CANPACK: New AS/RS for aluminum cans

Aluminum can manufacturer CANPACK has modernized its warehouse in Poland with Mecalux’s Automated Pallet Shuttle system. In the facility, finished goods are automatically stored as they leave production and subsequently distributed worldwide.

CANPACK: Over 275 billion cans of expertise

CANPACK is a leading manufacturer of innovative metal packaging. The company provides tailored solutions to its food industry clients, ranging from small businesses to large corporations. Headquartered in Kraków, CANPACK operates production facilities on nearly every continent: Europe, Asia, Africa, North America, and South America. Founded in 1992, CANPACK employs around 8,500 people across 27 production plants and operates in over 17 countries.

CHALLENGES

Connect the warehouse with manufacturing to streamline the management of finished goods.
Optimize available space to expand production lines and increase operational capacity.

SOLUTIONS

Automated Pallet Shuttle with a stacker crane.
Easy WMS Warehouse Management System.

BENEFITS

Fast and accurate management of finished goods, reducing lead times to speed up customer deliveries.
Efficient utilization of available space to accommodate higher production volumes of metal containers.

Known for its commitment to sustainability and innovation, CANPACK uses cutting-edge technologies to create aluminum packaging that is functional, attractive, and environmentally friendly. “The packaging industry is constantly evolving, driven by new trends, technological advances, and regulations. For companies in our sector, it’s not enough to adapt — you have to anticipate changes to stay competitive,” says a CANPACK representative.

Recently, CANPACK commissioned new production lines in Brzesko (Poland) to increase its manufacturing capacity. This plant is one of many the company operates worldwide, with centers in the Czech Republic, Colombia, Slovakia, the US, France, India, Morocco, the Netherlands, Poland, the UK, Russia, and Ukraine.

As part of the upgrade, the old Brzesko facility was replaced by a building complex featuring a 1.4-acre plant and a warehouse for semi-finished goods. The renovation added 21,528 ft² of production space.

AS/RS for aluminum cans and lids

“Connecting logistics with production was essential for optimizing our process efficiency. The AS/RS manages both the receipt and distribution of semi-finished products. This ensures a continuous flow to the next production stages while maximizing operational capacity,” says a CANPACK representative.

Mecalux equipped this warehouse with an automated storage and retrieval system (AS/RS): the Automated Pallet Shuttle with a stacker crane. CANPACK chose this high-density solution for its compact design, which maximizes available space to accommodate the highest possible number of products. In just 1,841 ft² — an area smaller than a tennis court — the company stores 620 pallets.

“The automated solution from Mecalux moves goods continuously and precisely, streamlining our logistics operations. It’s a system that manages inventory autonomously, keeping all products identified and under control,” says the representative. The storage system incorporates a stacker crane that transports pallets to the correct lane. A motorized shuttle then moves inside the lanes to position each item in its assigned location.

All operations are supervised by the Easy WMS warehouse management system. Integrated with the company’s ERP, the software controls inventory and facilitates production planning. “Efficient management minimizes wait times. It’s key to delivering around 60 pallets to production on time every day,” says the CANPACK representative.

Uninterrupted processes

All operations in CANPACK’s warehouse are fully automated. However, the AS/RS is also designed to run semi-automatically if necessary. This alternative ensures continuity of service under any circumstances — even in the unlikely event of a power outage.

CANPACK has an additional motorized shuttle that operators can place into the storage lanes using forklifts. Once in position, the shuttle autonomously stores and retrieves products from their assigned locations. “The Pallet Shuttle system enables us to achieve the throughput needed to manage goods arriving from production and subsequently sent to our clients,” the company notes.

Logistics innovation and sustainability

The modernization of CANPACK’s Brzesko facility reflects the business’s commitment to efficiency. By implementing advanced storage technologies, it has enhanced the management of its finished goods.

Process automation and better space utilization have increased the plant’s production capacity. In addition, worker safety has improved thanks to reduced reliance on traditional handling equipment.

In an ever-changing industry, CANPACK continues to combine innovation with sustainability. This approach strengthens its competitiveness and reaffirms its role as a benchmark in environmentally responsible packaging production.