| SectorContract confectionery production |
Gambarotta S.p.A., a historic confectionery manufacturer based in Novi Ligure, underwent a significant scale-up after the change of ownership in 2018 — doubling production lines and increasing third-party processing volumes, reaching over 900 tons of processed chocolate every year.
This growth created the need for a new warehouse capable of sustaining very high daily flows (500–1,000 pallets/day), while managing considerable seasonal peaks linked to Easter chocolate products, typically bulky and produced in large batches.
Key constraints and design requirements included:
To meet the new storage and productivity requirements, Modulblok designed an intensive semi-automated warehouse equipped with:
High-density racking served by 12 Logaut L-SOLE-800 Bi-Front Wi-Fi 4.0 shuttle satellites, engineered to accelerate pallet handling and optimize storage depth.
| Feature | Outcome |
| Ultra-thin 105 mm shuttle design | enables one additional storage level vs. conventional systems |
| Three functional storage zones | Bulky packaging, 2,730 pallet slots for semi-finished goods, 3,300 for finished goods |
| Laser positioning system | ensures precise pallet insertion and consistent operations |
| Magnetic fork-locking | stabilizes the shuttle during handling — considered by the customer more effective than anti-slip systems |
| Scalable layout | future addition of shuttles, AGV integration, layout expansion |
| Category | Specification |
| Industry | Third-party chocolate production |
| Warehouse type | Intensive racking + semi-automated shuttle system |
| Total area | 4,600 m² |
| Height | 12.5 m |
| Capacity | >10,000 pallet positions |
| Shuttle fleet | 12 Logaut L-SOLE-800 units |
| Load units handled | EPAL and 1000×1200 pallets (two satellite types) |
| Construction period | 2023–2024 |
| Environmental constraint | Constant temperature 14–15 °C |
Storage capacity maximized
10,000+ pallet positions achieved without increasing building height
Peak-season performance
Continuous movement of 500–1,000 pallets/day with reduced handling time
Safety improvements for operators & goods
Magnetic locking + laser positioning → secure, precise, low-risk handling
Sustainability integrated into production strategy
5,000 m² photovoltaic system installed, new plants planned, urban industrial area remediation (~36,000 m² asbestos removed)
Future-ready scalability
AGV-ready layout, WMS integration capability, storage expansion potential
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