Pallet Racking Warehouse for the pharmaceutical sector: the Biofarma project

Challenge

In the pharmaceutical, nutraceutical and cosmetics industries, storage must ensure well-controlled flows, operational continuity and strict control of storage conditions.

For Biofarma Group, the goal was to develop a warehouse able to:

• handle high volumes of finished goods, packaging and raw materials;
• integrate temperature- and humidity-controlled areas;
• reduce handling time and operator interference through targeted automation;
• maintain direct access to pallets and flexibility across multiple pallet formats.

Solution

Modulblok designed and delivered a pallet racking system structured by functional areas and different service levels, integrating an automated roller conveyor and automatic infeed/outfeed bays in the zones with the highest flow intensity.

The operating concept combines:

• pallet drop-off in dedicated bays using standard forklifts;
• transfer and high-level storage (where required) using very narrow aisle (VNA) turret trucks;
• area-specific handling strategies (temperature/humidity-controlled, ambient, raw materials).

Result: more orderly flows, more efficient handling, and a system designed for the typical requirements of pharma & cosmetics logistics.

Technical highlights

Storage capacity (pallet positions)

• Finished goods – temperature/humidity-controlled cell: 4,522 pallet positions (800×1200 / 1000×1200 / 1200×1200)
• Packaging – area 1: 13,020 pallet positions, served by VNA turret trucks with static bays on 3 levels
• Packaging – area 2: 3,120 pallet positions, served by reach trucks with static bays on 3 levels
• Raw materials – cell: 768 pallet positions, served by pedestrian pallet stackers (walk-behind)

Automation and flows

• Automated roller conveyor in the temperature/humidity-controlled area
• Automatic infeed/outfeed bays at the front end

Multi-format pallet handling

• 800×1200, 1000×1200, 1200×1200

Photo gallery