Automated rack-supported vertical storage system for gaskets and valves

Expectations & Challenge

Carrara S.p.A. is one of the leading European players in the design and manufacturing of sealing systems for the process industry, with consolidated expertise in packings, gaskets, and solutions for valves and pumps. In a context characterized by high customization and a strong R&D orientation, the management of components and moulds represents a critical factor in ensuring production continuity, reliability, and operational accuracy.

Within this framework, the adoption of a vertical storage system represented a strategic lever to overcome the limitations of existing solutions. The storage system exhibited several structural constraints:

• heterogeneous and non-standardized materials
• difficulty in achieving fast and accurate component retrieval
• presence of traditional vertical storage systems not optimized for current needs
• saturation of internal production space

In addition, there was a clear need to improve organization and traceability while reducing operational inefficiencies associated with manual handling.

The project objective was therefore to implement an automated vertical storage system capable of:

• increasing storage capacity through vertical development
• optimizing the use of available space
• improving material organization and traceability
• ensuring operational continuity throughout all implementation phases

Solution

Modulblok developed an integrated project for the construction of a rack-supported automated vertical storage system, designed in collaboration with the technology partner Vertilog for the automation component. Installed externally to the production facility and fully integrated both architecturally and functionally, the system represents an advanced solution where structure and automation operate in a coordinated manner.

The solution is based on Vertilog VL technology, an industrial vertical storage system with dynamic tray-based storage, served by an internal stacker crane that automatically manages storage and retrieval operations by transferring materials to operational bays. The system enables fully automated cycle management, ensuring continuity and control of material flows.

The project scope included:

• integrated design of structure and automation
• construction of an external rack-supported vertical storage system
• architectural integration with the existing facility
• management of operational transition without downtime

With 504 trays measuring 1,200 × 800 mm, a unit load capacity of 500 kg, and a total capacity of approximately 252 tonnes, the vertical storage system provides around 484 m² of usable storage surface over a height of 8.35 m. The dynamic level configuration, adjustable in 52 mm increments, allows the system to adapt to actual material dimensions, optimizing storage even for non-standard components and complex geometries.

The project also includes:

• advanced software management for irregular-shaped materials
• space optimization even in the presence of voids or complex forms
• high-level architectural finishes and integration with the existing building
• flexible configuration of operational bays

Benefits

The implementation of the automated vertical storage system enabled Carrara to achieve significant improvements in capacity, operational efficiency, and flow organization, transforming the warehouse into an integrated system supporting production.

1. Maximum storage density and space optimization

• continuous vertical saturation with levels configurable every 52 mm
• total capacity up to approximately 252,000 kg across 504 trays
• development of approximately 484 m² of usable storage surface in height
• construction of an external rack-supported vertical system (h 8.35 m)
• release of internal production space and improved facility layout

2. Operational efficiency and flow automation

• reduced material search and picking times
• elimination of non-value-added manual handling
• fast, controlled, and centralized access to trays
• automated management via internal stacker crane
• operational continuity even with single-bay configuration

3. Advanced management of complexity and variability

• optimized storage of heterogeneous and non-standard materials
• effective handling of components with irregular shapes and variable dimensions
• dynamic adaptation of storage space to actual material characteristics
• improved traceability and inventory visibility
• reduction of wasted space and operational inefficiencies

4. Scalability, cost efficiency, and innovation

• scalable vertical storage system with the possibility to increase tray count
• future addition of operational bays and system reconfiguration
• balance between high storage density and targeted automation
• more efficient investment compared to complex fully automated systems
• hybrid solution between vertical storage and high-flexibility miniload systems

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