Ondulati e Imballaggi del Friuli 

Challenge

Ondulati e Imballaggi del Friuli is a company operating in the production of corrugated cardboard packaging. The company engages Modulblok as part of a logistics evolution process aimed at making the growth of production volumes sustainable.

The warehouse, although developed over a large surface area, is fully saturated and organized on limited vertical levels, with handling operations carried out using traditional forklifts. This configuration limits storage capacity and introduces inefficiencies in flow management.

At the same time, the production model requires further development in terms of:

• increasing batch sizes to reduce setup times 
• ensuring continuous availability of finished goods 
• improving responsiveness in shipping operations 

The context is further complicated by the presence of heterogeneous load units, with dimensional variability and non-standard references that are not fully suitable for automation.

The design challenge is therefore clearly defined:

to increase storage capacity and density, improve operational efficiency and support production growth, while maintaining flexibility and without significantly expanding the available footprint.

Solution

Modulblok has designed a high-density automated rack-supported warehouse, developed vertically and based on a multi-deep storage configuration, with the objective of concentrating storage capacity and reorganizing logistics flows.

The project includes a clear separation between:

• standard references, managed through the automated system 
• out-of-gauge references, maintained under conventional storage 

A key element of the solution is the integration of Raider technology, a proprietary automation system developed by the Modulblok Group (through its affiliated company Logaut). This technology enables direct pallet handling without the use of dedicated guide rails, by exploiting the pallet fork entry spaces. This approach increases vertical density and reduces technical clearances, improving the ratio between available volume and effective storage capacity.

The system also integrates a complete flow management architecture:

• automatic inbound checks (dimensions, weight, fork entry space) 
• handling of rejected and non-compliant units 
• bypass lines for urgent shipments 
• automated shipping buffers 

This configuration transforms the warehouse into an active component of the production process, delivering tangible benefits across multiple areas:

Production support
Increased storage capacity allows for larger production batches, reducing setup times and improving operational continuity.

Flow efficiency
The reorganization of flows reduces unnecessary handling, increasing overall system efficiency and improving priority management.

Energy optimization
The concentration of activities within a single area reduces both internal and external transport, contributing to improved energy efficiency and enabling access to Industry 5.0 incentives.

Scalability over time
The system is designed with a scalable approach, allowing progressive increases in both storage capacity and operational performance, without requiring invasive structural modifications.

Technical Highlights

Industry
Corrugated cardboard packaging

System type
Automated rack-supported warehouse

Configuration
2 aisles – 14 levels

Structure height
24 m

Capacity
Approx. 8,100 pallet positions

Storage technology
Multi-deep system with patented Raider technology

Automation
Multi-level shuttles and pallet lifts

Load units
800×1200 and 1000×1200 pallets with overhang management up to +100 mm per side

Reference management
Selective automation with integration between automated system and conventional warehouse

Operational flows
Automatic inbound checks, sorting, automated storage, buffer management and shipping

Structure
Designed in compliance with safety requirements and applicable standards

Scalability
System expandable in both capacity and performance without structural modifications

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