PET Solutions: automated rack-supported warehouse for the mechanical engineering industry
Industry
MACHINERY MANUFACTURING
Key objectives
PET Solutions, part of the Pegaso Industries Group, designs and manufactures automated systems for PET and rPET processing. The company manages highly engineered products within a logistics environment characterised by complex production, storage and picking flows, handling Europallets and load units of varying sizes and configurations.
The main objectives of the project were:
- Centralise logistics activities within a single integrated system
- Increase operational productivity
- Reduce manual handling activities within the picking process
- Optimise the use of available space
- Improve continuity across logistics and production flows
Technical requirements and constraints
Growing storage volumes and the need to improve operational efficiency required a complete redesign of the logistics system, with a focus on greater integration between storage and automated material handling.
Key project requirements included:
- Handling Europallet load units with varying dimensions
- Target storage capacity of approximately 3,000 pallet locations
- Compact available footprint (62 × 20 m)
- Vertical development up to 18 m in height
- Integration between storage and picking operations
Our solution
Key features
1. High-density automated rack-supported warehouse
Modulblok designed a high-density automated rack-supported warehouse in which the storage structure and handling system are integrated into a single engineered solution.
The project was developed to optimise storage capacity, operational productivity and material flow management simultaneously, concentrating high storage volumes within a particularly compact footprint.
2. High-density automated system powered by RAIDER® technology
At the core of the installation is Logaut’s RAIDER® technology, an automated high-density storage solution designed to manage pallet handling through a multi-depth storage strategy.
The system uses the racking structure itself as the operating infrastructure, eliminating the need for additional handling components and reducing space requirements. This approach increases storage density while maximising the use of the available warehouse volume.
3. Integration between automation and picking operations
The system was engineered following a detailed analysis of operational missions and real material flows, with particular attention to picking activities and order preparation processes.
The installation integrates automated buffer areas, transfer shuttles, dedicated picking stations and software-driven load pre-positioning logic. Automated buffer stations prepare upcoming missions in advance, reducing waiting times and improving operator productivity while ensuring a continuous and efficient flow of materials throughout the warehouse.
Technical specifications
| Voce | Valore | |
|---|---|---|
| System type | Magazzino autoportante automatico con tecnologia Raider | |
| Storage capacity | 3.315 posti pallet | |
| Height | 18 metri | |
| Operative performance | 46 cicli combinati IN/OUT – 35 cicli OUT (picco) | |
| Operating stations | 2 baie di picking automatiche | |
| Surface | 62 x 20 m |
Key Benefits
Optimised use of available space
The high-density rack-supported configuration made it possible to accommodate more than 3,300 pallet locations within a compact footprint, maximising the use of available warehouse volume and increasing storage capacity without expanding the facility footprint.
Reduced manual handling activities
The automation of picking and material handling operations transformed a predominantly manual workflow into a highly automated process, significantly reducing labour requirements and lowering the number of operators dedicated to these activities from seven to one.
Increased operational productivity
The integration of RAIDER® technology, automated buffer systems and dedicated picking stations improved operational continuity and material flow management, ensuring high performance levels even during peak demand periods.
Automated mission preparation
The system automatically prepares outbound missions during off-peak hours, optimising picking sequences and reducing waiting times during daily operations.
Gallery
Browse the gallery to explore the project from installation through to full operational deployment.
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Warehouse Engineering is Modulblok’s magazine dedicated to the industrial culture of modern intralogistics. An editorial space created to explore and interpret the transformations reshaping today’s warehouse systems. Through technical content, industry insights and expert contributions, the magazine examines the technologies, operational models and competencies that are redefining the role of logistics across manufacturing and distribution environments. Its purpose is to provide a structured perspective on warehouse evolution, connecting technological innovation with the engineering principles that drive the design, performance and long-term reliability of modern storage systems.
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