 0.9 x (the totality 

of variable actions). 

• Permanent actions + variables + incidentals. 

State Service Limit (SSL) 

In each of the load cases the buckling of the 

It is also necessary to ponder the uncertainty 

as to the different actions that can 

affect the racking (described previously). 

To do this, there are established security 

coefficients considered, for both the load 

coefficient and the material, and which 

can range between 1.0 and 1.5. 

Some countries have specific national legislation 

which obliges you to use greater 

weighting coefficients in the facilities that 

are built on its territory (A deviations). 

Eccentricities 

When the design and/or handling of the 

storage system allows the pallets to syste- 

Vertical and horizontal actions due to the placement of pallets. 


157


En 15620. - Steel static storage 

systems. Tolerances, deformations 

and clearances. 

- Flatness of the slab and its buckling under 

load. 

- Clearance between pallets, and between 

the pallet and racks. 

- Clearance between racks and civil 

works. 

- Aisle width according to the load unit, 

the forklift type and the number of pallet 

locations per hour. 

The asymmetrical position of the pallets in respect to the beams. 

matically become off-centred, the increased 

load that causes this off-centring on 

beams and braces must also be taken into 

account in the design of the structure. 

Likewise, the eccentricities of the lines of 

the structural system must be observed, in 

the event that they are deemed excessive. 

Eccentricities in the positioning of 

the pallets 

- Asymmetric position of the pallets in regard 

to the beams. 

- Load is not evenly distributed on the 

pallet. 

- Load overflow in regards to the pallet. 

Thus, not only is it imperative for the manufacturer 

to carry out a good structural 

analysis and design of the installation, 

but it is also makes good use of the same, 

so that actions against the racking 

does not exceed those considered in the 

installation’s structural calculation. This is 

all the fruit of many years of experience, 

and studies and trials by FEM (Federation 

of European Maintenance) and other 

agencies. 

It is essential to keep in mind: 


systems. Specification of storage 

equipment. 

Individual responsibilities of the different 

system suppliers that make up the storage 

equipment. 


systems. Application and 

maintenance of storage equipment. 

- Designation of a person responsible for 

the security of the storage equipment. 

- Safe load sign. 

- Education and training of the warehouse 

staff. 

- Damage to the racks and assessment of 

the level of damage. 

- Regular inspections. u 

Eccentricities of the diagonals of the 

vertical bracing 

Although the diagonals of the vertical bracing 

are not physically connected to the 

racks on the junctions that form the neutral 

lines of the uprights and the beams, 

in the 2D calculations the diagonals can 

be viewed as attached to these junctions, 

provided that the eccentricities of the same 

are kept below certain values depending on 

the width of the brace and the edge of the 

beams. The same happens with the diagonals 

of the frames. 

Conclusion: the safety of the 

installation and responsibilities 

Lastly, we want to point out that in a large 

part of the incidents that occur in palletised 

installations, human error interferes 

and are primarily caused by scraping or 

impacts of forklifts against the racking. 

On the other hand, these impacts may 

represent higher than normal actions on 

the racks, than those established in the EN 

15512 norm. 

Software for the structural calculation of racks 

Currently, all the mentioned analysis throughout this article are done via 

computerised calculation programmes. Mecalux has applied their extensive 

experience in design, manufacture and installation of warehouse systems to the 

development of a powerful design software, capable of finding the best option 

for each warehouse layout, the dimensions of the storage structures and the most 

ideal profiles. In this way, optimization of capacity and cost of the warehouse is 

procured, with the utmost safety. 


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