Fercam, operating in the transport and logistics sector, manages the storage, distribution to retail stores, and handling of returned unsold goods for a well-known footwear brand at its warehouse located within the Bologna Freight Village (Interporto di Bologna). The site handles very high volumes, with intense daily picking and movement operations.
The context was ideal for a transition towards Industry 4.0: the company needed an automated system capable of reducing operational costs, improving efficiency, and ensuring precision and flexibility in box handling.
Customer Expectations and Challenges
Main objectives
Automate the shoe box handling flow (inbound, picking, and outbound)
Significantly reduce the use of manual labor in repetitive tasks
Minimize human errors and optimize inventory management
Ensure dimensional flexibility (box sizes ranging from 300×400 mm to 400×700 mm)
Integrate residual return flows and reinjection into picking lines
Technical constraints and requirements
The warehouse had to comply with fire safety regulations, ensuring proper water drainage to lower levels
Each storage location needed to guarantee stable box support, considering sliding-based handling
The system had to integrate seamlessly with the Warehouse Management System (WMS) to orchestrate automatic storage and retrieval operations
Picking activities represented the majority of the client’s day-to-day operations
Modulblok’s Proposed Solution
Customized system configuration based on:
Automated Handling System (Miniload)
The system stores and retrieves cardboard boxes using side forks that push or pull the units along the aisles.
The entire material flow is managed by the WMS, which assigns all storage and retrieval missions.
At the front of the installation, two superimposed roller conveyor levels (both ground-accessible) serve as an interface loop for feeding boxes into the picking areas.
“Modulblok” Press-Folded Shelves
Each shelf features a 50% solid surface (ensuring stable support for boxes) and a 50% open surface (allowing water drainage for fire safety compliance).
Manufactured through a press-bending process, these shelves form continuous surfaces combining robustness and fire-prevention functionality.
Picking and Sorting
Operators use a pick-to-light system for item picking.
Once the order is completed, the remaining boxes are redirected — either re-stored into the system or sent to an additional picking bay for further processing.
The completed order is then automatically transferred to the labeling and shipping area.
Key Figures / Operational Data
Parameter
Value
Outbound UDCs to picking (8h)
3,400
Inbound UDCs from picking (8h)
2,400
Inbound UDCs from refilling (8h)
1,800
UDC flow per hour
550 inbound / 425 outbound
System type
Pallet racking + automatic miniload
Surface area – pallet racking
5,500 m²
Surface area – miniload + handling
2,170 + 330 m²
System height
13 m
Storage capacity
10,514 pallets + 82,350 boxes
Benefits Achieved
Drastic reduction in labor requirements at picking bays With the Modulblok automated system, Fercam now manages the entire pick & pack flow with only seven operators assigned to the picking bays.
Optimized return management The automated solution enables direct reintegration of returned boxes into the storage system without manual intervention.
Minimized errors and increased flexibility Automation reduces human error, improves inventory accuracy, and enhances operational flexibility.
Full control of costs and lead times The system provides precise tracking of handling times and costs, ensuring predictable and efficient operations.
